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 Tayal1, Vikram Singh2 , Sudhir Kumar3 and Rohit Garg4 1 Lecturer, Deptt. of Mech. Engg., Govt. Polytechnic, Sirsa (Haryana), India. email: [email protected] Associate Professor, Deptt. of Mech. Engg., YMCAUST, Faridabad, India. email: [email protected] 3 Professor, Deptt. of Mech. Engg., NIET, Greater Noida(U.P), India. email: [email protected] 2 4 Principal, Indus Institute of Engg. & Tech., Jind (Haryana), India. email: [email protected] 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 501 Proceedings of the National Conference on Trends and Advances in Mechanical Engineering, YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012 researchers have used compound casting to join different similar and dissimilar metallic couples such as steel/cast iron, steel/Cu, steel/Al, Cu/Al, Al/Al, and Mg/Mg, joining dissimilar light metals such as aluminum and magnesium by the compound casting process is still a relatively unexplored area. In this study, compound casting as an economic straightforward in situ technique was used to join dissimilar aluminum and magnesium light metals. Through the combination of various materials, this compound casting process can help components meet the most 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 of production 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 casting solution makes it possible to produce this component as a single piece. The intelligently designed casting made from aluminium or magnesium alloy ensures the high functional integrity of flanges and bearing carriers, for instance. In difficult areas, a carefully positioned insert such as a semi-finished product made of steel or an aluminum alloy provides the necessary strength. In comparison with conventional die casting, the manufacture of a compound casting piece requires additional handling, for example manipulation of inserts or perhaps pretreatment of the surfaces. 3.1. Applications of Compound Casting Compound casting parts are already used in vehicle construction for parts of the chassis, such as the engine block, shock strut supports and gearbox casing, as well as bodywork components, for example door frames and connection supports and as dashboard mounts in the interior. And according to information from the automotive industry, multi-material components are on the increase. This is proven by compound cast parts such as the 6cylinder magnesium engine with aluminum insert from BMW and other components which are undergoing development but have not yet been announced. The aircraft industry, too, is relying more and more on compound cast materials. 3.2. Compound Casting Process The compound casting process to prepare the Al/Mg couples from commercially pure aluminum and commercially pure magnesium are as under. In this process cylindrical inserts with 20 mm diameter and 100 mm height were machined from aluminum and magnesium ingots. Their surfaces were ground with silicon carbide papers up to 1200 grit, then rinsed with acetone and placed within a cylindrical cavity of a CO2 sand mold with 30 mm diameter and 80 mm height. Two series of samples were prepared. In the first series, aluminum ingots were melted in a clay-graphite crucible placed in an electrical resistance furnace. The molten aluminum was cast around the magnesium inserts at 7000C under normal atmospheric conditions. In the second series, magnesium ingots were melted in a steel crucible placed in the same furnace under the covering flux, to protect magnesium melt form oxidation. The molten magnesium was cast around the aluminum inserts at 7000C under normal atmospheric conditions. Schematic sketches of the mold used in the casting process 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 on Trends and Advances in Mechanical Engineering, YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012 4. Literature Review A lot of research material is referred to describe the insights of the compound casting process. However 10 major papers are selected as arranged in descending order of their year of publication in table-1. These 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 be determined. Table-1 Depicting title of papers along with year & journal in which published S.NO Title of Paper Year of Publication Name of Journal 1. Dissimilar joining of Al/Mg light metals by compound casting process 2011 Journal of Materials Science 2. Mechanical testing of titanium/ aluminium– silicon interface: Effect of T6 heat treatment 2011 Materials Science and Engineering A 3. Aluminium–aluminium compound fabrication by high pressure die casting 2011 Materials Science and Engineering A 4. Interface formation between liquid and solid Mg alloys—An approach to continuously metallurgic joining of magnesium parts 2010 Materials Science and Engineering A 5. Effect of copper insert on the microstructure of gray iron produced via lost foam casting 2009 Materials and Design 6. Light metal compound casting 2009 