CDC Process for A206/E357 Combined Structure

The CDC (Cast-Decant-Cast) Process is a casting technique for the production of functionally gradient materials (FGMs).  FGMs are a special class of bimetals, and instead of having a sharp interface between the two metals, FGMs have a smooth gradient in concentration, microstructure and properties. Some of the strongest cast aluminum alloys, typically the 200 series aluminum-copper alloys, are underutilized in some designs since they are very difficult to weld to structure. This work explores CDC development casting of A206 and E357 aluminum alloys as a prelude to use as welded on armor structure for rotorcraft. Mechanical properties and analyses of the interface provide useful guidelines for the development of a full scale test piece.