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1
Kiattisaksri, Chatcharit. "Time-Resolved and In-Situ Study on Evolution of Spheroidal Graphite Nodules and Volume Change During Solidification in Ductile Cast Iron." Kyoto University, 2019. http://hdl.handle.net/2433/244548.
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Martinez, Thomas. "Etude de l'endommagement lors du démasselotage à chaud de bielles en fonte GS ADI moulées forgées." Thesis, Reims, 2016. http://www.theses.fr/2016REIMS002/document.
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Les travaux de cette thèse ont été initiés par la volonté industrielle de lever le verrou technologique du démasselotage à chaud de bielles en fonte GS. Ces bielles sont obtenues par un procédé de fabrication hybride innovant mêlant forgeage et fonderie en moule métallique. Ce procédé exige que le démasselotage soit effectué dans la « chaude de coulée » lorsque la fonte GS est en phase austénitique. La découpe de la fonte dans ces conditions de température fait apparaître des défauts majeurs sur les surfaces découpées préjudiciables à la suite du process. Pour pouvoir répondre à cette problématique, une étude est menée sur la caractérisation du comportement et de l’endommagement de la fonte GS dans les conditions de température du process. Une attention particulière est portée sur l’influence de la microstructure nodulaire sur les mécanismes de la rupture. Afin de se doter d’outils de simulation pour mettre au point le processus de démasselotage à chaud, les paramètres du modèle de comportement et d’endommagement de Gurson-Tvergaard-Needleman appliqués à la fonte GS sont identifiés par méthode inverse. Enfin, un plan d’expérience est déployé sur un démonstrateur de découpe instrumenté afin d’obtenir la configuration optimale des paramètres process pour une découpe sans défaut. Cette dernière étude met en avant la présence d’une transition d’un mode de rupture ductile à fragile lors de l’apparition des défauts de démasselotageThis work was initiated by the technological problematic of hot trimming of nodular cast iron connecting rods. These connecting rods are obtained by an innovative hybrid process that combines forging and metal mold casting. This process requires the trimming to be conducted at high temperatures in the is the austenitic phase of the cast iron. Hot trimming of cast iron brings up major defects on the cut surfaces which are detrimental to the continuing process. To address this problem, a study is conducted on the characterization of the mechanical behavior of nodular cast iron in the process temperature conditions. A particular attention is paid to the influence of the nodular microstructure on the failure mechanisms. To develop simulation tools for nodular cast iron hot trimming, the parameters of Gurson-Tvergaard-Needleman model are identified by inverse method for our material. Finally, a design of experiment is deployed using an instrumented demonstrator to obtain the optimum parameters configuration for a maximized cut surface quality. This latest study highlights the presence of a transition from ductile to brittle mode of failure leading to the hot trimming defects
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Musilová, Iveta. "PROGRESIVNÍ VÝROBNÍ POSTUPY A MODELOVÁNÍ STRUKTUR A VLASTNOSTÍ LITIN S KULIČKOVÝM GRAFITEM." Doctoral thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2010. http://www.nusl.cz/ntk/nusl-233882.
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The thesis is concerned with relationships between progressive technological processes of spheroidal graphite cast iron’s production and their structural properties. The aim of the work is to explain causal relationship between parameters of the proposed manufacturing technology of the iron type given (involving selected variants of modification and inoculation of melt and the parameters of melt crystallization, solidification and cooling down in a mould), their structure and even chemical heterogeneity of elements in this structure. For close specification of presented relationships three-dimensional model of spheroidal graphite growth was used, which was developed at the Brno University of Technology, Faculty of Mechanical Engineering. Its usability in praxis has been verified on the basisis of the application of this model on experimentally acquired data. The U GRAFIT 20 model of the authors Stránský and Million counting segregation in the frame of eutectic cell has not still been used for prediction of segregation in real condition in greater extent. On the basis of the above mentioned model microsegregation within “on average” of the cell has been discovered during experimental melts. Microsegregation has been described by segregation and heterogeneity indexes. Calculated values of segregation and heterogeneity indexes have been compared with experimentally verified values. On the basis of comparison of calculated and measured values the possibility of further usage of the mentioned model in praxis has been explored.
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Boeri, Roberto Enrique. "The solidification of ductile cast iron." Thesis, University of British Columbia, 1989. http://hdl.handle.net/2429/30598.
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The microsegregation of Mn, Cu, Cr, Mo, Ni and Si has been measured in cast ductile iron and in ductile iron which has been quenched when partially solidified. Effective segregation coefficients have been determined for each of the elements, and used to calculate the segregation on the basis of the Scheil equation. The calculated values agree reasonably well with the values of the solute concentration as a function of the solid fraction measured in quenched samples.
The microstructure of the solid phases during the solidification of ductile iron has been observed. Solidification of eutectic ductile iron begins with the independent nucleation of austenite and graphite in the melt. Later the graphite nodules are enveloped by austenite, and further solidification takes place by the thickening of the austenite layers enveloping the graphite. Isolated pockets of interdendritic melt are the last material to solidify.
On the basis of the measured segregation of the different alloying elements, the mechanisms by which the segregation affects the microstructure are considered, and an explanation for the effect of segregation on the hardenability of ductile iron is proposed.
A mathematical model of the solidification of eutectic ductile iron is formulated which includes heat flow, nucleation and growth of graphite nodules, and the segregation of Si. The model uses equilibrium temperatures given by the ternary Fe-C-Si equilibrium diagram. Using the mathematical model, cooling curves, nodule
count and nodular size distribution are determined as a function of position in the casting sample. The results are compared to measured temperatures, nodule count and nodule size in rod castings of 12.5, 20 and 43mm radius. There is good agreement between the calculated and measured values for the 43mm radius rod, and not quite good agreement for the rods of smaller radii. The changes in solidification predicted by the model when some solidification parameters are varied are consistent with experimental observations with the same variation in the parameters.Applied Science, Faculty of
Materials Engineering, Department of
Graduate
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Khan, Fareed Ashraf. "Some aspects of convection as well as graphite and carbide formations during casting." Licentiate thesis, KTH, Metallernas gjutning, 2018. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-228388.
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It is an established fact that segregation during casting affects the physical properties of carbon-based ferro alloys; this motivates the study of the segregation behaviour of carbon and carbide-forming solute elements. In this context, this thesis investigates two different situations: the effects of cooling rate and turbulence on the precipitation behaviour of the graphite nodules in nodular cast iron; the nature of carbide precipitation in a bearing steel grade and the effects of subsequent soaking on these carbides. The structures of boiling water reactor inserts cast by the uphill and downhill casting of nodular cast iron were examined. The samples were taken from representative locations in the top, middle and bottom cross sections of the castings. It was observed that in uphill-cast inserts the nodules were larger but fewer in number the bottom section, whereas in downhill-cast inserts the nodules in the bottom section were smaller, but greater in number. Variation in volume fraction of the graphite nodules across the inserts was also observed. The probable cause of this variation was the difference in cooling rate in different sections of the insert. Between the steel tubes located at the central part of the casting, the fraction of graphite was lower, which could be the result of carburization of the steel tubes. To study the effects of melt stirring during the solidification of nodular cast iron, several experiments were conducted at variable cooling rates and for different stirring times. Examination of the microstructure was conducted using Light Optical Microscope (LOM) and Scanning Electron Microscope (SEM). It was observed that during stirring the melt oxidized and oxide nuclei were formed. The number of nucleation sites for the precipitation of graphite nodules increased, which raised the nodule count and the fraction of the graphite precipitated. The matrix transformed from pearlite to ferrite, which could be due to the fact that more carbon had diffused out of the matrix. The segregation behaviour in hypereutectoid bearing steel produced by ingot casting was also studied. The effects of soaking on micro and macro segregation was investigated in samples taken from as cast and soaked ingots; emphasis was laid on the bulk matrix and A-segregation channels. Samples were also taken from ingots which were soaked and then hot worked. The micro and macro examination of the microstructure was conducted using LOM and SEM. Quantitative and qualitative composition analysis was performed using Energy-dispersive X-ray spectroscopy (EDX) and an electron micro probe analyzer (EMPA). It was observed that M3C, M2C and M6C had precipitated. The carbide morphology in the bulk matrix was different to that in the A-segregation channels. All the primary carbides in the bulk matrix were found to have dissolved after 4 hours of soaking at 1200oC.Det är ett faktum att segringar som uppstår under gjutning påverkar materialegenskaperna hos kolbaserade järnlegeringar; detta utgör motivationen till studien av segringsuppträdandet hos kol och karbidbildande ämnen. Denna avhandling behandlar två olika aspekter inom ramen för detta ämne: påverkan av kylningshastighet och turbulens på kärnbildningen av grafitnoduler i nodulärt gjutjärn samt karbidbildning i kullagerstål och dess påverkan på den efterföljande värmebehandlingen av dessa karbider. Strukturen hos rör till vattenkokare som tillverkats av nodulärt gjutjärn som gjutits med fyllning från botten eller från toppen undersöktes. Prover togs från representativa tvärsnittspositioner från toppen, mitten och botten av de gjutna ämnena. Resultaten visade att användandet av bottenfyllda kokiller gav upphov till större men färre karbider i nedre delen av ämnet, medans användandet av toppfyllda kokiller gav upphov till mindre men fler karbider i nedre delen av ämnet. Variationer av volymfraktionen av grafitnoduler längs tvärsnitten observerades också. Den mest sannolika orsaken till denna variation var skillnaden i kylhastighet i de olika områdena av tvärsnitten. Hos rör tillverkade av det centrala delen av ämnet så var fraktionen grafit lägre, vilket kan bero på en uppkolning av rören. Ett flertal experiment utfördes med varierande kylningshastigheter och olika omrörningstider för att studera inverkan av omrörning av smältan på stelningen av nodulärt gjutjärn. Studier av mikrostrukturen genomfördes med ljusoptisk mikroskopi och svepelektronmikroskopi. Resultaten visade att smältan oxiderades under omrörningen, vilket resulterade i bildandet av oxider. Detta ledde till en ökning av kärnbildningsområden för grafitnoduler, vilket ledde till en ökning av antalet noduler samt fraktionen av grafit som fälldes ut. Strukturen omvandlades från perlit till ferrit, vilket troligen orsakades av att kol hade diffunderat ut från strukturen. Segringsbeteendet hos hypereutektoida kullagerstål tillverkade genom götgjutning undersöktes också. Effekten av värmebehandling på mikro- och makrosegringar undersöktes i prover tagna från gjutna och värmebehandlade ämnen. Fokus var på att studera strukturen i ämnena samt A-segringar. Dessutom togs prover från ämnen som först värmebehandlats och därefter varmbearbetats. Både mikro- och makroundersökningar av mikrostrukturen utfördes med ljusoptisk mikroskopi och svepelektronmikroskopi. Dessutom så genomfördes kvantitativa sammansättningsbestämningar med energidispersiv röntgenspektroskopi och elektronmikroprobsanalys. Resultaten visade att M3C, M2C och M6C karbider hade fällts ut. Karbidmorfologin i huvuddelen av strukturen skiljde sig från den som återfanns i A-segringar. Samtliga primära karbider i huvuddelen av strukturen hade lösts upp efter 4 timmars värmebehandling vid 1200oC.