Science in China 7. Solidification processed Mg/Al bimetal macrocomposite: Microstructure and mechanical properties 2008 Journal of Alloys and Compounds 8. Interface formation in aluminium–aluminium compound casting 2008 Acta Materialia 9. Mechanical testing of titanium/aluminium– silicon interfaces by push-out 2008 Journal of Materials Science 10. Effect of continuous cooling heat treatment on interface characteristics of S45C/copper compound casting 2004 Journal of Materials Science These 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 be determined. Table-2 depicts a detailed review of 10 papers on compound casting process or some other processes which are very similar to compound casting process. Outcomes of the different reviews along with testing mechanisms and few observed values are also shown. 503 Proceedings of the National Conference on Trends and Advances in Mechanical Engineering, YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012 Table 2 Depicting outcomes of the different reviews Paper No. 1 2 Material Al-Mg Titanium/alu minium– silicon Ti/Al–7Si– 0.3Mg Process Compound Casting Insert Moulding (Aluminizi ng followed by Insertion process.) Major Findings • Joining of aluminum and magnesium by the compound casting process is possible only via casting magnesium melt around the aluminum insert, while in the case of casting aluminum melt around the magnesium insert, a gap is formed at the interface due to presence of oxide layers on the surface of the aluminum melt and magnesium insert and also because of the interface loosening, caused by higher coefficient of thermal expansion of the magnesium insert than the cast aluminum. • Formation of the interface in the compound casting process is diffusion controlled and the interface consists of three different layers. • The layers adjacent to the aluminum and magnesium base metals are composed of the Al 3 Mg 2 intermetallic compound and the (Al 12 Mg 17 + ) eutectic structure, respectively, and the middle layer is composed of the intermetallic Al 12 Mg 17 compound. The present paper reports on the application of a T6 heat-treatment to the chemically bonded Ti/AS7G bimetallic assemblies. • The results obtained after pushout and circular bending tests highlight the potential of this joining process for producing bimetallic castings with high mechanical strengths. • As expected, the heat treatment results in an improvement of the mechanical properties of the AS7G matrix itself when applied to Ti/AS7G assemblies. A significant increase of the load level characteristic for damage onset is observed. • This result is of particular interest, especially when compared to iron-based inserts in equivalent matrixes, for which a 504 Testing Method • Scanning electron microscope (SEM). • Energy dispersive X-ray spectroscopy (EDS). • Wavelength dispersive X-ray spectroscopy (WDS) detectors. • X-ray diffractometer. • Push out test. • Vickers tester. • Optical microscopy (OM). Scanning electron microscopy (SEM). Energy dispersive spectroscopy (EDS). Electron probe microanalysis (EPMA). Classical push-out test. Circular bending tests T6-type heat treatment • • • • • • hardness Proceedings of the National Conference on Trends and Advances in Mechanical Engineering, YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012 • 3 Al-Al Compound Casting using high pressure die casting • • dramatic weakening of the interface chemical bond was noticed after T6 heat treatment. After T6 treatment, the shape of the Si particles changes from angular to round as a result of a partial re-dissolution at 540◦C. Moreover, the size and number of these particles decrease significantly in the vicinity of the insert/alloy interface due to a selective migration of Si towards the Ti insert by solid-state diffusion. The fabrication of an aluminium– aluminium compound was successfully realized by high pressure die casting. A permanent activation of an Al insert’s surface was achieved by combining zincate treatment and zinc galvanizing. The layer reacts during the casting process and a continuous metallic transition forms. Width as well as microstructure of the transition zone between matrix and insert varies with varying initial layer thickness. • • • • • • 4 Mg-Mg Magnesium melt (pure Mg or AJ62) is cast onto a solid magnesium substrate (AZ31) i.e (a) AZ31/AJ62 and (b) AZ31/“Mg” compounds Compound Casting • • • • • • A pre-treatment technique to enable the wettability of solid magnesium substrates by magnesium melts was realized. By means of laboratory-scale compound casting experiments the reproducible production of all-magnesium compounds was successfully established. The newly developed joining method eliminates many disadvantages of conventional approaches, considering galvanic corrosion, welding depth or low process efficiency. The coating, an easily deposited metallic Zn/MgZn2 layer with good adhesion, is applied via combining chemical, electrochemical and heat treatments. It leads to a