Composite part with external part cast around internal insert and method for producing the same

Abstract

Composite parts and methods for making the same are disclosed. A composite part may include an internal insert component that is coated on at least a portion of its surface with certain types of particles, an external part component cast around the coated insert, and a particle-rich region that is formed between the two components, where the particle-rich region includes particles from the coated insert. A method for producing a composite part may include the steps of: positioning an internal insert component that is coated on at least a portion of its surface within a mold cavity of a casting die; casting a molten material of the external part component around the coated insert; and solidifying the molten material to form the external part component of the composite part.

1 . A composite metal part, comprising:
 an internal insert component that is made from a first metal material and includes a coating on at least a portion of an outer surface;   an external part component that is made from a second metal material and is cast around at least a portion of the internal insert component; and   a particle-rich region that includes a plurality of dispersed particles from the coating and is located between the internal insert component and the external part component, wherein the first metal material is different than the second metal material.   
     
     
         2 . The composite metal part of  claim 1 , wherein the particle-rich region includes an intermetallic layer formed from the first metal material, the second metal material, and the coating. 
     
     
         3 . The composite metal part of  claim 1 , wherein the particle-rich region forms a layer between the first and second metal materials having a thickness of approximately 20 micrometers (μm) to 180 micrometers (μm), inclusive. 
     
     
         4 . The composite metal part of  claim 1 , wherein the first metal material includes a magnesium-based material. 
     
     
         5 . The composite metal part of  claim 1 , wherein the internal insert component is hollow. 
     
     
         6 . The composite metal part of  claim 1 , wherein the second metal material includes an aluminum-based material. 
     
     
         7 . The composite metal part of  claim 6 , wherein the aluminum-based material includes one of an aluminum A380 alloy, an A360 alloy, an Aural-2 alloy, or an ADC12 alloy. 
     
     
         8 . The composite metal part of  claim 6 , wherein both the coating on the internal insert component and the plurality of dispersed particles in the particle-rich region include at least one material selected from the group consisting of: a silicon-based material, a titanium-based material, an oxide, or a carbide. 
     
     
         9 . The composite metal part of  claim 1 , wherein the composite metal part is a steering knuckle. 
     
     
         10 . The composite metal part of  claim 1 , further comprising a support pin engaged with the internal insert component and cast with the external part component. 
     
     
         11 . The composite metal part of  claim 1 , wherein the external part component defines a gap along an outer surface, thereby partially exposing the internal insert component. 
     
     
         12 . The composite metal part of  claim 1 , wherein the particles of the coating of the internal insert component are initially applied in a substantially homogeneous distribution about the portion of the outer surface of the internal insert component. 
     
     
         13 . A method of forming a composite part having an internal insert component and an external part component, comprising the steps of:
 positioning the internal insert component within a mold cavity, wherein the internal insert component comprises a first metal material, and wherein at least a portion of an outer surface of the internal insert component is covered with a coating comprising a plurality of particles;   casting a molten material around the internal insert component, the molten material comprising a second metal material different from the first metal material; and   solidifying the molten material to form the external part component of the composite part, thereby dispersing the particles to form a particle-rich region located between the internal insert component and the external part component.   
     
     
         14 . The method of  claim 13 , further comprising cooling the internal insert component as the molten material is cast around the internal insert. 
     
     
         15 . The method of  claim 13 , wherein the first metal material includes a magnesium-based material, and the second metal material includes an aluminum-based material. 
     
     
         16 . The method of  claim 15 , wherein both the coating on the internal insert component and the plurality of dispersed particles in the particle-rich region include at least one material selected from the group consisting of: a silicon-based material, a titanium-based material, an oxide, or a carbide. 
     
     
         17 . The method of  claim 13 , wherein the coating is distributed substantially homogeneously about the portion of the outer surface of the internal insert component. 
     
     
         18 . The method of  claim 17 , wherein a percentage by weight of the coating varies no more than 12% along the portion of the outer surface of the internal insert component prior to the casting of the molten material. 
     
     
         19 . The method of  claim 13 , further comprising cooling the particle-rich region using a directed cooling path to the internal insert component. 
     
     
         20 . The method of  claim 19 , wherein the cooling path is along a support pin supporting the internal insert component in the mold cavity.