QC 20180523
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Lukhi, Mehul. "Micromechanical Simulation of Fatigue in Nodular Cast Iron." Technische Universität Bergakademie Freiberg, 2020. https://tubaf.qucosa.de/id/qucosa%3A72791.
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In the present thesis, fatigue behavior of nodular cast iron (NCI) is investigated using micromechanical simulations. An elastic-plastic porous material experiences an increase in a void volume fraction with each cycle of loading. This is called void ratchetting. The hypothesis of this thesis is to explain the fatigue failure of NCI using void ratchetting mechanism. The strain-life, stress-life, notch support effect, and fatigue crack growth are studied using the micromechanical simulations. In all these studies, matrix material is defined as an elastic-plastic with isotropic/kinematic hardening. No damage law is used to define material degradation. The axisymmetric cell model is developed to study strain-life and stress-life approaches for fatigue. The cell model is subjected to cyclic loading and cycle by cycle simulations are carried out until failure. The failure of the cell model is defined based on the drop in the macroscopic response of the cell model. The notch support effect is investigated using a 2D plane strain model within stress-life concept. From the simulation results, strain-life and stress-life curves are extracted, and they are in qualitative and quantitative agreement with experimental data collected from literature. The fatigue crack growth is studied using a micromechanical cell model under small scale yielding conditions. The graphite particles are considered as voids, and they are resolved discretely in fracture process zone. The region outside of the fracture process zone is considered as a homogenized medium. When positive alternating loads are applied, ligaments in the fracture process zone show ratchetting behavior, which is responsible for an effective fatigue crack growth. This mechanism is relevant for the fatigue crack growth in NCI. The 2D plane strain boundary layer model is able to predict the effect of load ratio on threshold for the fatigue crack growth and the fatigue crack growth rate. The fatigue crack growth rate curves obtained from the simulations are compared with experimental data. It is essential to note that the void ratchetting (plastic collapse of the intervoid ligaments) is a crucial mechanism in NCI and more focus should be given to this mechanism as it is simple to implement and gives satisfying simulation results.
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Westphal, Mark Emil. "Fracture toughness of coral graphite cast iron." Thesis, Georgia Institute of Technology, 1988. http://hdl.handle.net/1853/16892.
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MELLO, CARLOS ALBERTO TORRES DE. "FATIGUE LIFE OF A FERRITIC NODULAR CAST IRON OF DIFFERENT MICROSTRUCTURES." PONTIFÍCIA UNIVERSIDADE CATÓLICA DO RIO DE JANEIRO, 2003. http://www.maxwell.vrac.puc-rio.br/Busca_etds.php?strSecao=resultado&nrSeq=3721@1.
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Esta pesquisa teve como objetivos promover variações
microestruturais em um ferro fundido nodular ferrítico tipo
ASTM A536 60-40-18, pelo do uso de resfriadores durante a
solidificação do material e pela adoção de tratamentos
térmicos pós-fundição, bem como avaliar a influência de
tais variações microestruturais sobre as propriedades
mecânicas e vida em fadiga do material.
Inicialmente, amostras do material foram fundidas em areia
com e sem o uso de resfriadores. Após a fundição, algumas
amostras de ambas as condições de resfriamento sofreram
normalização, enquanto outras foram recozidas, perfazendo
seis diferentes condições microestruturais: sem resfriador
bruta de fundição (SRB); sem resfriador normalizada (SRN);
sem resfriador recozida (SRR); com resfriador bruta de
fundição (CRB); com resfriador normalizada (CRN) e com
resfriador recozida (CRR).
Em seqüência, corpos de prova de todas as condições
mencionadas acima foram ensaiados em tração e,
posteriormente, sofreram análises metalográficas
qualitativas e quantitativas. Dando continuação a etapa
experimental, levantaramse as curvas tensão versus número
de ciclos para a falha das condições microestruturais SRB,
SRR, CRB e CRR, por meio de ensaios de fadiga em flexão
rotativa. A vida em fadiga do material também foi
relacionada com às características metalúrgicas de cada
condição.The objectives of the present work were to promote microstructural variations in an ASTM A 536 60-40-18 ferritic nodular cast iron, making use of cast coolers during and adopting heat treatments after casting, as well as to evaluate the influence of the microstructural variations on the mechanical properties and fatigue life of the material. Initially, samples of the material were cast in sand moulds with and without internal coolers. After casting, a number of samples in both cooling conditions were subjected to normalizing and annealing heat treatments and, therefore, six different microstructural conditions were obtained: as- cast without cooler (SRB), normalized without cooler (SRN), annealed without cooler (SRR), as-cast with cooler (CRB), normalized with cooler (CRN) and annealed with cooler (CRR). Tensile test were carried out on specimens representing the above mentioned conditions and their microstructures were analysed by qualitative and quantitative metallography. In the sequence of the experimental procedure, rotating bend fadigue test were performed in order to establish the stress-life curves for the SRB, SRR, CRB and CRR microstructural conditions. The fadigue life of the material was also related to the metallurgical characteristics of each condition. The metallographic analysis has indicated that the use of coolers increases the number of graphite nodules, reduces the graphite nodule size and otimizes the spherical morphology. However, these microstructural modifications seam to have no significant influence on the mechanical properties of the material. As to the effect of normalizing annealing, boht treatments not imply in significant changes in the mechanical properties of the as-cast conditions. Regarding the fadigue resistance of the material in the as-cast conditions, the CRB sample showed a longer fatigue life than the SRB samples and this performance under cyclic loading was attributed to the fact that the CRB condition is characterized by a higher number of graphite nodules of class VI. A comparison between the as-cast and annealed conditions indicated that the microstructural conditions SRR and CRR presented a lower fatigue resistance than the conditions SRB and CRB, respectively. This behaviour was associated with the microstructural features of the as-cast conditions, namely the smaller graphite nodule size, the higher microhardness of the matrix and the presence of the bull`s-eye structure. Finally, the experimental stress-life curves were modelled by means of Coffin-Manson law, which was considered efficient in the fadigue life data of ferritic nodular cast iron.
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Franklin, Steven E. "A study of graphite morphology control in cast iron." Thesis, Loughborough University, 1986. https://dspace.lboro.ac.uk/2134/32998.
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The objectives of the research project were to gain a deeper understanding of the factors influencing the graphite morphology in cast iron; particularly the role of different solute elements in relation to the industrial manufacture of compacted graphite iron. A number of melt treatment processes were assessed for their abilities to produce low nodularity compacted graphite microstructures over a range of casting section thicknesses. In this respect, the magnesium-titanium method was found to be superior to treatment using cerium Mischmetall and calcium additives; and very promising results were obtained with methods using zirconium as a major constituent of the treatment alloy. Scanning electron microscopy, secondary ion mass spectrometry and X-ray microanalysis were used to study the structural characteristics of different cast iron microstructures and the elemental distributions of important solutes between the phases. This information was used to clarify the role of the main solute elements in graphite morphology control and to assess current graphite growth theories.
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Castillo-Bozzo, Ricardo N. "A fracture mechanics study of flake graphite cast iron." Thesis, Imperial College London, 1985. http://hdl.handle.net/10044/1/37651.
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Björkblad, Anders. "Fatigue Assessment of Cast Components : Influence of Cast Defects." Doctoral thesis, KTH, Lättkonstruktioner, 2008. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-9133.
