Wear-resistant component and system

A system comprising:

• a die defining a cavity;
• a wear-resistant component including:
• a substrate disposed within the cavity, formed from a metal, defining a bore, and having a bore surface;
• wherein the metal is aluminum or an aluminum alloy selected from the group consisting of A380, A383, A360, ZA-8, ZA-12, and ZA-27;
• wherein the substrate includes:
• a first region having a first microstructure and a first average particle size;
• wherein the first microstructure includes a second phase of a plurality of particles formed from silicon that are dispersed within the metal;
• and
• a second region having a second microstructure and a second average particle size;
• and
• wherein the first average particle size is larger than the second average particle size;
• wherein the first microstructure transitions to the second microstructure at a distance from the bore surface;
• wherein the first microstructure is disposed between the bore surface and the second microstructure;
• and
• a core insert disposed within the bore.

A method of forming a wear-resistant component, the method comprising:

• disposing a molten metal into a cavity defined by a die at a pressure of from 10 MPa to 175 MPa;
• wherein the molten metal is aluminum or an aluminum alloy selected from the group consisting of A380, A383, A360, ZA-8, ZA-12, and ZA-27;
• placing a core insert into the cavity to form a bore surface at an interface of the molten metal and the core insert;
• solidifying the molten metal around the core insert;
• concurrent to solidifying, cooling the molten metal at the bore surface at a rate of from 0.01° C. per second to 1.5° C. per second to thereby form a substrate having:
• a first region having a first microstructure and a first average particle size;
• wherein the first microstructure includes a second phase of a plurality of particles formed from silicon that are dispersed within the metal;
• and
• a second region having a second microstructure and a second average particle size;
• wherein the first average particle size is larger than the second average particle size;
• wherein the first microstructure transitions to the second microstructure at a distance from the bore surface;
• wherein the first microstructure is disposed between the bore surface and the second microstructure;
• and
• after cooling, removing the core insert from the substrate to define a bore and thereby form the wear-resistant component.