Residual stress, microstructure, and mechanical properties analysis of HPDC aluminum engine block with cast-in iron liners

During the manufacturing of cast aluminum (Al) engine blocks with iron (Fe) cylinder liners, the mismatch of thermal expansion/contraction coefficients between the Al cylinder wall and the Fe liners results in the development of high residual strains/stresses. This evolution of residual stress can surpass the strength of the currently used alloys and can lead to the premature failure of the engine block. Thus, improving the mechanical …