Lightweight brake rotor and components with composite materials

A product comprising:

• placing a first insert and a second insert in a casting mold so that the first insert and second insert are in spaced-apart relationship in the mold, each of the first insert and the second insert comprising a first material;
• casting a molten second material into the casting mold so that the second material flows between the first insert and the second insert and solidifying the second material to provide a product comprising a cast over body portion with the first insert and second insert, the cast over body portion comprising the second material and so that the second material is mechanically locked or metallurgically bonded to the first material and so that one or both of the first insert and the second insert provides working surface(s) for the product.

A product comprising:

• placing at least a first insert in a casting mold so that the first insert, the first insert comprising a plurality of projections extending from first surface thereof and the first insert comprising a second surface, the second surface providing a working surface, the first insert comprising a first material;
• casting a molten second material into the casting mold so that the second material provides a cast over body portion comprising the second material and so that the second material is mechanically locked to the plurality of projections and solidifying the second material to provide a product.