OCTOBER 19-20, 2012 - YMCA University of Science & Technology

Proceedings of the National Conference on
Trends and Advances in Mechanical Engineering,
YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012
COMPOUND CASTING - A LITERATURE REVIEW
Rajender Kumar Tayal 1 , Vikram Singh 2 , Sudhir Kumar 3 and Rohit Garg 4
1 Lecturer, Deptt. of Mech. Engg., Govt. Polytechnic, Sirsa (Haryana), India. email: tayal.rajender@gmail.com
2 Associate Professor, Deptt. of Mech. Engg., YMCAUST, Faridabad, India. email: singhvikram77@gmail.com
3 Professor, Deptt. of Mech. Engg., NIET, Greater Noida(U.P), India. email: s_k_tomar02@yahoo.com
4 Principal, Indus Institute of Engg. & Tech., Jind (Haryana), India. email: rohit_garg123@yahoo.com
Abstract
The lightweight construction philosophy is based on the principle of making the best possible use of the material.
Whenever a single material does not satisfy the demands of a specific application, compound structures may
generate a solution. Especially in lightweight construction, a multi-material-mix can provide ideal specific
properties that are suitable for the conditions to which a part is subjected. Typically such combinations of
dissimilar materials provide desired properties in various areas of the single part. Compound casting is a
process, which yields such multimaterial components. The technique is not much old and a few researchers have
worked on it. However, the paper presents a recent reviews of literature on compound casting. In this paper, the
literature on compound casting is reviewed in a way that would help researchers, academicians and
practitioners to take a closer look at the growth, development and applicability of this technique. The review
aims at providing an insight into the compound casting process backgrounds and shows the great potential for
further investigations and innovation in the field. The survey of existing works has revealed several gaps in the
fields of substrate pretreatments, continuous flow behavior of metal during the process, correlation between
mechanical and geometrical part properties, and industrial application of some advanced processes.
Keywords: Compound casting, Literature, Interface
1. Introduction
Vehicle construction and aerospace in particular demand solutions which save as much weight as possible while
fulfilling identical or even greater requirements with regard to component properties, and which can be produced
at low cost. Light weight constructions in the transport industry help to reduce weight and thus save fuel. To
optimize performance, a combination of materials is the most efficient method, because one material is often
insufficient. Light metals are not easy to join, though. Weak links arise at the joints such as rivets, welds or
brazing connections.
In lightweight construction, the light metals magnesium and aluminum are employed to an ever increasing extent
as magnesium and aluminum are the first and second engineering light metals, respectively, and are attractive in
vehicle structure applications for improving energy efficiency. For these reasons, efforts are high to work and
research on efficient and economical methods to process these materials and thus to reduce the component’s
dimensions. Whenever a single material does not satisfy the demands of a specific application, compound
structures may generate a solution. Especially in lightweight construction, a multi-material-mix can provide ideal
specific properties that are suitable for the conditions to which a part is subjected. Typically such combinations
of dissimilar materials provide desired properties in various areas of the single part. Components constructed
using hybrid methods have proven to offer a useful approach. The compound casting is the process which meets
a wide range of requirements within one component by combining different materials. In addition to saving
weight, it has the added advantage of reducing bonding processes.
2. Casting
Casting is a manufacturing process by which a liquid material is usually poured into a mold, which contains a
hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting,
which is ejected or broken out of the mold to complete the process. Casting materials are usually metals or
various cold setting materials. Casting is most often used for making complex shapes that would be otherwise
difficult or uneconomical to make by other methods.
3. Compound Casting
Compound casting is a process through which two metallic materials—one in solid state and the other liquid—
are brought into contact with each other. In this way, a diffusion reaction zone between the two materials and
thus a continuous metallic transition from one metal to the other is formed. This method could join semi-finished
parts with complex structures, simply by casting a metal onto or around a solid shape. However, many
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