Compound casting for lightweight applications with optimized properties
| Reference number | |
| Coordinator | RISE SWECAST AB - Swerea SWECAST AB |
| Funding from Vinnova | SEK 2 384 327 |
| Project duration | April 2018 - December 2021 |
| Status | Completed |
| Venture | FFI - Sustainable Production |
| Call | 2016-05469-en |
Important results from the project
The project has aimed to develop and implement compound casting as a method for producing lightweight components for the automotive industry with maintained performance and with an objective to be able to cast ductile iron and aluminum together to achieve a lowered weight by 30% in a truck hub. Ductile iron cylinders have been cast together with aluminum and the method has been evaluated for different critical properties and full-size, compound cast hubs have been produced. Good properties have been obtained in the joint. A weight reduction of up to 35% has been achieved.
Expected long term effects
The project has provided information about which surface treatment of the ductile iron that leads to an intermediate layer between ductile iron and aluminum with good metallic bonding and thereby good mechanical and thermal performance. Through the manufacture of full-size hubs, the technology has been possible to be tested in an industrial casting process with good results. By including a metal matrix composite brake disc in the concept, an even greater weight reduction has been achieved. By compound casting, the useful weight of truck transports can be increased.
Approach and implementation
Eight different surface treatments have been analyzed regarding how joint quality between ductile iron and aluminum. This has been evaluated by analyzing thermal conductivity, mechanical performance and microstructure of the component. Hot-dipping showed good performance and was also judged to be relatively easy to implement industrially, which is why this method was further developed and optimized for various process parameters. Based on optimized parameters, about 30 full-size hubs were cast. Method development and analysis also included two master theses.