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<p>In this study, bimetallic castings of metal matrix composite alloy (MMCA), comprising high-carbon grey cast iron (HCGCI) and high-chromium stainless steel 304 (HCSS 304), were successfully fabricated via green sand mould casting. Microstructural analysis of the interfacial region employed optical microscopy (OM), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD). Results revealed a robust, defect-free metallurgical bond formed through uphill diffusion, with carbon migrating from the HCGCI towards the HCSS 304 side and counter-diffusion of chromium. This process generated carbides in the interfacial zone, enhancing hardness and structural integrity. Interfacial hardness surpassed that of both parent materials, while impact strength achieved an optimal balance of toughness and strength. Average ultimate tensile strength fell between those of the constituents. Overall, the HCGCI/HCSS 304 bimetal synergistically combines the wear resistance and damping capacity of grey cast iron with the strength and corrosion resistance of stainless steel, positioning it as a promising functionally graded material for advanced engineering applications.</p>

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Fabrication and Mechanical Properties of Bimetallic Materials Made from Liquid HCGCI/HCSS 304 Using the Green Sand Mould Casting Process

  • 期刊论文

  • 发表日期：

    2026年3月19日

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  • Bateshwar Prasad,
  • Amitesh Kumar,
  • Nandita Gupta

摘要

In this study, bimetallic castings of metal matrix composite alloy (MMCA), comprising high-carbon grey cast iron (HCGCI) and high-chromium stainless steel 304 (HCSS 304), were successfully fabricated via green sand mould casting. Microstructural analysis of the interfacial region employed optical microscopy (OM), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD). Results revealed a robust, defect-free metallurgical bond formed through uphill diffusion, with carbon migrating from the HCGCI towards the HCSS 304 side and counter-diffusion of chromium. This process generated carbides in the interfacial zone, enhancing hardness and structural integrity. Interfacial hardness surpassed that of both parent materials, while impact strength achieved an optimal balance of toughness and strength. Average ultimate tensile strength fell between those of the constituents. Overall, the HCGCI/HCSS 304 bimetal synergistically combines the wear resistance and damping capacity of grey cast iron with the strength and corrosion resistance of stainless steel, positioning it as a promising functionally graded material for advanced engineering applications.