complete change of the substrate’s surface reactivity towards Mg melts, providing excellent wettability. An area-wide, continuously metallurgic, defect-free and welldefined transition between AZ31 505 • • • Optical microscopy. Scanning electron microscopy (SEM Philips XL30). The EDX system of the SEM are used for analysing the element composition Hardness tester using a Vickers indenter. The tensile tests are performed with the tensile testing machine. Elongation is measured with an extensometer Energy-dispersive X-ray spectroscopy (EDX). Scanning electron microscope (SEM, Camscan Series 4). Microhardness. Differential scanning calorimetry Proceedings of the National Conference on Trends and Advances in Mechanical Engineering, YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012 • 5 Copper wires with diameters of 0.4, 1, and 2 mm into polystyrene patterns, followed by pouring of gray iron melt. Lost foam casting (LFC) process • • • • • 6 Al-Al, Al-Mg (a)AlMg1/Al Si7 (b) AlMg1/AlC u7 Compound Casting with Zincate process and Zn galvanizin g • • substrate and AJ62 magnesium cast alloy (as well as 99.98% pure Mg) was achieved. The coating material has only a on the minor influence compounds’ microstructure and mechanical properties The melted copper wire dissolved in the gray iron matrix up to about 0.9 wt.% and the copper exceeding the limits of solubility was dispersed throughout the matrix. Some copper particles segregated at the bottom of the mold due to their high specific gravity. The graphite morphology in reference sample (without copper insert) was type A flakes. In samples containing copper wire, graphite type changed to B, D or E flakes depending on the experimental variables. When the copper insert was completely or extensively melted, type D or E flake graphite formed in the specimen due to the high undercooling during eutectic solidification. When the copper insert was not melted or was partially melted, type B flake graphite appeared inside the Wire Affected Zone around the copper wire, due to rather high undercooling during eutectic solidification. Different metallic or non-metallic materials in the form of wire, particles, and so on, can be inserted into the polystyrene patterns during pattern making stage of lost foam casting process. This procedure can be utilized for in-mold alloying, production of bi-metal and composite materials, study of interface between the matrix and the insert, and investigation of reaction phases formed at the interface. Through adequate surface treatments and coatings, the AlMg1 substrate’s wettability was improved in a way that the couples of Al–Al and Al–Mg were successfully produced. Interfaces showed very low (Al– Mg) to no (Al–Al) formation of IMPs, and other defects, such as oxide inclusions, contraction 506 • • Optical microscopy. Scanning electron microscopes (SEM) coupled with an energy dispersive spectroscopy (EDS) system • • • • Electron microscopy EDX investigations Optical micrographs Diffusion simulations using DICTRA software Proceedings of the National Conference on Trends and Advances in Mechanical Engineering, YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012 • • • 7 Mg shell and Al core Disintegrat ed melt deposition (DMD) method and toppouring followed by hot coextrusio n • • • 8 Al-Al Compound Casting • • • cavities or cracks. The combined coating of zincate treatment and electrolyticallydeposited zinc for Al–Al compounds offers major advantages compared to other approaches to joining light metals. The zincate treatment is the most important process step also for surface preparation of the substrate for Al–Mg compounds. This treatment is followed by electrolytic deposition of an Mn layer of several microns thickness to protect the substrate from liquefaction by the Mg melt, without sacrificing too much of wettability. A thin layer of IMPs forms during couple production, which might affect mechanical integrity. Keeping this interface thin is a possible way to improve the compound’s properties. Mg/Al macrocomposite containing Mg shell and Al core can be synthesized using a combination of DMD method and top-pouring, followed by hot coextrusion. Mg based macrocomposite containing Mg shell and Al core is thermally more stable than monolithic Mg, due to fairly uniform Al volume fraction and mechanical interlocking at the interface. Millimeter length scale Al reinforcement in Mg improves stiffness and significantly increases failure strain and work of fracture of Mg while 0.2%YS and UTS are compromised. Couples of AlMg1 substrate and various Al alloys were successfully produced by means of a laboratory-scale compound casting process. A combination of pre-treatments and Zn coatings drastically enhanced wettability of the substrate, generating defect-free interfaces. The combined coating of zincate treatment and electrolytically deposited Zn offers major advantages compared to other 507 • Olympus metallographic microscope. • Hitachi S4300 fieldemission