compound casting - a literature review - YMCA University of Science ...

Proceedings of the National Conference onTrends and Advances in Mechanical Engineering,YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012COMPOUND CASTING - A LITERATURE REVIEWRajender Kumar Tayal 1 , Vikram Singh 2 , Sudhir Kumar 3 and Rohit Garg 41 Lecturer, Deptt. of Mech. Engg., Govt. Polytechnic, Sirsa (Haryana), India. email: tayal.rajender@gmail.com2 Associate Professor, Deptt. of Mech. Engg., YMCAUST, Faridabad, India. email: singhvikram77@gmail.com3 Professor, Deptt. of Mech. Engg., NIET, Greater Noida(U.P), India. email: s_k_tomar02@yahoo.com4 Principal, Indus Institute of Engg. & Tech., Jind (Haryana), India. email: rohit_garg123@yahoo.comAbstractThe 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 maygenerate a solution. Especially in lightweight construction, a multi-material-mix can provide ideal specificproperties that are suitable for the conditions to which a part is subjected. Typically such combinations ofdissimilar materials provide desired properties in various areas of the single part. Compound casting is aprocess, which yields such multimaterial components. The technique is not much old and a few researchers haveworked on it. However, the paper presents a recent reviews of literature on compound casting. In this paper, theliterature on compound casting is reviewed in a way that would help researchers, academicians andpractitioners to take a closer look at the growth, development and applicability of this technique. The reviewaims at providing an insight into the compound casting process backgrounds and shows the great potential forfurther investigations and innovation in the field. The survey of existing works has revealed several gaps in thefields of substrate pretreatments, continuous flow behavior of metal during the process, correlation betweenmechanical and geometrical part properties, and industrial application of some advanced processes.Keywords: Compound casting, Literature, Interface1. IntroductionVehicle construction and aerospace in particular demand solutions which save as much weight as possible whilefulfilling identical or even greater requirements with regard to component properties, and which can be producedat low cost. Light weight constructions in the transport industry help to reduce weight and thus save fuel. Tooptimize performance, a combination of materials is the most efficient method, because one material is ofteninsufficient. Light metals are not easy to join, though. Weak links arise at the joints such as rivets, welds orbrazing connections.In lightweight construction, the light metals magnesium and aluminum are employed to an ever increasing extentas magnesium and aluminum are the first and second engineering light metals, respectively, and are attractive invehicle structure applications for improving energy efficiency. For these reasons, efforts are high to work andresearch on efficient and economical methods to process these materials and thus to reduce the component’sdimensions. Whenever a single material does not satisfy the demands of a specific application, compoundstructures may generate a solution. Especially in lightweight construction, a multi-material-mix can provide idealspecific properties that are suitable for the conditions to which a part is subjected. Typically such combinationsof dissimilar materials provide desired properties in various areas of the single part. Components constructedusing hybrid methods have proven to offer a useful approach. The compound casting is the process which meetsa wide range of requirements within one component by combining different materials. In addition to savingweight, it has the added advantage of reducing bonding processes.2. CastingCasting is a manufacturing process by which a liquid material is usually poured into a mold, which contains ahollow 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 orvarious cold setting materials. Casting is most often used for making complex shapes that would be otherwisedifficult or uneconomical to make by other methods.3. Compound CastingCompound 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 andthus a continuous metallic transition from one metal to the other is formed. This method could join semi-finishedparts with complex structures, simply by casting a metal onto or around a solid shape. However, many501

