High Performance Auto Parts Could be Produced Using CastCon Manufacturing Process

High performance auto parts such as aluminum composite cladding aluminum brake and Ti/Ti₃/Al joined exhaust valve with localized Ti+TiC composite coating could be produced using a new manufacturing method - the CastCon process. The aluminum composite cladding aluminum brake consists of an aluminum alloy body with a cladding of SiC and graphite particulate filled aluminum composite on the friction surface of a brake disk or a drum. This structure can ensure an over-all light weight and integral strength and ductility. The SiC particulate in the cladding composite increases abrasion resistance and the graphite particulate provides required lubrication. The cladding can be as thick as desired. There is a flexibility in the manufacturing process for selecting SiC and graphite loading volumes as well as particulate size and shape. This allows the part to be engineered to achieve maximum performance. Ti/Ti₃Al joined exhaust valves with localized Ti+TiC composite coating consists of a Ti₃Al head, which is subjected to high temperature in a cylinder; a titanium alloy body, which works in the lower temperature environment outside of the cylinder; and Ti+TiC composite coating on the contact surface to improve wear resistance for long seal life. This kind of exhaust valve is expected to be light weight, resulting in less noise and increased gas milage. It also should have better reliability than ceramic valves, and hold a tight seal longer than conventional steel valves.

The CastCon process is a manufacturing approach which combines casting, forging, P/M, bonding and coating to produce high performance components. It is capable of producing parts with a wide variety of sizes, shapes, materials and structural characteristics. Demonstration parts of various sizes and shapes have been produced using this process, including aluminum composite cladding aluminum disks and Ti/Ti₃Al joined exhaust valves with Ti+TiC composite coating. The results are introduced.