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This thesis is on the fatigue assessment of cast components with special attention to defects. The primary material in view is nodular cast iron, but also cast steel is considered. However, the fatigue behaviour is in principle valid for general use on other cast metals.The first two papers is about general cast material behaviour in fatigue loading. The materials considered are a high strength alloyed cast steel and a medium strength nodular cast iron. It is concluded that cast defects is the main fatigue initiation cause and it is only in exception that the fatigue life is not ruled by fracture mechanics. The third paper is a fracture mechanics evaluation of a nodular iron cast sleeve. The analysis of the component is based on crack initiation from cast defects and low-cycle fatigue. Fracture mechanics material parameters for Paris law, c and m, are extracted for the materials considered. In paper D design quality rules for nodular cast iron based on the Swedish standard SS 11 40 60 is presented. The quality rules regard cast defects in fatigue assessments and facilitate defect-based component design. In paper E, a finite element tool that is capable to predict and calculate 3D crack propagation for embedded cracks and defects is presented. The tool is an add-on for ANSYS finite element program. In paper F, closure equations for nodular cast iron are proposed in parallel to refined fracture mechanics material data. The paper includes crack propagation at different load ratios and in different microstructures.Summarized, the thesis composes a further development of the fatigue assessment of cast components. The central role of defects in fatigue is clarified and tools are provided for fracture mechanics evaluations of defects as well as for defect based design. The quality rules are also fit for application in manufacturing and for acceptance tests, hence covering the span from design to complete product.QC 20100712
Gjutdesign
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Hernando, Juan Carlos. "Morphological characterization of primary austenite in cast iron." Licentiate thesis, Tekniska Högskolan, Högskolan i Jönköping, JTH, Material och tillverkning, 2017. http://urn.kb.se/resolve?urn=urn:nbn:se:hj:diva-35585.
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Automotive industry products portfolio includes a wide variety of complex‐shaped cast iron products, such as truck engine components, that need to withstand a constant trend of higher demands, especially urged by stricter environmental regulations on emissions. Combined with this continued demand on properties improvement, cast iron industry faces a process problem related to the lack of understanding of solidification and mechanisms behind defect formation. Casting products are highly affected by the product design and the manufacturing method itself, which governs the final microstructure and hence the final mechanical properties. Wall thickness of the moulding material strongly influences the solidification time, varying the microstructural coarseness, resulting in a component with different properties depending on the local shape of the casting. The main objective of this work is the characterization of the primary austenite microstructure and its coarsening process, which has been poorly documented in cast iron literature, to allow the prediction and control of these microstructural features present in the casting. The microstructural evolution of the primary austenite in hypoeutectic lamellar graphite iron (LGI) is studied under isothermal coarsening conditions. The dendritic microstructure suffered major morphological changes that included dendrite fragmentation, globularization, and coalescence. Empirical relations based on morphological parameters are introduced to predict the microstructural evolution of primary austenite. A novel technique for colour‐etching and semi‐automatic image analysis for the characterization of quenched dendritic microstructures in cast iron is presented. A new experimental technique for production of graphitic iron with varying nodularity is presented as a solution to control the production of compacted (CGI) and spheroidal graphite iron (SGI) under laboratory conditions. The nodularity evolution is controlled as a function of the holding time and the residual Mg, allowing the study of the primary solidification and primary microstructures of hypoeutectic CGI and SGI in future investigations.
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Bobyliov, Konstantin. "Casting voids influence on spheroid graphite cast iron high-cycle fatigue strength." Doctoral thesis, Lithuanian Academic Libraries Network (LABT), 2008. http://vddb.library.lt/obj/LT-eLABa-0001:E.02~2008~D_20081128_120950-42235.
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The influence of casting voids on spheroid cast iron cracking threshold is investigated. The experimental results and their analytical and numerical analysis basing on linear fracture mechanics is presented.Nagrinėjamas liejimo tuštumų poveikis stipriojo ketaus pleišėjimo slenksčiui. Pateikiami eksperimentiniai rezultatai ir jų analitinė bei skaitinė analizė, remiantis tiesine irimo mechanika.
Исследуется влияние литейных пустот на порог трещиностойкости чугуна с шаровидным графитом. Представлены результаты экспериментального исследования и их аналитический и численный анализ, опираясь на линейную механику разрушения.
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Velichko, Alexandra. "Quantitative 3D characterization of graphite morphologiesin cast iron using FIB microstructure tomography." Aachen Shaker, 2008. http://d-nb.info/992480035/04.
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Ye, Jianchang. "Roles of graphite in the reduction of azo-aromatic compounds with elemental iron." Access to citation, abstract and download form provided by ProQuest Information and Learning Company; downloadable PDF file, 137 p, 2006. http://proquest.umi.com/pqdweb?did=1172118261&sid=5&Fmt=2&clientId=8331&RQT=309&VName=PQD.
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Hellström, Kristina. "Density variations during solidification of lamellar graphite iron." Licentiate thesis, Tekniska Högskolan, Högskolan i Jönköping, JTH, Material och tillverkning, 2017. http://urn.kb.se/resolve?urn=urn:nbn:se:hj:diva-37869.
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Andrade, Ricardo Batista de. "Parametros termicos e estruturais em ferros fundidos cinzento e nodular solidificados em moldes de areia e unidirecionalmente." [s.n.], 2009. http://repositorio.unicamp.br/jspui/handle/REPOSIP/265196.
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Orientador: Rezende Gomes dos SantosTese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica
Made available in DSpace on 2018-08-13T04:21:01Z (GMT). No. of bitstreams: 1 Andrade_RicardoBatistade_D.pdf: 11899050 bytes, checksum: c01c8dae77c3bdae9d6a75358f3c1ffe (MD5) Previous issue date: 2009
Resumo: No presente trabalho a solidificação unidirecional em regime transiente de um ferro fundido cinzento com composição hipoeutética e de um ferro fundido nodular de composição eutética são aplicadas para analisar a influência dos parâmetros do processo no número de veios ou nódulos de grafita. Para efeito de comparação foram fundidas algumas amostras em moldes de areia convencionais. Os resultados experimentais das variações de temperatura durante a solidificação foram utilizados para estimar as variações dos parâmetros de solidificação. As curvas de variação do número de veios e nódulos por unidade de área com a velocidade de solidificação e a taxa de resfriamento indicaram que os números de veios e nódulos decrescem e suas dimensões aumentam com a queda desses parâmetros. Os resultados mostraram também que para posições longe da interface metal/molde na solidificação unidirecional os números de veios ou nódulos se aproximam dos obtidos em moldes de areia, portanto obteve-se a influência dos parâmetros de solidificação na microestrutura para praticamente todos os processamentos utilizados na prática de fundição destas ligas. Algumas medidas de variação de dureza com a distância da interface metal/molde foram realizadas, indicando que para o ferro fundido cinzento a dureza diminui e para o ferro fundido nodular aumenta com a diminuição da velocidade de solidificação.
Abstract: In the present work unsteady state unidirectional solidification of a hypoeutectic gray cast iron and of a eutectic ductile cast iron is applied to analyze the influence of the process parameters an the flake and nodule count. For comparison purpose some samples were cast in sand molds. The experimental results of temperature variation in the casting were used to estimate the variations of solidification parameters. From the results curves relating flake and nodule count and solidification rate and flake and nodule count and cooling rate were obtained indicating that the number nodule decreases and their dimensions increase as these parameters decreases. From the results obtained relations were established between these parameters. The results showed that nodule count observed for unidirectional solidification far from metal/mold interface approaches to the observed in sand mold, permitting to' analyze the influence solidification parameters an the microstructure formation far almost all foundry processes of these alloys. Some measurements of hardness variations from metal/mold interface were carried out indicating that far gray cast iron hardness decreases and for ductile iron increases as solidification rate decreases.
Doutorado
Materiais e Processos de Fabricação
Doutor em Engenharia Mecânica
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Yeliyur, Siddegowda Darshan. "Gray-cast iron classification based on graphite flakes using image morphology and neural networks." Thesis, California State University, Long Beach, 2016. http://pqdtopen.proquest.com/#viewpdf?dispub=10017846.
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Gray-cast iron is an iron carbon alloy which is regularly used in manufacturing processes. Carbon is distributed in the iron material in the form of graphite. The distribution of the graphite flakes in the alloy contributes greatly towards the chemical and physical properties of the metal alloy. Thus it is important to identify and classify the Gray-cast iron based on the morphological parameters of the graphite flakes. Gray-Cast iron is classified into five types in ISO-945 represented with the letters A through E. These five classes possess different structures or distributions of the graphite flakes. The current project presents an automated classification method using image processing and machine learning algorithms. The method presented here obtains the required parameters from the microstructure through image morphological operations. The image information is subsequently fed through a supervised machine learning algorithm which is trained using parameters such as area of the flakes, perimeter, minimum inter-particle distance and chord length from over twenty samples. The algorithm calculates the percentage of the type of the flakes present in the given image. The simulation is done in MATLAB and was tested for six images in each class. Class C and D were classified with 100 percent accuracy, Class A and B were classified with accuracy of 82 percent and Class E was identified with accuracy of 68 percent.
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Boutorabi, S. M. A. "The austempering kinetics, microstructure and mechanical properties of spheroidal graphite unalloyed aluminium cast iron." Thesis, University of Birmingham, 1991. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.520795.