Proceedings of the National Conference onTrends and Advances in Mechanical Engineering,YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012researchers have used compound casting to join different similar and dissimilar metallic couples such assteel/cast iron, steel/Cu, steel/Al, Cu/Al, Al/Al, and Mg/Mg, joining dissimilar light metals such as aluminumand magnesium by the compound casting process is still a relatively unexplored area. In this study, compoundcasting as an economic straightforward in situ technique was used to join dissimilar aluminum and magnesiumlight metals.Through the combination of various materials, this compound casting process can help components meet themost diverse of requirements. And with the hybrid construction process, the material bond is created by recasting– separate hot or cold bonding/jointing processes are not necessary. This in turn reduces the number ofproduction steps needed in the manufacturing process.A good example of applications in this field is the manufacturing of engine blocks. As a pure sheet steel solution,it consists of numerous individual parts which are joined to one another. In contrast, the compound castingsolution makes it possible to produce this component as a single piece. The intelligently designed casting madefrom aluminium or magnesium alloy ensures the high functional integrity of flanges and bearing carriers, forinstance.In difficult areas, a carefully positioned insert such as a semi-finished product made of steel or an aluminumalloy provides the necessary strength. In comparison with conventional die casting, the manufacture of acompound casting piece requires additional handling, for example manipulation of inserts or perhapspretreatment of the surfaces.3.1. Applications of Compound CastingCompound casting parts are already used in vehicle construction for parts of the chassis, such as the engineblock, shock strut supports and gearbox casing, as well as bodywork components, for example door frames andconnection supports and as dashboard mounts in the interior. And according to information from the automotiveindustry, multi-material components are on the increase. This is proven by compound cast parts such as the 6-cylinder magnesium engine with aluminum insert from BMW and other components which are undergoingdevelopment but have not yet been announced. The aircraft industry, too, is relying more and more on compoundcast materials.3.2. Compound Casting ProcessThe compound casting process to prepare the Al/Mg couples from commercially pure aluminum andcommercially pure magnesium are as under.In this process cylindrical inserts with 20 mm diameter and 100 mm height were machined from aluminum andmagnesium ingots. Their surfaces were ground with silicon carbide papers up to 1200 grit, then rinsed withacetone and placed within a cylindrical cavity of a CO2 sand mold with 30 mm diameter and 80 mm height. Twoseries of samples were prepared. In the first series, aluminum ingots were melted in a clay-graphite crucibleplaced in an electrical resistance furnace. The molten aluminum was cast around the magnesium inserts at 700 0 Cunder normal atmospheric conditions.In the second series, magnesium ingots were melted in a steel crucible placed in the same furnace under thecovering flux, to protect magnesium melt form oxidation. The molten magnesium was cast around the aluminuminserts at 7000 C under normal atmospheric conditions. Schematic sketches of the mold used in the castingprocess and the prepared Al/Mg couple are illustrated in Fig. 1.Figure 1 Schematic sketches of (a) the mold used for the casting process and (b) the prepared Al/Mg couple.502

Proceedings of the National Conference onTrends and Advances in Mechanical Engineering,YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 20124. Literature ReviewA lot of research material is referred to describe the insights of the compound casting process. However 10 majorpapers are selected as arranged in descending order of their year of publication in table-1. These selected papersare studied in detail so that every aspect of the process i.e. from preparation of substrate, pretreatments, pouringsystem, solidification behavior, microstructural analysis & mechanical properties can be determined.Table-1 Depicting title of papers along with year & journal in which publishedS.NOTitle of PaperYear ofPublicationName of Journal1.Dissimilar joining of Al/Mg light metals bycompound casting process2011Journal