Patent ID: 8672018

Claim:
A method of forming a cylinder head including a cast portion, the method comprising: providing a preform defining a portion of a combustion chamber; wherein the preform is made of a composite material including a first layer made of a first material, a second layer made of a second material different from the first material, and a first bonded interface therebetween; wherein the first layer defines a combustion surface of the combustion chamber; positioning the preform in a die cavity of a casting die configured to form the cast portion of the cylinder head, wherein the preform is positioned such that the second layer is exposed to the die cavity and the first layer is in contact with the casting die; forming a cylinder head casting by: providing a molten casting material to the die cavity such that the molten casting material is in fluid communication with the second layer of the preform; and solidifying the molten casting material to form a cast portion and to form a second bonded interface between the cast portion and the second layer of the preform; and wherein the second bonded interface is characterized by a cast microstructure including the casting material and the second material; the second bonded interface forming a metallurgical bond between the cast portion and the second layer.