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The effect of austempering processing variables on the transformation kinetics, microstructure and mechanical properties of the Fe-C-AI family of spheroidal graphite cast irons, in which the silicon is below 0.2wt% has been investigated. These alloys are described as SO Al cast irons. In the preliminary experiments the spheroidisation and inoculation treatments for SO Al were developed and the microstructure and tensile properties in the as cast and normalised SO Al cast iron at 2.2 and 3.2% of Al examined. The results show that the sequence of spheroidisation of SO Al iron differs significantly from those observed in SG Si iron. Whilst the treatment to introduce some Mg into the melt is required in both irons to alter the growth habit of graphite from flake to spheroidal, the behaviour of the irons towards the subsequent inoculation with various inoculating alloys is quite different. A wide range of mechanical properties of SG Al irons can be obtained, similar to SG Si irons, in the as cast or heat treated conditions. The effects of austenitizing temperatures of 850, 900 and 950°C, austempering temperatures of 300 to 450°C and austempering times of 5 to 300 minutes on impact and tensile properties have been investigated. X-ray diffraction has been used to determine the volume fraction, lattice parameter and carbon content of retained austenite and bainitic ferrite produced under different austempering conditions. Optical and scanning electron microscopy were used to analyse the microstructure. It has been shown that the basic mechanisms for the isothermal transformation of austenite to bainite are essentially similar to those of austempered SO silicon cast irons for both lower and upper bainite. This can be attributed to the strong graphitising effect of aluminium which delays the formation of transformation carbides. However, the higher carbon contents of retained austenite in SG Al iron show the stronger carbide inhibiting characteristics of aluminium compared with those of silicon. The first stage starts with the nucleation of bainitic ferrite from the grain boundaries and adjacent to the graphite nodules. The second stage in upper bainite fonnation is the growth of ferrite, during which carbon diffusion occurs ahead of the ferrite-austenite interface thus enriching the surrounding austenite. This is followed in the third stage by carbide precipitation in the high carbon retained austenite. In lower bainite fonnation the nucleating ferrite is supersaturated with carbon, and carbide precipitation occurs inside ferrite plates. The results show that the rate of fIrst stage transfonnation is higher in SO Al than in the corresponding SO Si iron, and the high carbon retained austenite has a longer life time with a high carbon content. Increasing the austempering temperature was shown to increase structural coarseness and retained austenite content, leading to reduced strength and hardness and improved impact properties and ductility. Retained austenite produced in austempered SO Al iron showed more stability at a high austempering temperature of 450°C, compared to SO Si iron. This was attributed to the graphitising potential of aluminium which suppresses the formation of carbide at that temperature. Austenitizing temperature was found to control the carbon content of both the matrix and of the retained austenite. Increasing the austenitizing temperature was shown to increase the matrix carbon content and to slow the bainitic reaction. Microstructures obtained at higher austenitizing temperature revealed two types of retained austenite: one with a film morphology and the other in a blocky form surrounded by ferrite growing in different directions. The length of bainitic ferrite appears to increase with austenitizing temperature. Austenitizing temperature had a greater effect on hardness in the lower bainitic region and on impact values in the upper bainitic region. The results obtained show that the controlling austempering variables for an SO Al iron of a given starting composition and microstructure are closely similar to those of SO Si iron. The transformation mechanisms are also similar, but the transformation kinetics differ and, to a small extent, microstructural differences give rise to differences in properties between the two types of irons.
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Lachambre, Joël. "Développement d'une méthode de caractérisation 3D des fissures de fatigue à l'aide de la corrélation d'images numériques obtenues par tomographie X." Thesis, Lyon, INSA, 2014. http://www.theses.fr/2014ISAL0050/document.
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Ce mémoire présente une méthode mise au point pour caractériser et analyser des fissures de fatigue présentant un fort caractère tridimensionnel dans des matériaux métalliques opaques. L'analyse consiste à déterminer avec précision la position du front de la fissure étudiée et à mesurer des valeurs de facteurs d'intensité des contraintes le long du front par projection sur les séries de Williams du champ de déplacement issu de la corrélation numérique d'images 3D obtenues par tomographie aux rayons X. La corrélation d'images 3D numériques est utilisée afin de mesurer le champ de déplacement en volume lors de la mise sous chargement d'une éprouvette fissurée fatiguée. La corrélation d'images nécessitant un mouchetis, le matériau retenu pour les expériences est la fonte à graphite sphéroïdal car il présente un mouchetis 3D naturel (les nodules de graphites) parfaitement imagé par tomographie aux rayons X. Le cyclage est appliqué à l'aide d'une machine de fatigue in situ permettant d'alterner des phases de propagation de la fissure avec des acquisitions tomographiques sous différentes charges. L'introduction d'un défaut artificiel (une entaille obtenue par usinage laser) permet de maîtriser l'amorçage et la propagation de la fissure in situ. La méthode de corrélation d'images 3D numériques employée dans ces travaux étant basée sur des éléments finis, nous avons cherché à tirer profit de différents outils développés dans le cadre de cette méthode. Les surfaces libres sont spécifiées afin de bien conditionner le maillage et un enrichissement dans l'esprit des X-FEM permet de renseigner la fissure dont la position est repérée grâce à la trace laissée dans le résidu de corrélation entre l'image avant cyclage et la dernière image acquise. Une régularisation mécanique est également introduite dans le calcul sous forme d'un filtre de longueur d'onde choisie. Le champ de déplacement mesuré avec précision est ensuite projeté sur les séries de Williams augmentées des termes correctifs de Leblond et Torlai qui prennent en compte la courbure du front de la fissure. L'annulation du terme super-singulier d'ordre -1 des séries de Williams est utilisée pour détecter la position du front de la fissure. Une procédure itérative a été mise en place afin de concilier l'enrichissement et la courbure du front avec la projection sur les séries de Williams. Une fois la position du front 3D de la fissure déterminée et les valeurs des facteurs d'intensité des contraintes associées calculées, les résultats obtenus sont confrontés à la littératureThis manuscript describes a methodology used to compute Stress Intensity Factor values along the curved front of a fatigue crack inside a nodular cast iron. An artificial defect is introduced at the surface of a small sample. The initiation and growth of a fatigue crack from this defect during constant amplitude cycling is monitored in situ by laboratory x-ray tomography. The method for processing the 3D images in order to compute SIF values is described in detail. The results obtained show variations of the stress intensity factor values along the crack front
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Lukhi, Mehul [Verfasser], Meinhard [Akademischer Betreuer] Kuna, Meinhard [Gutachter] Kuna, and Sebastian [Gutachter] Münstermann. "Micromechanical Simulation of Fatigue in Nodular Cast Iron / Mehul Lukhi ; Gutachter: Meinhard Kuna, Sebastian Münstermann ; Betreuer: Meinhard Kuna." Freiberg : Technische Universität Bergakademie Freiberg, 2020. http://d-nb.info/1226110894/34.
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Velichko, Alexandra [Verfasser]. "Quantitative 3D Characterization of Graphite Morphologies in Cast Iron using FIB Microstructure Tomography / Alexandra Velichko." Aachen : Shaker, 2009. http://d-nb.info/1161310541/34.
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König, Mathias. "Microstructure Formation During Solidification and Solid State Transformation in Compacted Graphite Iron." Doctoral thesis, Tekniska Högskolan, Högskolan i Jönköping, JTH. Forskningsmiljö Material och tillverkning – Gjutning, 2011. http://urn.kb.se/resolve?urn=urn:nbn:se:hj:diva-15694.
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Compacted graphite iron (CGI) is rapidly becoming an attractive alternative material for engine components in the automotive industry, replacing lamellar graphite iron (LGI) in applications where high mechanical strength is desired. However, the gain in mechanical strength comes with a cost; thermal conductivity, process control and machining are three areas that are more challenging for CGI. This generates a need for research regarding various aspects concerning CGI. In this thesis the microstructure formation during solidification and solid state transformation will be the focus of interest. The phase transformations relevant for microstructure formation of importance to properties in CGI were studied. Experiments were performed in an industrial foundry giving this research direct relevance to regular production of CGI castings. Solidification of the grey (graphite/austenite) eutectic will be discussed, focusing on some relevant aspects influencing the graphite morphology of CGI. The formation of graphite nodules has been investigated by studying colour-etched microstructures. In a material containing mainly CGI cells it was found that nodules form either early during solidification as a consequence of high undercooling or late in the solidification sequence due to a combination of high undercooling and segregation of nodularising elements. Solidification of the white (cementite/austenite) eutectic was studied using chill wedges and the influence of some alloying elements on the amount of carbides was examined. To further enhance the understanding of carbide formation in CGI a commercial casting simulation software was used to correlate real castings to simulations. It was found that the alloying elements investigated influence the carbide formation in a similar way as in other graphitic cast irons and that high nodularity CGI is more prone to chill formation than low nodularity CGI. The solid state transformation was studied and a deterministic model was developed. The model divides a eutectic cell into layers, in order to take into account segregation of alloying elements, which was observed to be influential for the ferrite growth. Moreover, the effect of alloying elements on mechanical properties (tensile properties and hardness) was evaluated. Properties were correlated to microstructural features originating from both solidification and solid state transformations. The trends found generally confirmed previous results regarding properties in graphitic cast irons.
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Erturk, Murat Tolga. "Microstructural And Mechanical Characterization Of Metal Active Gas Welded Joint Between Cast Iron And Low Carbon Steel." Master's thesis, METU, 2011. http://etd.lib.metu.edu.tr/upload/12612992/index.pdf.
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This study focuses on joining pearlitic ductile cast iron with low carbon steel by welding and investigation of this joint in microstructural and mechanical viewpoints. For this purpose E355 steel and GJS600-3 cast iron were joined using metal active gas (MAG) welding process by G3Si1 filler wire. The joining process is shaped mainly by the problems related to the low weldability of cast. Preheating was applied to prevent formation of cooling cracks and effects of post weld heat treatments (PWHT) were surveyed. Micro examination and micro hardness tests were applied to characterize the general microstructure. Grain size measurements were done for E355. Hardness profiles, tension and impact toughness properties were designated via mechanical tests. Fatigue behavior was surveyed and general fracture characteristics were determined via scanning electron microscopy (SEM) examinations.