of Materials Science2.Mechanical testing of titanium/ aluminium–silicon interface: Effect of T6 heat treatment2011Materials Science and EngineeringA3.Aluminium–aluminium compound fabricationby high pressure die casting2011Materials Science and EngineeringA4.Interface formation between liquid and solid Mgalloys—An approach to continuouslymetallurgic joining of magnesium parts2010Materials Science and EngineeringA5.Effect of copper insert on the microstructure ofgray iron produced via lost foam casting2009Materials and Design6.Light metal compound casting2009Science in China7.Solidification processed Mg/Al bimetalmacrocomposite: Microstructure and mechanicalproperties2008Journal of Alloys and Compounds8.Interface formation in aluminium–aluminiumcompound casting2008Acta Materialia9.Mechanical testing of titanium/aluminium–silicon interfaces by push-out2008Journal of Materials Science10.Effect of continuous cooling heat treatmenton interface characteristics of S45C/coppercompound casting2004Journal of Materials ScienceThese selected papers are studied in detail so that every aspect of the process i.e. from preparation of substrate,pretreatments, pouring system, solidification behavior, microstructural analysis & mechanical properties can bedetermined. Table-2 depicts a detailed review of 10 papers on compound casting process or some other processeswhich are very similar to compound casting process. Outcomes of the different reviews along with testingmechanisms and few observed values are also shown.503

Proceedings of the National Conference onTrends and Advances in Mechanical Engineering,YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012Table 2 Depicting outcomes of the different reviews• Scanning electronPaper Material Process Major Findings Testing MethodNo.1 Al-Mg Compound • Joining of aluminum andAl 12 Mg 17 intermetallicCastingmagnesium by the compoundcasting process is possible onlymicroscope (SEM).via casting magnesium melt • Energy dispersivearound the aluminum insert, X-ray spectroscopywhile in the case of casting (EDS).aluminum melt around themagnesium insert, a gap is • Wavelengthformed at the interface due to dispersive X-raypresence of oxide layers on thesurface of the aluminum melt andspectroscopy (WDS)detectors.magnesium insert and alsobecause of the interface • X-rayloosening, caused by higher diffractometer.coefficient of thermal expansionof the magnesium insert than the • Push out test.cast aluminum.• Vickers hardness• Formation of the interface in thecompound casting process istester.diffusion controlled and theinterface consists of threedifferent layers.• The layers adjacent to thealuminum and magnesium basemetals are composed of theAl 3 Mg 2 intermetallic compoundand the (Al 12 Mg 17 + ) eutecticstructure, respectively, and themiddle layer is composed of thecompound.2 Titanium/aluminium–siliconTi/Al–7Si–0.3MgInsertMoulding(AluminizingfollowedbyInsertionprocess.)The present paper reports on theapplication of a T6 heat-treatment to thechemically bonded Ti/AS7G bimetallicassemblies.• The results obtained after pushoutand circular bending testshighlight the potential of thisjoining process for producingbimetallic castings with highmechanical strengths.• As expected, the heat treatmentresults in an improvement of themechanical properties of theAS7G matrix itself when appliedto Ti/AS7G assemblies. Asignificant increase of the loadlevel characteristic for damageonset is observed.• This result is of particularinterest, especially whencompared to iron-based inserts inequivalent matrixes, for which a• Optical microscopy(OM).• Scanning electronmicroscopy (SEM).• Energy dispersivespectroscopy (EDS).• Electron probemicroanalysis(EPMA).• Classical push-outtest.• Circular bendingtests• T6-type heattreatment504

