Compound casting is a process in which a single component is made from two metallic materials, such as aluminum and steel. Solid-liquid bimetallic compounds can be produced by suitable process control. This technology can reduce the number of joining processes, and the specific properties of the respective metal component can be used for specifically designed product properties, for example, where lightweight and high strength are needed. This paper presents an experimental methodology for producing a purely material-bonded bimetallic joint from cast aluminum and zinc-coated sheet steel in 3D sand casting using an inductive heating system. The process-related temperature characterisation in the compound zone is described using a heating test rig and temperature measurements. It shows that inductive preheating can only produce a material bond between the aluminum casting and the coated steel sheet. Shear tensile tests showed strengths between 15 MPa and 22 MPa. Laser surface pre-treatment using laser ablation cutting on the coated steel sheet was carried out to investigate the benefit of possible microform-locking. The results show a strength-reducing influence on the tensile shear tests. Micrographs showed the formation of Al_4.5FeSi and Al₇Fe₂Si, as well as the formation of other undefined intermetallic phases. The thickness of the compound zone is 10 µm.

Combining light metals like aluminum to produce lightweight structures offers a high weight‐saving and contributes to a circular economy in automotive car body construction. Compound casting is a promising process for producing car body parts. Difficulties arise in creating metallic continuity between insert and casting. Insert coatings are used to remove the oxide layer and thereby improve the wettability of the melt. This study uses a hybrid joining method to improve the metallic bond between insert and casting. Induction heating differently influences the strength properties of age‐ and nonage‐hardenable inserts. Compression shear tests characterize the metallic bond strength. Microscopic images show the influence of the process variables on the compound quality. Reproducible sound metallic bonding with low scattering is achieved by enhancing the compound casting process through induction and no insert coating. Cast wall thicknesses down to 4 mm contribute to further lightweight potential as they have the same strength level as the reference sample. A decisive factor is the insert temperature in the compound zone. Thereby, insert preheating conditions play a crucial role. Additional heat treatment of hardenable compounds leads to a further increase in metallic bond strength.

The production of hollow cores using 3D sand printing is state-of-the-art. Hollow cores are advantageous in decoring, gas permeability and material consumption. The methodology for producing hollow cores, as in 3D sand printing, is not transferable to core shooting. However, using sacrificial ice cores (SaIC) as a tool to produce hollow cores in a core shooting process enable complex hollow structures, as in 3D sand printing. Recently there has been an effort towards more environmentally friendly production. In this regard, water glass binders are in the focus of the metal casting industry and research institutions. This work presents a new method for producing water glass-bonded hollow cores using SaIC in a core shooting process. The manufacturing principle is detailed using a bending test bar and a near-series prototype core. The bending strength of the hollow bending test bars reaches up to 300 N/cm². Due to the hollow structure, the decoring behaviour is significantly improved compared to solid cores.