According to study it was concluded that successful weld joint could be formed between the materials by suitable preheating. Formation of ledeburitic white cast iron and martensite in heat affected zone of cast piece was witnessed. It was possible to lower high hardness values of these phases gradually by increasing post weld heat treatment temperatures. The weld joint behaved superior to the base metals under tension and fatigue tests. In tension tests failure occurred at E355 base metal whereas fatigue loading resulted failure at GJS600-3. A great impact toughness variation was determined between two pieces. It is seen that heat treatments had minor effect on mechanical test results except hardness. The study was concluded that a useful fusion weld joint between these materials can be built.
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Wollmann, Daniela. "Avaliação da resistência à fadiga de contato de ferro fundido nodular nitretado por plasma." Universidade Tecnológica Federal do Paraná, 2012. http://repositorio.utfpr.edu.br/jspui/handle/1/565.
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Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES), Fundação AraucáriaEste trabalho apresenta um estudo sobre a resistência à fadiga de contato de um ferro fundido nodular nitretado por plasma. Os experimentos foram realizados em um equipamento do tipo esfera sobre plano. Os corpos de prova foram usinados a partir de uma barra de ferro fundido nodular perlítico e em seguida temperados e revenidos. Após a preparação superficial por meio de retificação, lixamento e polimento, as amostras foram divididas em três grupos: 1) temperadas e revenidas; 2) temperadas, revenidos e nitretadas por plasma por 8 horas a 400 °C; e 3) mesmos parâmetros do grupo 2, porém submetidas a um tratamento adicional de Difusão em forno por 16 horas a 400 °C, visando aumentar a profundidade de camada endurecida e dissolver possíveis traços da formação de camada de compostos. Foram feitas medidas de dureza superficial, perfis de dureza, análises das fases e de tensões residuais por meio de difração de raios-X, rugosidade e microscopia eletrônica de varredura, para a caracterização das amostras em diferentes estágios do trabalho. Os ensaios de fadiga de contato foram realizados com lubrificação e a uma pressão de contato máxima de 3,6 GPa. Análises de Weibull mostraram uma vida em fadiga aproximadamente cinco vezes menor para os corpos de prova nitretados por plasma, com ou sem difusão, apesar destes apresentarem tensão residual compressiva significativamente superior aos temperados e revenidos. A menor vida em fadiga dos corpos de prova nitretados foi atribuída a menor dureza de substrato e a ocorrência de um mecanismo de falha distinto dos mecanismos clássicos de fadiga de contato de rolamento, demonstrado nas análises das superfícies ensaiadas.
This work presents a study on the contact fatigue resistance of a plasma nitrided ductile cast iron. The experiments were carried out using a ball-on-washer machine. Specimens were machined from a perlitic ductile cast iron bar, and then quenched and tempered. After surface grinding and polishing, the specimens were divided into three groups a) the first group was tested after the described process, which means as quenched and tempered; b) the second group was plasma nitridedat 400 °C for 8 hours; c) the third one was plasma nitrided as previously described and submitted to a diffusion process at 400 °C for 16 hours in order to extend the hardened zone and to dissolve any trace of compound layer within the microstructure. Surface hardness, hardness profiles, phase analyses and residual stress measurements by X-ray diffraction, surface roughness and optical and scanning electron microscopy were applied to characterize the surfaces during different stages of this work. Rolling contact fatigue tests were conducted at a maximum contact pressure of 3.6 GPa under flood lubrication. Weibull analysis showed that fatigue lives of plasma nitrided specimens were approximately five times shorter than those just quenched and tempered, even though the residual stress measurements showed significantly higher compressive stresses for the nitride conditions. The lower fatigue life for the plasma nitrided specimens was attributed to the lower matrix hardness and to a failure mechanism distinct from the classical rolling contact fatigue mechanisms, showed by surface analisis.
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Maluf, Omar. ""Influência do roleteamento no comportamento em fadiga de um ferro fundido nodular perlítico"." Universidade de São Paulo, 2002. http://www.teses.usp.br/teses/disponiveis/88/88131/tde-17032004-163144/.
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O processo de roleteamento é um tratamento superficial, comumente utilizado em peças fabricadas em aços e ferros fundidos nodulares, em regiões onde há concentradores de tensões, com o intuito de melhorar as propriedades de resistência à fadiga. Este processo endurece e introduz tensões residuais compressivas na camada superficial do material, através de deformação controlada, provocando uma redução das tensões de tração que atuam na superfície da peça submetida a carregamentos cíclicos. Este trabalho teve como principal objetivo o estudo do efeito do roleteamento superficial sobre o comportamento em fadiga de um ferro fundido nodular de matriz perlítica, utilizado na fabricação de virabrequins pela indústria automobilística. Foram realizados ensaios de fadiga por flexão rotativa em corpos de prova lisos e com entalhe. Os corpos de prova com entalhe foram divididos em dois grupos, com e sem roleteamento superficial. Foi utilizado entalhe com geometria semicircular com raio de 1,20mm e profundidade de 0,70mm. Para o processo de roleteamento foi utilizado um rolete com diâmetro de 15,00mm e com raio de curvatura de 1,30mm e aplicada uma força de compressão de 2390N. A introdução de tensões residuais compressivas pelo trabalho a frio, dificultou a nucleação e a propagação de trincas na camada superficial dos entalhes roleteados. Isto ficou evidenciado pelo aumento do valor do limite de fadiga para 483MPa obtido para o material entalhado e roleteado, enquanto que para o material nas condições de sem entalhe e somente entalhado estes valores foram de 300MPa e 168Mpa, respectivamente.Surface rolling is a mechanical treatment commonly used in parts fabricated with steel and ductile cast iron, specifically in stress concentration regions, to improve fatigue properties. This process hardens and introduces compressive residual stresses to the surface of the material through the application of controlled strains, thus provoking a reduction of resulting tensile stress at its surface under cyclic loading. This work deals with the effect of surface rolling on high cycle fatigue behavior of a pearlitic ductile cast iron used in crankshaft by automotive industries. Rotating bending fatigue tests were performed in both smooth and notched specimens. The notched specimens were divided into two groups: with and without surface rolling treatment. The specimens notch geometry was semicircular with radius of 1.20mm and depth of 0.70mm. The rolling treatment was carried out using a roller with diameter of 15,00mm, curvature radius of 1.30mm and a compression force of 2390N. The introduction of compressive residual stresses under cold work made difficult the nucleation and propagation of the crack on the rolled surface of the notch. It was confirmed by the increase of the endurance limit of the surface rolled specimens to 483MPa in comparison with the smooth and notched specimens, respectively, 300MPa and 168 MPa.
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Rosário, John Ferney Alvarez. "Avaliação da integridade da superfície no torneamento de um ferro fundido nodular com carboneto." Universidade de São Paulo, 2006. http://www.teses.usp.br/teses/disponiveis/3/3132/tde-05092006-131535/.
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Neste trabalho, estudou-se a integridade superficial durante o torneamento de um ferro fundido nodular com carbonetos, considerando a heterogeneidade microestrutural (fração volumétrica, tamanho e morfologia de grafita e dos carbonetos) e os efeitos dos parâmetros de corte (avanço, velocidade de corte e profundidade de corte), baseados num planejamento fatorial fracionário 24-1. Este texto apresenta, numa primeira parte, uma revisão baseada em referências bibliográficas clássicas da engenharia de superfícies, na tentativa de definir os conceitos que compõem a integridade da superfície. Posteriormente, descrevem-se os resultados de ensaios preliminares, realizados com a finalidade avaliar os níveis do processo e os efeitos desses parâmetros na integridade da superfície. Finalmente, realizaram-se os ensaios de usinagem em corpos-de-prova de ferro fundido nodular com carboneto, nos diâmetros de 80 mm e 140mm. Durante os ensaios de torneamento empregaram-se duas velocidades de corte (60 m/min e 180 m/min), dois avanços (0,1 mm/rev e 0,3 mm/rev) e duas profundidades de corte (0,2 mm e 0,3 mm). Após os ensaios de usinagem, foram realizadas: a avaliação das propriedades do material usinado (dureza e microestrutura), a análise de topografia da superfície usinada mediante avaliação da rugosidade, e a avaliação da influência dos parâmetros de usinagem na rugosidade. Encontrou-se uma dependência estatisticamente significativa da variação nas propriedades mecânicas dos corpos-de-prova em função da microestrutura, e mostraram-se os efeitos dessas variações em termos da integridade da superfície usinada.In this work, the surface integrity of a ductile cast iron with carbides was studied during turning operations, considering the microstructural heterogeneity (volume fraction, size and morphology of the graphite and carbides) and the effect of the machining parameters (feed, cutting speed and depth of cut), based on a fractional factorial design 24-1. This work presents, initially, a literature review based on classic works on surface engineering, as an attempt to define the main concepts of surface integrity. Later, the results of preliminary test are described, which were conducted in order to define the process levels and the effects of these levels on the surface integrity. Finally, turning tests were conducted on specimens of ductile iron with carbides, at diameters of 80 and 140 mm. Two cutting speeds (60 m/min and 180 m/min), two feeds (0,1 mm/rev and 0,3 mm/rev) and two depths of cut (0,2 mm and 0,3 mm) were selected during the tests. Machined specimens were analyzed in terms of the properties of the machined material (hardness and microstructure) and of the roughness of the machined surface. The effect of the machining parameters on the roughness was also studied. A statistically significant dependence was observed for the properties of the machined specimens as a function of the microstructure and the effect of these properties on the surface integrity is presented.
