Effect of diffusion of elements on microstructural, mechanical, and machining characteristics of Al7075/ZnAl4 functionally graded material with and without Ag and Pb interface

The current experimental work uses die casting, a liquid processing method, to create functionally graded material (FGM). To reduce the production of undesired intermetallic compounds, the FGM samples were created both with and without interfacing foil during the procedure. Mechanical properties including impact strength and microhardness were examined throughout the manufactured sample's cross-section. In addition, the interfacial bonding of FGM samples with and without an interacting foil was determined by estimating the shear strength. Analysis of the samples using X-ray diffraction (XRD) and scanning electron microscopy (SEM) reveals the existence of compounds in the sample as well as the diffusion of Al and Zn particles from one side to the other. Compared to the FGM without foil, it is observed that the diffusion rate at the interface is regulated when the foil is present. In addition, it was found that, in contrast to pb foil, the inclusion of Ag foil limited the rate at which particles could move from one side to the other. Additionally, machining investigations are carried out at varying depths on both sides of the sample in the direction of the interface with the assistance of electric discharge machining.