article published yes Moritz Neuser author 32340 Malte Christian Schlichter author 61977 Kay-Peter Hoyer author 48411 Mathias Bobbert author 7850 Gerson Meschut author 320560000-0002-2763-1246 Mirko Schaper author 43720 43 department 158 department 157 department 9 department 321 department 44th Conference of the International Deep Drawing Research Group (IDDRG 2025) TRR 285 - A: TRR 285 - Project Area A project TRR 285 – A02: TRR 285 - Subproject A02 project TRR 285 – A01: TRR 285 - Subproject A01 project TRR 285: Methodenentwicklung zur mechanischen Fügbarkeit in wandlungsfähigen Prozessketten project Lightweight design is a driving concept in modern automotive engineering to minimize resource consumption over a vehicle's lifecycle through multi-material design, which relies on the use of joining techniques in car body fabrication. Multi-material design and the increasing trend towards producing large structural components using the megacasting process pose considerable challenges, particularly in the mechanical joining of aluminium-silicon (AlSi) castings. These castings typically exhibit low ductility and are prone to cracking when mechanically joined. Based on the excellent castability of hypoeutectic AlSi alloys, these are applied in sand casting and die casting as well as in megacasting. With a silicon content between 7 wt% and 12 wt%, these AlSi-alloys have a plate-like silicon phase that initiates cracks during mechanical joining. To enhance the joinability of castings, the research hypothesis is that improved solidification conditions enable a significant modification in the microstructure and therefore, increase the mechanical properties. During the manufacture of the castings using the sand casting process, the solidification conditions within the structural elements are varied to modify the microstructure to obtain castings with graded microstructure. The castings are evaluated using mechanical, microstructural and joining testing methods and finally, a microstructure-joinability correlation is established. 2025Lissabon (Portugal) eng JoiningCastingSelf-pierce rivetingAluminium casting alloy 10.1051/matecconf/202540801081 408 M. Neuser, M. C. Schlichter, K.-P. Hoyer, M. Bobbert, G. Meschut, and M. Schaper, “Mechanical joinability of microstructurally graded structural components manufactured from hypoeutectic aluminium casting alloys,” <i>44th Conference of the International Deep Drawing Research Group (IDDRG 2025)</i>, vol. 408, Art. no. 01081, 2025, doi: <a href="https://doi.org/10.1051/matecconf/202540801081">10.1051/matecconf/202540801081</a>. Neuser, M., Schlichter, M. C., Hoyer, K.-P., Bobbert, M., Meschut, G., &#38; Schaper, M. (2025). Mechanical joinability of microstructurally graded structural components manufactured from hypoeutectic aluminium casting alloys. <i>44th Conference of the International Deep Drawing Research Group (IDDRG 2025)</i>, <i>408</i>, Article 01081. <a href="https://doi.org/10.1051/matecconf/202540801081">https://doi.org/10.1051/matecconf/202540801081</a> Neuser, Moritz, et al. “Mechanical Joinability of Microstructurally Graded Structural Components Manufactured from Hypoeutectic Aluminium Casting Alloys.” <i>44th Conference of the International Deep Drawing Research Group (IDDRG 2025)</i>, vol. 408, 01081, 2025, doi:<a href="https://doi.org/10.1051/matecconf/202540801081">10.1051/matecconf/202540801081</a>. @article{Neuser_Schlichter_Hoyer_Bobbert_Meschut_Schaper_2025, title={Mechanical joinability of microstructurally graded structural components manufactured from hypoeutectic aluminium casting alloys}, volume={408}, DOI={<a href="https://doi.org/10.1051/matecconf/202540801081">10.1051/matecconf/202540801081</a>}, number={01081}, journal={44th Conference of the International Deep Drawing Research Group (IDDRG 2025)}, author={Neuser, Moritz and Schlichter, Malte Christian and Hoyer, Kay-Peter and Bobbert, Mathias and Meschut, Gerson and Schaper, Mirko}, year={2025} } Neuser M, Schlichter MC, Hoyer K-P, Bobbert M, Meschut G, Schaper M. Mechanical joinability of microstructurally graded structural components manufactured from hypoeutectic aluminium casting alloys. <i>44th Conference of the International Deep Drawing Research Group (IDDRG 2025)</i>. 2025;408. doi:<a href="https://doi.org/10.1051/matecconf/202540801081">10.1051/matecconf/202540801081</a> M. Neuser, M.C. Schlichter, K.-P. Hoyer, M. Bobbert, G. Meschut, M. Schaper, 44th Conference of the International Deep Drawing Research Group (IDDRG 2025) 408 (2025). Neuser, Moritz, Malte Christian Schlichter, Kay-Peter Hoyer, Mathias Bobbert, Gerson Meschut, and Mirko Schaper. “Mechanical Joinability of Microstructurally Graded Structural Components Manufactured from Hypoeutectic Aluminium Casting Alloys.” <i>44th Conference of the International Deep Drawing Research Group (IDDRG 2025)</i> 408 (2025). <a href="https://doi.org/10.1051/matecconf/202540801081">https://doi.org/10.1051/matecconf/202540801081</a>. 598722025-05-12T15:21:06Z2026-02-24T13:41:58Z