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The present paper attempts to fabricate the functionally graded materials (FGMs) with two dissimilar metals using Gravity Die Casting (GDC) with and without an interfacing layer. AZ91D and Al7075 alloys are used in this study as base metals. The Zn layer is used as interfacing material to prepare the FGMs. The interfacial microstructures of the said FGMs reveal α-Mg, Al 5 Mg 11 Zn 4 , and MgZn 2  compounds. The absence of a Zn interface layer revealed harmful Al-Mg intermetallics such as Al 12 Mg 17 , Al 3 Mg 2,  and Mg 5 Al 8 . The microstructural examination reveals that the presence of the Zn interface protects the diffusion of Al particles with Mg particles. Further studies on the Zn interfacing layer increased the microhardness value, whereas FGMs without interface showed increased shear and impact strength.

Characterization of AZ91D/Al7075 FGMs fabricated through gravity casting: effect of Zn interface