Influence of insert dimensions on distortion during reverse cladding

Conventional cladding involves depositing a protective layer onto a substrate, whereas reverse cladding entails applying the substrate material onto a surface-treated insert. The thermal energy generated during substrate fabrication promotes metallurgical bonding through interdiffusion. In this study, the die-casting technique was employed to integrate austenitic stainless-steel sheet inserts with hypo-eutectic aluminum–silicon alloys, focusing on the effect of insert size on the reverse cladding process. Inserts measuring 80 mm × 30 mm × 1 mm exhibited significant distortion due to shrinkage cavities at the casting base, caused by elevated thermal resistance. Inserts of 80 mm × 30 mm × 2 mm showed reduced distortion as a result of improved undercooling, while inserts of 79 mm × 30 mm × 2 mm and 78 mm × 30 mm × 2 mm demonstrated minimal distortion owing to decreased thermal resistance due to filling of aluminum into the gaps between die and insert. The findings reveal that thinner, longer inserts tend to deform due to higher thermal resistance, whereas thicker, shorter inserts enhance heat conduction and dimensional stability. This study provides a practical framework for selecting optimal insert dimensions to achieve defect-free metallurgical bonding during reverse cladding through die casting.