scanning electron microscope (FESEM). • Image analysis using Scion software. • Interfacial integrity was observed using FESEM coupled with energy dispersive X-ray spectroscopy (EDS). • The coefficients of thermal expansion (CTE) using an automated thermomechanical analyser. • Optical microscopy. • Glow discharge optical spectroscopy (GDOS) • One-dimensional diffusion simulations performed using DICTRA software. Microhardness measurement.xc Proceedings of the National Conference on Trends and Advances in Mechanical Engineering, YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012 9 10 Titanium(ins ert)/aluminiu m–silicon Ti/Al–7Si S45C steel insert to copper Insert moulding Cast welding or compound casting • approaches to joining light metals Bimetallic specimen test pieces of an AS-7 matrix locally reinforced with a titanium insert that have been produced using an experimental procedure allowing the control of both the interfacial reaction layer and the metallurgical health of the matrix (directional solidification). • Push-out test and a variant that is the circular-bending test to investigate the mechanical strength. • Characterization of the interfacial zone by Optical Microscopy (OM), Scanning Electron Microscopy (SEM) and Electron Micropobe Analyses (EPMA). • Finite Element Modeling (FEM) was performed to describe the stress distribution in a bimetallic slice during push-out test at different load level. • The results obtain under push-out solicitation highlight the potential of the joining process for producing castings with high mechanical performances. • When a chemical bond is established at the Ti/AS-7 interface an important rise of mechanical properties for the bimetallic assembly is observed: the mean shear strength value is about 120 MPa whereas it is of 48 MPa for simply fretted specimens. • A three steps failure sequence proposed is both characterized by crack propagation from bottom to top and matrix yielding from top to bottom. • Heat treatment formed reacted layers in the interface. The layer near the S45C steel matrix was the cast welding layer; another close to the copper matrix was the irregular layer, and the other between these two layers was the middle layer. • The microstructure of the compound casting was observed by OM (optical microscope) and SEM (scanning electron microscope). • EPMA proved that most of the iron atoms diffused into the copper matrix and only a few copper atoms diffused into the iron matrix during diffusion occurred between two matrices. X-ray diffraction showed that the chemical compounds of the interface were CuFeO2 and C. • The interface phase was analyzed by Xray diffraction and the composition was determined using EDS and EPMA (electron probe micro-analysis). • • Furnace-cooling yielded the largest interface shear strength, and water quenching yielded the least.The fractured region was near the S45C steel matrix in the cast welding layer. A push-out test was used to determine the interface shear strength 508 Proceedings of the National Conference on Trends and Advances in Mechanical Engineering, YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012 5. Gaps in Existing Literature A limited work is done on compound casting processes till now. In many cases, one material alone does not satisfy 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 solidstate joining methods such as tungsten inert gas welding, laser welding, friction-stir welding, and vacuum diffusion bonding. The major problem in these joining processes is the formation of much more intermetallic compounds with a very high hardness and brittleness between two meats as an interlayer, which is deleterious to the mechanical properties. However, solid-state joining processes such as friction-stir welding and vacuum diffusion bonding can achieve relatively higher joining strengths compared to fusion methods, due to elimination of defects like shrinkage, porosities and inclusions. In addition, long process time and high corresponding operating cost of the vacuum diffusion bonding and specific requirements for the shape of the substrate in friction-stir welding may render these solid-state joining processes not easy for practical and industrial applications. 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 of compound casting w.r.t. mechanical properties such as tensile strength, hardness, elongation and impact strength etc. is not reported in literature till now. 6. Conclusion It 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 component by 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 and melted metal. The zincate process followed by Zinc electroplating is the best way to remove the effect of oxide layer at the interface. Formation of the interface in the compound casting process is diffusion controlled and usually the interface consists of three different layers. Heat treatment formed reacted layers in the steel-copper interface. 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