Compound casting for innovative products and combined properties

Important results from the project

The aim of the project is to use the compound casting technique to combine ductile iron and aluminium. One of the goals in the pre study was to find a suitable method for joining the different materials. Another goal was to use a demonstrator to demonstrate a potential weigh reduction of 30 %. Additionally, the project was supposed to propose a relevant analysis method for the interface and to propose a plan for further work. All goals set in the project have been achieved.

Expected long term effects

A conceptual hybrid hub was developed within the project which demonstrates that 30 % weight reduction of a heavy vehicle wheel hub is possible using compound casting. Moreover, a simplified demonstrator has been constructed to be able to demonstrate the production process and the properties of the joint. The effect of an industrially functional compound casting process is expected to be significant. The process can be used to optimise components in many applications, where ductile iron or steel is used today because the mechanical properties of aluminium are insufficient.

Approach and implementation

Within the project, Volvo has developed a conceptual hybrid wheel hub made from ductile iron and aluminium. The hybrid hub has been used to set the requirements on the process and the final properties. A simplified demonstrator has been developed and cast with different material combinations and surface treatments. The interface has been evaluated with respect to metallurgical quality and mechanical strength. The influence of heat treatment on the joint has also been studied.