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

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