3 Al-Al CompoundCastingusing highpressuredie casting4 Mg-MgMagnesiummelt (pureMg or AJ62)is cast onto asolidmagnesiumsubstrate(AZ31) i.e(a)AZ31/AJ62and(b)AZ31/“Mg”compoundsProceedings of the National Conference onTrends and Advances in Mechanical Engineering,YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012dramatic weakening of theinterface chemical bond wasnoticed after T6 heat treatment.• After T6 treatment, the shape ofthe Si particles changes fromangular to round as a result of apartial re-dissolution at 540 ◦C.Moreover, the size and number ofthese particles decreasesignificantly in the vicinity of theinsert/alloy interface due to aselective migration of Si towardsthe Ti insert by solid-statediffusion.• The fabrication of an aluminium–aluminium compound wassuccessfully realized by highpressure die casting. Apermanent activation of an Alinsert’s surface was achieved bycombining zincate treatment andzinc galvanizing.• The layer reacts during thecasting process and a continuousmetallic transition forms. Widthas well as microstructure of thetransition zone between matrixand insert varies with varyinginitial layer thickness.CompoundCasting • A pre-treatment technique toenable the wettability of solidmagnesium substrates bymagnesium melts was realized.• By means of laboratory-scalecompound casting experimentsthe reproducible production ofall-magnesium compounds wassuccessfully established.• The newly developed joiningmethod eliminates manydisadvantages of conventionalapproaches, considering galvaniccorrosion, welding depth or lowprocess efficiency.• The coating, an easily depositedmetallic Zn/MgZn2 layer withgood adhesion, is applied viacombiningchemical,electrochemical and heattreatments. It leads to a completechange of the substrate’s surfacereactivity towards Mg melts,providing excellent wettability.• An area-wide, continuouslymetallurgic, defect-free and welldefinedtransition between AZ31505• Optical microscopy.• Scanning electronmicroscopy (SEMPhilips XL30).• The EDX system ofthe SEM are usedfor analysing theelement composition• Hardness testerusing a Vickersindenter.• The tensile tests areperformed with thetensile testingmachine.• Elongation ismeasured with anextensometer• Energy-dispersiveX-ray spectroscopy(EDX).• Scanning electronmicroscope (SEM,Camscan Series 4).• Microhardness.• Differentialscanningcalorimetry

5 Copperwires withdiameters of0.4, 1, and 2mm intopolystyrenepatterns,followed bypouring ofgray ironmelt.6 Al-Al,Al-Mg(a)AlMg1/AlSi7(b)AlMg1/AlCu7Lost foamcasting(LFC)processCompoundCastingwithZincateprocessand ZngalvanizingProceedings of the National Conference onTrends and Advances in Mechanical Engineering,YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012substrate and AJ62 magnesiumcast alloy (as well as 99.98%pure Mg) was achieved.• The coating material has only aminor influence on thecompounds’ microstructure andmechanical properties• The melted copper wire dissolvedin the gray iron matrix up toabout 0.9 wt.% and the copperexceeding the limits of solubilitywas dispersed throughout thematrix. Some copper particlessegregated at the bottom of themold due to their high specificgravity.• The graphite morphology inreference sample (without copperinsert) was type A flakes. Insamples containing copper wire,graphite type changed to B, D orE flakes depending on theexperimental variables.• When the copper insert wascompletely or extensively melted,type D or E flake graphite formedin the specimen due to the highundercooling during eutecticsolidification.• When the copper insert was notmelted or was partially melted,type B flake graphite appearedinside the Wire Affected Zonearound the copper wire, due torather high undercooling duringeutectic solidification.• Different metallic or non-metallicmaterials in the form of wire,particles, and so on, can beinserted into the polystyrenepatterns during pattern makingstage of lost foam castingprocess. This procedure can beutilized for in-mold alloying,production of bi-metal andcomposite materials, study ofinterface between the matrix andthe insert, and investigation ofreaction phases formed at theinterface.• Through adequate surfacetreatments and coatings, theAlMg1 substrate’s wettabilitywas improved in a way that thecouples of Al–Al and Al–Mgwere successfully produced.• Interfaces showed very low (Al–Mg) to no (Al–Al) formation ofIMPs, and other defects, such asoxide inclusions, contraction• Optical microscopy.• Scanning electronmicroscopes (SEM)coupled with anenergy dispersivespectroscopy (EDS)system• Electron microscopy• EDX investigations• Optical micrographs• Diffusionsimulations usingDICTRA software506