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Sjögren, Torsten. "Influences of the Graphite Phase on Elastic and Plastic Deformation Behaviour of Cast Irons." Doctoral thesis, Linköpings universitet, Konstruktionsmaterial, 2007. http://urn.kb.se/resolve?urn=urn:nbn:se:liu:diva-8776.
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The amount and morphology of the graphite phase largely controls the resulting properties of cast iron. For instance, in flake graphite cast irons the mechanical properties are low while the thermal conductivity is high. This is in contrast with spheroidal graphite cast irons where the mechanical properties are high and the thermal conductivity is low. These differences are due to the different graphite morphologies and must be accounted for in the design work and material selection of cast iron components. In this work the influence of the graphite phase on the elastic and plastic deformation behaviour of cast irons has been studied. The material grades studied originate from castings for marine diesel engine piston rings with different chemical analyses. Two groups of pearlitic cast iron materials were studied; one with differences in graphite morphology and one with grey irons that differed in graphite content. For these different material grades the mechanical properties were correlated to microstructural parameters. In addition to standard uniaxial tensile tests, acoustic emission measurements were used for the study of deformation. When studying the modulus of elasticity of the cast iron it was found that the modulus of elasticity of the inherent graphite phase depends on the roundness of the graphite particles and is due to the strong anisotropy of the graphite phase. A linear correlation between nodularity and the modulus of elasticity of the graphite phase was derived. This correlation made it possible to account for the anisotropy of the graphite phase in the model used. By applying the linear function when modelling the effective modulus of elasticity, a high accuracy between experimental and theoretical values was achieved. Another factor affecting the elastic response when subjecting a cast iron component to tensile load was found to be the plastic deformation that actually occurs at very low strains for all of the studied cast iron grades. It was observed that the plastic deformation in the low strain elastic region, quantified by using acoustic emission measurements, increased linearly with decreasing modulus of elasticity. These measurements showed that the amount of plastic deformation in the elastic region was largely controlled by the graphite morphology. It was concluded that as the roundness of the graphite particles increases, the plastic deformation activity in the elastic region decreases. The plastic deformation activity continued linearly into the pronounced plastic region of the tensile tests. A decrease in roundness or increase in graphite fraction resulted in an increase of the amount of plastic deformation and the strain hardening exponent. A dependence between strength coefficient and graphite fraction was observed. Models for the flow curves for pearlitic cast irons were developed and shown to accurately reproduce the observed experimental curves. The surveys performed and conclusions from this thesis will be helpful in the design of new cast iron materials.
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Elmabrouk, Omar Mustafa. "An Investigation Of Compacted Graphite Cast Iron Production By Means Of Thermal Analysis Technique And Other Process Control Windows." Phd thesis, METU, 2007. http://etd.lib.metu.edu.tr/upload/3/12608096/index.pdf.
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ABSTRACT
AN INVESTIGATION OF COMPACTED GRAPHITE IRON PRODUCTION BY MEANS OF THERMAL ANALYSIS TECHNIQUE AND OTHER PROCESS CONTROL WINDOWS
El-mabrouk, Omar
PhD, Metallurgical and Material Engineering Department
Supervisor: Prof. Dr. Ali Kalkanli
January 2007, 123 pages
Compacted graphite irons have been proved valuable in many applications such as exhaust manifolds, hydraulic valves, and diesel engine blocks, the process of producing compacted graphite irons is not a straight forward process because of its narrow processing windows and its high sensitivity to the section thickness, treatment reaction time, pouring temperatures and charge composition.
In this thesis, compacted graphite was produced with minimum variations through all section thickness and the effect of Mg/S ratio, section thickness, and treatment agents on the graphite morphology, electrical resistivity property and fracture strength at high temperatures was investigated.
The range of Mg/S ratio and the section thickness was from 2/3 to 7/1 and 5 mm to 40 mm respectively. FeSiMg and FeSiMg cermish metal were used as a treatment agent.
Optical metallographic method was implemented to investigate the graphite
morphology change. For being a distinguishable characteristic for compacted graphite iron over ductile iron, thermal conductivity changes at high temperatures ranging from room temperature to 500 0C was examined by a suitable electrical setup in the manner of electrical conductivity changes by measuring the electrical resistance.
On the other hand, due to the higher values of mechanical properties of compacted graphite iron over those of gray iron, tensile strength was also examined by means of tensile test.
The relation between the compacted graphite shape and the alloy properties such as fracture strength and thermal conductivity was investigated. The most important controlling parameters to produce compacted graphite are Mg/S ratio and oxygen activity. The relation between these parameters with both fracture strength and thermal conductivity was established by means of multiple regression analysis technique.
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Cox, G. J. "The effect of composition and heat-treatment on the mechanical properties and micro structure of spheroidal-graphite cast iron." Thesis, Aston University, 2003. http://ethos.bl.uk/OrderDetails.do?uin=uk.bl.ethos.484343.
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Santos, Elder Gregol dos. "Avaliação da carburação de um ferro fundido nodular em fornos de indução de média frequência." Universidade do Estado de Santa Catarina, 2014. http://tede.udesc.br/handle/handle/1669.
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The carburiser materials have been widely used in the foundry industry, motivated by increasing use of scrap steel and consequent reduction in the use of pig iron. Several factors, besides of recovery of carbon in the metal bath, can be associated with the use of carburisers, including the effect on the levels of silicon, sulfur, nitrogen and degree of nucleation of metal. This paper evaluates the effects of the use of carburisers materials, of the types natural graphite, synthetic graphite, graphite permanent mold residue (used in molds of continuous casting) and synthetic graphite with low sulphur amount. The method of addition was chosen on the surface of the liquid bath, at a medium frequency induction furnace, 2500 kg capacity, tests at three different temperatures. Was observed that there was no incorporation of nitrogen of carburisers to liquid metal, and the sulfur content was altered only when used synthetic carburiser. The increase in temperature caused an increase in the value of carburation efficiency, regardless of the type of carburisers. In general, it was observed an increase 21-32% when the temperature is changed from 1480 to 1545 ° C. Only the special synthetic carburisers showed lower sensitivity to temperature increase, showing an increase of only 5% efficiency. It was found that the ash content of the carburiser is a variable that affects significantly the dissolution process of the carburiser. The results showed that the carburisers with lower ash content, have higher carburation efficiency. This paper proposed the concept of rate of gain of associated carbon, which was effective for predicting the behavior of % C of liquid metal after the addition of the carburiser. It was found that the rate of gain associated initial carbon is favored with increasing temperature and the sulfur content of liquid metal, and impaired with an increase in the percentage of ash in carburiser. As for the value of the combined rate of dissolution, this showed an increase when the temperature of addition is growing. It was noted that the value of maximum rate of efficiency has relation with the value of the combined rate of dissolution, allowing to conclude that the higher the value of the combined dissolution rate, the faster the process reaches its maximum efficiency. The results observed for the residue of graphite mold, in the carburation efficiency, efficiency rate and combined rate of dissolution, showed that this material has the potential to be used as carburante in foudry. Comparing the initial and final conditions of the experiments, it was found that bath treated with synthetic carburiser with low% S, showed a reduction in the degree eutetic supercooling at temperatures of 1485 and 1545 ° C and the chill residue contributed to the reduction of degree eutetic supercooling at temperatures of 1485, 1515 and 1545 ° C. When analyzing the behavior of the degree eutetic supercooling with time after the addition of carburiser, was possible to identify three different behaviors.
Os materiais carburantes têm sido amplamente utilizados na indústria de fundição, em função da crescente utilização de sucata de aço e a consequente redução do uso de ferro gusa. Vários fatores, além da recuperação de carbono no banho metálico, podem ser associados ao uso dos carburantes, entre eles o efeito nos teores de sílicio, enxofre, nitrogênio e no grau de nucleação do metal. Este trabalho apresenta a avaliação dos efeitos do uso de materiais carburantes, dos tipos grafite natural, grafite sintético, resíduo de coquilha de grafite (utilizado em matrizes de fundição contínua) e grafite sintético com baixo teor de enxofre. O método de adição escolhido foi sobre a superfície do banho líquido, em um forno à indução de média frequência, de 2500 Kg de capacidade, realizando testes em três temperaturas distintas. Observou-se que não houve incorporação de nitrogênio do carburante pelo metal líquido, e o teor de enxofre sofreu alteração somente quando usado o carburante sintético. O aumento da temperatura provocou um aumento no valor da eficiência de carburação, independente do tipo de carburante. De maneira geral, observou-se um aumento de 21 32% na eficiência, quando a temperatura é alterada de 1480 a 1545°C. Apenas o carburante sintético especial apresentou menor sensibilidade ao aumento da temperatura, mostrando um aumento de apenas 5% de eficiência. Verificou-se que o teor de cinzas do carburante é uma variável que afeta significativamente o processo de dissolução do carburante. Os resultados evidenciaram que os carburantes com menor teor de cinzas, apresentam maiores valores de eficiência de carburação. Este trabalho propôs o conceito da taxa de ganho de carbono associada, a qual se mostrou efetiva para a previsão do comportamento do % C do banho, após a adição do carburante. Verificou-se que a taxa de ganho de carbono associada inicial, é favorecida com o aumento da temperatura e do teor de enxofre do metal, sendo prejudicada com aumento do percentual de cinzas do carburante. Quanto ao valor da taxa de dissolução combinada, esta mostrou um aumento quando a temperatura de adição é crescente. Notou-se que o valor da taxa de eficiência máxima possui relação com o valor da taxa de dissolução combinada, permitindo concluir que quanto maior o valor da taxa de dissolução combinada, mais rapidamente o processo atinge a sua eficiência máxima. Os resultados observados para o resíduo de coquilha de grafite, na eficiência de carburação, taxa de eficiência e na taxa de dissolução combinada, evidenciaram que este material tem potencial para ser utilizado como carburante. Comparando as condições iniciais e finais dos experimentos, verificou-se que banhos tratados com carburante sintético com baixo %S, apresentaram uma redução no super-resfriamento do eutético, nas temperaturas de 1485 e 1545°C, e o resíduo de coquilha contribuiu para a redução do super-resfriamento do eutético nas temperaturas de 1485, 1515 e 1545°C. Quando analisado o comportamento do grau de super-resfriamento com o tempo, após a adição dos carburantes, foi possível identificar três comportamentos distintos.