7 Mg shell andAl coreDisintegrated meltdeposition(DMD)methodand toppouringfollowedby hotcoextrusion8 Al-Al CompoundCastingProceedings of the National Conference onTrends and Advances in Mechanical Engineering,YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012cavities or cracks.• The combined coating of zincatetreatment and electrolyticallydepositedzinc for Al–Alcompounds offers majoradvantages compared to otherapproaches to joining lightmetals.• The zincate treatment is the mostimportant process step also forsurface preparation of thesubstrate for Al–Mg compounds.This treatment is followed byelectrolytic deposition of an Mnlayer of several micronsthickness to protect the substratefrom liquefaction by the Mgmelt, without sacrificing toomuch of wettability.• A thin layer of IMPs formsduring couple production, whichmight affect mechanical integrity.Keeping this interface thin is apossible way to improve thecompound’s properties.• Mg/Al macrocompositecontaining Mg shell and Al corecan be synthesized using acombination of DMD methodand top-pouring, followed by hotcoextrusion.• Mg based macrocompositecontaining Mg shell and Al coreis thermally more stable thanmonolithic Mg, due to fairlyuniform Al volume fraction andmechanical interlocking at theinterface.• Millimeter length scale Alreinforcement in Mg improvesstiffness and significantlyincreases failure strain and workof fracture of Mg while 0.2%YSand UTS are compromised.• Couples of AlMg1 substrate andvarious Al alloys weresuccessfully produced by meansof a laboratory-scale compoundcasting process.• A combination of pre-treatmentsand Zn coatings drasticallyenhanced wettability of thesubstrate, generating defect-freeinterfaces.• The combined coating of zincatetreatment and electrolyticallydeposited Zn offers majoradvantages compared to other• Olympusmetallographicmicroscope.• Hitachi S4300 fieldemissionscanningelectron microscope(FESEM).• Image analysis usingScion software.• Interfacial integritywas observed usingFESEM coupledwith energydispersive X-rayspectroscopy (EDS).• The coefficients ofthermal expansion(CTE) using anautomatedthermomechanicalanalyser.• Optical microscopy.• Glow dischargeoptical spectroscopy(GDOS)• One-dimensionaldiffusionsimulationsperformed usingDICTRA software.Microhardnessmeasurement.xc507

9 Titanium(insert)/aluminium–siliconTi/Al–7SiInsertmouldingProceedings of the National Conference onTrends and Advances in Mechanical Engineering,YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012approaches to joining light metals• Bimetallic specimen test piecesof an AS-7 matrix locallyreinforced with a titanium insertthat have been produced using anexperimental procedure allowingthe control of both the interfacialreaction layer and themetallurgical health of the matrix(directional solidification).• The results obtain under push-outsolicitation highlight the potentialof the joining process forproducing castings with highmechanical performances.• Push-out test and avariant that is thecircular-bending testto investigate themechanical strength.• Characterization ofthe interfacial zoneby OpticalMicroscopy (OM),Scanning ElectronMicroscopy (SEM)and ElectronMicropobe Analyses(EPMA).• When a chemical bond isestablished at the Ti/AS-7interface an important rise ofmechanical properties for thebimetallic assembly is observed:the mean shear strength value isabout 120 MPa whereas it is of48 MPa for simply frettedspecimens.• Finite ElementModeling (FEM)was performed todescribe the stressdistribution in abimetallic sliceduring push-out testat different loadlevel.• A three steps failure sequenceproposed is both characterized bycrack propagation from bottom totop and matrix yielding from topto bottom.10 S45C steelinsert tocopperCastwelding orcompoundcasting• Heat treatment formed reactedlayers in the interface. The layernear the S45C steel matrix wasthe cast welding layer; anotherclose to the copper matrix wasthe irregular layer, and the otherbetween these two layers was themiddle layer.• The microstructureof the compoundcasting wasobserved by OM(optical microscope)and SEM (scanningelectronmicroscope).• EPMA proved that most of theiron atoms diffused into thecopper matrix and only a fewcopper atoms diffused into theiron matrix during diffusionoccurred between two matrices.X-ray diffraction showed that thechemical compounds of theinterface were CuFeO2 and C.• Furnace-cooling yielded thelargest interface shear strength,and water quenching yielded theleast.The fractured region wasnear the S45C steel matrix in thecast welding layer.• The interface phasewas analyzed by X-ray diffraction andthe composition wasdetermined usingEDS and EPMA(electron probemicro-analysis).• A push-out test wasused to determinethe interface shearstrength508

Proceedings of the National Conference onTrends and Advances in Mechanical Engineering,YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 20125. Gaps in Existing LiteratureA limited work is done on compound casting processes till now. In many cases, one material alone does notsatisfy the requirements of lightweight constructions, and dissimilar joining between two metals must be needed.A variety of attempts have been dedicated to joining meals and alloys using different fusion welding and solidstatejoining methods such as tungsten inert gas welding, laser welding, friction-stir welding, and vacuumdiffusion bonding. The major problem in these joining processes is the formation of much more intermetalliccompounds with a very high hardness and brittleness between two meats as an interlayer, which is deleterious tothe mechanical properties. However, solid-state joining processes such as friction-stir welding and vacuumdiffusion bonding can achieve relatively higher joining strengths compared to fusion methods, due to eliminationof defects like shrinkage, porosities and inclusions. In addition, long process time and high correspondingoperating cost of the vacuum diffusion bonding and specific requirements for the shape of the substrate infriction-stir welding may render these solid-state joining processes not easy for practical and industrialapplications. Microstructure and EDX (energy dispersive x-ray) analysis are performed by some scientists/researchers but Differential Thermal Analysis are not performed. Optimization of process parameters ofcompound casting w.r.t. mechanical properties such as tensile strength, hardness, elongation and impact strengthetc. is not reported in literature till now.6. ConclusionIt may be concluded from above studies that:• The compound casting process presents a solution for meeting the demands of a specific application,particularly in light weight constructions.• The compound casting is the process which meets a wide range of requirements within one componentby combining different materials.• It is possible to make light metal compound cast parts using the combination of light metals like Al-Al,Mg-Mg and Al-Mg, Ti-Al, Cu-steel and Cu- grey cast iron etc.• It is necessary to remove the natural oxide layer for complete diffusion at interface between solid andmelted metal.• The zincate process followed by Zinc electroplating is the best way to remove the effect of oxide layerat the interface.• Formation of the interface in the compound casting process is diffusion controlled and usually theinterface consists of three different layers.• Heat treatment formed reacted layers in the steel-copper interface. Furnace-cooling yielded the largestinterface shear strength, and water quenching yielded the least.• The heat treatment results in an improvement of the mechanical properties of the AS7G matrix itselfwhen applied to Ti/AS7G assemblies. A significant increase of the load level characteristic for damageonset is observed.7. References[1] E. Hajjari, M. Divandari,S. H. Razavi,S. M. Emami,T. Homma,S. Kamado,(2011) “Dissimilar joining ofAl/Mg light metals by compound casting process.”, Journal of Material Science 46:6491–6499.[2] O. Dezellus, M. Zhe, F. Bosselet, D. Rouby, J.C. Viala,(2011) “Mechanical testing of titanium/aluminium–silicon interface: Effect of T6 heat treatment.”, Materials Science and Engineering A 528, 2795–2803[3] M. Rübner, M. Günzl, C. Körner, R.F. Singer,(2011) “Aluminium–aluminium compound fabrication by highpressure die casting.”, Materials Science and Engineering A 528, 7024– 7029[4] K.J.M. Papis, J.F. Löffler, P.J. Uggowitzer, (2010)“Interface formation between liquid and solid Mg alloys—An approach to continuously metallurgic joining of magnesium parts.”, Materials Science and Engineering A527, 2274–2279.[5] M. Mehdi Hejazi, M. Divandari, E. Taghaddos, (2009)“Effect of copper insert on the microstructure of grayiron produced via lost foam casting.”, Materials and Design 30, 1085–1092[6] Konrad J. M. Papis, Joerg F. Loeffler & Peter J. Uggowitzer,(2009) “Light metal compound casting.”,Sciencein China Series E: Technological Sciences, vol. 52, no. 1, 46-51[7] M. Paramsothy, N. Srikanth, M. Gupta,(2008) “Solidification processed Mg/Al bimetal macrocomposite:Microstructure and mechanical properties.” Journal of Alloys and Compounds 461, 200–208[8] K.J.M. Papis a, B. Hallstedt b, J.F. Lo¨ffler a, P.J. Uggowitzer, (2008)“Interface formation in aluminium–aluminium compound casting.”, Acta Materialia 56, 3036–3043.509

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