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Dong, Ming-Jing. "Effet de l'endommagement sur la ténacité de la fonte à graphite sphéroïdal." Châtenay-Malabry, Ecole centrale de Paris, 1995. http://www.theses.fr/1995ECAP0392.
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Cette étude porte sur l'influence de l'endommagement sur la loi de comportement et sur la ténacité de la fonte a graphite sphéroïdal. La microstructure des fontes GGG 40, GS 52 5%, GS 52 25%, a été caractérisée par analyse à la microsonde, observation au MEB, et analyse d'images. L’endommagement est décrit d'une part à l'échelle macroscopique par les paramètres D, le coefficient de dilatance et l'évolution du coefficient de poisson plastique, et d'autre part a l'échelle microscopique par observation au MEB des différents stades de la décohésion de l'interface graphite/matrice. Nous trouvons que la décohésion apparait des les premiers stades de la déformation plastique macroscopique. D augmente de 30% quand la déformation plastique varie de 0 à 2%, puis l'endommagement se stabilise jusqu'a la rupture finale. Les différents types de graphite donnent les mécanismes d’endommagement différent. La fonte ne peut donc pas être considérée comme un matériau dense. La contrainte critique à l'interface pour la décohésion est de 82 MPA. La modélisation numérique de la loi de comportement montre que en tenant compte des effets du palier de plasticité, de l'empilement des nodules, des contraintes résiduelles, les nodules de graphite peuvent être remplacés par des cavités en accord avec les observations des mécanismes d'endommagement. La taille de la zone endommagée en tête de fissure a été déterminée par observation sur une éprouvette CT 25 de fonte GGG 40 et par des calculs analytique et numérique rendant compte de l'effet de la contrainte hydrostatique. Les résultats expérimentaux et ceux des modèles montrent bien que l'endommagement joue un rôle important dans le cas des éprouvettes CT 25. L’endommagement en tête de fissure modifie la valeur conventionnelle de kC, et entraine une augmentation de la ténacité par comparaison avec celle de la matrice massive. En présence de cavités nous montrons que, l'état de contrainte ne joue pas le même rôle sur la taille de la zone plastique que dans les matériaux denses.
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Souza, José Vitor Cândido de. "Desenvolvimento de pastilhas cerâmicas à bases de Si3N4 para aplicações tribológicas /." Guaratinguetá : [s.n.], 2005. http://hdl.handle.net/11449/105366.
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Resumo: Nesse trabalho foram desenvolvidas três composições à base de Si3N4 com quantidades e tipos de aditivos diferentes, com objetivos de desenvolver cerâmicas densas de altas resistências, para posteriores testes como ferramentas de corte na usinagem de torneamento do ferro fundido cinzento, ferro fundido vermicular e a liga Ti-6Al-4V. As composições utilizaram aditivos Y2O3/Al2O3 (10%) e AlN/Y2O3 (15 e 20%), e foram sinterizadas pelo processo de sinterização normal. Em seguida foram caracterizadas quanto as propriedades físicas e mecânicas, apresentando bons resultados. Posteriormente a composição de melhores propriedades (SNYA20), foi transformada em inserto para usinagem de corte de acordo com a norma ISO 1832. Os testes de torneamento foram realizados no ferro fundido cinzento com variações de parâmentros, onde para Vc=300m/min, f=0,32mm/rot e ap=1,00mm, alcançou um comprimento de corte de 6533m, superior aos encontrados em literatura, com diminuição dos desgastes, para maiores Vc e ap. O torneamento da liga Ti-6Al-4V em alta velocidade (Vc=180m/min, f=0,10mm/rot e ap=0,50mm), alcançou comprimento de corte de Lc=466m, para um desgaste VBmax=2,20mm. No torneamento do ferro fundido vermicular, com variações de parâmetros, alcançou resultados superiores aos encontrados na literatura com ferramentas cerâmicas comercial, utilizando Vc=200mm/min, f=0,20mm/rot e ap= 0,50mm, obteve-se comprimento de corte Lc=1658m. Os resultados de usinagem obtidos nesse trabalho estão relacionados com as propriedades e fases obtidas. Entretanto alem dos resultados obtidos essas ferramentas apresentam custo em torno de 50% das comerciais e redução de 17- 20% de custo no processo, devido ao uso de fluido refrigerante e proteção ao meio ambiente.Abstract: In this work three compositions to base Si3N4 with amounts and types of different additives had been developed, with objective to develop dense ceramics of high strength to possible test as cutting tools in turning of gray cast iron, compacted graphite iron and titanium alloy (Ti-6Al-4V). The compositions had used additives Y2O3/Al2O3 (10%) and AlN/Y2O3 (15 and 20%), and were sinterized by process normal sintering. After sintering the physical and mechanical properties had been characterized, showing interesting results. Posterior the composition the best properties (SNYA20), was transformed into cutting tools to machining in the stand norm ISO 1832. The turning tests had been carried in gray cast iron with different parameters, where to Vc=300m/min, f=0,32mm/rev and ap=1,00mm, obtained a cut length of 6533m, achieving value superior at found in literature, with important reduction to larger cutting speed and cut depth. The turning of the Ti-6Al-4V alloy in high cutting speed (Vc=180m/min, f=0,10mm/rev and ap=0,50mm), obtained cutting length of Lc=466m, to VBmax=2,20mm. In turning compacted graphite iron, with different parameters, obtained value superior at found in literature, when utilize cutting tools ceramics of commercial materials, using for this Vc=200mm/min, f=0,20mm/rev and ap = 0,50mm. These condition obtained cut length of Lc=1658m. The results achieved in this work have been associated with the important physical and mechanical proprieties and phase of cutting tools. However the results obtained with these cutting tools present lower cost (50%) when compared with commercial cutting tools of similar material e reduction of cost in around 17-20%, because the do not use coolant, beside of protection at environment.
Orientador: Sérgio João Crnkovic
Coorientador: Olivério Moreira de Macedo Silva
Doutor
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Sundaram, Dinesh. "The Effect of Solidification time and Cooling rate on the Ultimate tensile Strength of Grey Cast Iron." Thesis, KTH, Materialteknologi, 2018. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-238856.
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Tensile strength modelling is usually done to predict the mechanical properties of lamellargraphite iron considering microstructural features. This work attempts to create a simplifiedmodel incorporating cooling rate and solidification time without considering themicrostructural features. This model will save time and cost in industry with the presence of acommercially available software such as Magmasoft which simulates solidification time andcooling rate. A plate model was designed for this purpose as the test geometry to createvariation in solidification time and cooling rate. By altering fraction solid, thermalconductivity, specific heat capacity in Magmasoft, a good fit was created between simulatedcooling curve and experimental cooling curves. The experimental UTS data of samples fromthree moulds were investigated and a regression model was created using statistics toolMinitab. The effect of solidification time and alloying on the graphite length Lmax was studiedfor twelve samples from each mould. Quantification of the effect of cooling rate and alloyingon the pearlitic properties of grey iron like matrix microhardness, pearlite inter-lamellarspacing was also investigated in this work.The developed model has sixty three percent correlation and explains UTS well in terms ofsolidification time and cooling rate. Microhardness measurements show that there is an almostlinear relationship between the cooling rate and microhardness of the matrix structure.Microhardness data also provides an overview of the pearlite fineness/interlamellar spacing.Analysis of the outliers showed that the presence of free ferrite on a fully pearlitic structurereduces the UTS significantly. Comparison of the regression model obtained from this workwith previous work showed that, there is a reduction in the predicted strength with this model.The effort to identify the reason for this reduction was not successful and needs furtherinvestigation. Pearlite inter-lamellar spacing measurement was not accurate. The relationshipbetween pearlite interlamellar spacing and matrix microhardness needs to be investigated inthe future using a better technique for pearlite spacing measurement. This will be useful tounderstand the effect of cooling rate on pearlite spacing and consequently on the UTS of greycast iron.Draghållfasthetsmodellering görs vanligtvis för att förutsäga de mekaniska egenskaperna av lamellärt grafitjärn. Detta arbete har försökt att skapa en förenklad modell som innehåller kylhastighet och stelningstid utan att överväga mikrostrukturella egenskaper. Modellen kommer att spara tid och kostnad i industrin tillsammans med kommersiellt tillgänglig mjukvara som Magmasoft som simulerar stelningstiden och kylningshastighet. En plattformig modell utformades för detta ändamål som testgeometrin för att skapa variation i stelningstid och kylningshastighet. Genom att ändra fraktion fast fas, termisk konduktivitet och specifik värmekapacitet i Magmasoft skapades en bra anpassning mellan simulerade och experimentella kylkurvor. Experimentella draghållfasthetsdata (UTS) för prover från tre gjutningar undersöktes och en regressionsmodell skapades med hjälp av statistikverktyg Minitab. Effekten av stelningstid och legeringshalt på grafitlängden Lmax studerades för tolv prover från varje form. Effekten av kylhastighet och legering på de perlitiska egenskaperna hos grått järn som matrismikrohårdhet och perlitlamellavstånd undersöktes också i detta arbete. Den utvecklade modellen har sextiotre procent korrelation och förklarar UTS väl med avseende på stelningstid och kylningshastighet. Mikrohårdhetsmätningar visar att det finns ett nästan linjärt förhållande mellan kylhastigheten och mikrohårdheten hos matrisstrukturen. Mikrohårdhetsdata ger också en översikt över perlitens finhet/interlamellära avstånd. Analys av outliers visade att närvaron av fri ferrit på en fullständigt perlitisk struktur minskar UTS betydligt. Jämförelse av regressionsmodellen erhållen från detta arbete med tidigare arbete visade det att det finns en minskning av den förutsagda styrkan med denna modell. Ansträngningen att identifiera orsaken till denna minskning var inte framgångsrik och behöver ytterligare undersökas. Perlit mellan lamellär avståndsmätning var inte korrekt. Förhållandet mellan perlitens interlamellära avstånd och matrismikrohet måste undersökas i framtiden med hjälp av en bättre teknik för perlit-avståndsmätning. Detta kommer att vara användbart att förstå effekten av kylhastighet på perlitavståndet och följaktligen på UTS av grå gjutjärn
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Jacumasso, Tiago. "INFLUÊNCIA DOS PARÂMETROS DE AUSTÊMPERA EM FERRO FUNDIDO NODULAR: MICROESTRUTURA, PROPRIEDADES MECÂNICAS E ASPECTOS DA GEOMETRIA FRACTAL NA FRATURA." Universidade Estadual de Ponta Grossa, 2018. http://tede2.uepg.br/jspui/handle/prefix/2684.
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Coordenação de Aperfeiçoamento de Pessoal de Nível Superior
A mecânica da fratura foi desenvolvida, utilizando-se uma descrição geométrica euclidiana que pressupõem uma trinca lisa sem irregularidades. Por esta razão, a modelagem matemática de uma trinca rugosa, usando a geometria fractal, tem sido a preocupação de vários autores nas últimas décadas. O intuito destes pesquisadores é descrever o fenômeno da fratura de forma mais autentica e precisa. Uma das formas de se avaliar as propriedades mecânicas de um material fraturado é usando o conceito de integral-J. Este conceito aplicado ao fenômeno da fratura define uma curva de resistência ao crescimento de trinca chamado de curva J-R. Sendo assim, vários modelos fractais de curva J-R têm sido propostos. Um dos modelos que vem ganhando destaque na literatura científica foi proposto por ALVES (2010, 2011). Por esta razão investigou-se, neste trabalho, a aplicação desse modelo no estudo da fratura do ferro fundido nodular e ferro fundido nodular austemperado (ADI). O objetivo foi avaliar os efeitos dos tratamentos térmicos de austêmpera na microestrutura e nas propriedades mecânicas de uma liga de ferro fundido nodular. Para tanto foi empregado duas rotas de tratamentos térmicos: austêmpera convencional, consistindo de austenitização a 900ºC por 60min, seguida de austêmpera até 250ºC e à 300ºC, com permanência por 60min e 120min para cada temperatura, totalizando quatro condições, com resfriamento ao ar. As amostras tratadas termicamente foram caracterizadas com auxílio de microscopia óptica, microscopia eletrônica de varredura (FEG) e difração de raios X (DRX), com objetivo de determinar suas fases e microconstituintes. O efeito das condições de tratamento nas propriedades mecânicas foi verificado por ensaios de dureza Vickers e de impacto instrumentado Charpy. Por meio de ensaios de impacto instrumentado e solicitação mecânica de tração e com o auxílio de microscopia eletrônica por emissão de campo (FEG) foi possível estudar o crescimento de trincas rugosas na fratura do ferro fundido nodular austemperado, comparando os resultados entre as quatro condições de tratamento térmico de austêmpera. Deste modo, foi possível fornecer dados experimentais para comprovar a validade da equação da curva J-R na presença de uma trinca rugosa proposta por ALVES (2010, 2011) com base na geometria fractal e na mecânica da fratura. Os resultados obtidos permitiram comparar e discutir o efeito das rotas de tratamento térmico, no sentido de desenvolver as propriedades mecânicas do ferro fundido nodular para aplicações diversas. As curvas D J ajustadas pelo modelo fractal mostraram-se em boa concordância com aquelas obtidas pelo método descrito na ASTM E1820-17a (2017). O ADI tratado a 300ºC por 60 minutos foi o material que apresentou as melhores condições de resistência mecânica a tração e ao impacto, superando o material bruto de fundição na tenacidade a fratura, calculada pelos parâmetros fractais da curva. Este ferro fundido nodular austemperado é comparado ao da classe de alta resistência de ADI.
The mechanics of the fracture were developed using a geometric Euclidean description that assumes a smooth crack without irregularities. For this reason, the mathematical modeling of a rough crack, using fractal geometry, has been the concern of several authors in the last decades. The aim of these researchers is to describe the fracture phenomenon more authentically and accurately. One of the ways to evaluate the mechanical properties of a fractured material is by using the concept of integral-J. This concept applied to the fracture phenomenon defines a crack growth resistance curve called the J-R curve. Thus, several fractal J-R curve models have been proposed. One of the models that have gained prominence in the scientific literature was proposed by ALVES (2010, 2011). For this reason we investigated the application of this model in the study of nodular cast iron and austempered nodular cast iron (ADI). The objective was to evaluate the effects of thermal treatments of austempering in the microstructure and mechanical properties of a ductile cast iron alloy. Two routes of thermal treatments were used: conventional austenitic, consisting of austenitization at 900ºC for 60min, followed by tempering up to 250ºC and at 300ºC, with permanence for 60min and 120min for each temperature, totaling four conditions, with air cooling. The thermally treated samples were characterized by optical microscopy, scanning electron microscopy (FEG) and X - ray diffraction (XRD), in order to determine their phases and microconstituents. The effect of the treatment conditions on the mechanical properties was verified by tests of Vickers hardness and instrumented impact Charpy. By means of instrumented impact and mechanical tensile stress tests and with the aid of field emission electron microscopy (FEG), it was possible to study the growth of rough cracks in austempered nodular cast iron fracture, comparing the results between the four conditions of heat treatment. Thus, it was possible to provide experimental data to prove the validity of the J-R curve equation in the presence of a rough crack proposed by ALVES (2010, 2011) based on fractal geometry and fracture mechanics. The results obtained allowed to compare and discuss the effect of heat treatment routes in order to develop the mechanical properties of nodular cast iron for different applications. The D J curves fitting by the fractal model show in agreement with the curves obtained by the method described in the ASTM E1820-17a (2017). The ADI treated at 300ºC for 60 minutes was the material that presented the best conditions of tensile and impact mechanical strength, surpassing the crude casting material in the fracture toughness, calculated by the fractal parameters of the curve. This austempered nodular cast iron is compared to that of the ADI high strength class.
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Cristofolini, Renato. "Estudo da potencialidade da aplicação do ferro fundido nodular ASTM A536 60-40-18 como materia prima para processos de tixoconformação." [s.n.], 2009. http://repositorio.unicamp.br/jspui/handle/REPOSIP/263560.
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Orientador: Maria Helena RobertTese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica
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Resumo: Este trabalho analisa a tixohabilidade, a viabilidade de produção de pastas tixotrópicas e as transformações de fase que ocorrem na tixofundição do ferro fundido nodular ASTM A536 60-40-18. A análise da tixohabilidade é feita através de análises térmicas utilizando técnicas de Análise Térmica Diferencial (ATD) e Calorimetria Exploratória Diferencial (CED) em diferentes condições operacionais (tipo de ciclo e taxas de aquecimento/resfriamento), e através de simulação termodinâmica utilizando software THERMOCALC®. São discutidas a influência das condições dos ensaios nas temperaturas de transformações e intervalos de solidificação, e os resultados comparados com os obtidos por simulação. São discutidas as transformações de fases que ocorrem e as respectivas temperaturas, sendo proposto diagrama de fases para a liga específica em estudo. São determinadas a sensibilidade da variação da fração líquida com a temperatura (dFL/dT) e sugeridas janelas de tixoconformação, para todas as condições analisadas. Os resultados obtidos indicam uma faixa de operação para a tixoconformação da ordem de 20oC, onde uma transformação eutética se faz presente e a variação da fração líquida com a temperatura pode ser controlada adequadamente. A janela de tixoconformação depende da taxa de transferência de calor empregada: quanto maior a taxa, maior o intervalo de transformação eutética e maior a janela de tixoconformação. Quanto à análise da viabilidade de produção de pastas tixotrópicas, foram produzidas pastas por fusão parcial controlada a distintas temperaturas dentro da faixa de operação para tixoconformação determinada previamente. As microestruturas resultantes foram analisadas por microscopia ótica (MO) e eletrônica de varredura (MEV), difratometria de raios-x e microanálise utilizando energia dispersiva (EDS). Os resultados mostram a viabilidade de produção de pastas com características tixotrópicas, nas condições analisadas, apesar da estreita faixa de temperaturas da janela de tixoconformação do material estudado. Mostram ainda que a temperatura de tratamento influencia a quantidade e dimensões dos nódulos de grafita presentes na matriz da pasta, sendo que temperaturas de tixofundição superiores à faixa de transformação eutética podem levar à rápida dissolução desses nódulos e como consequência, o aumento da dureza da liga e redução de sua ductilidade. O produto tixofundido apresenta, à temperatura ambiente, estrutura constituída essencialmente de martensita, resultado do resfriamento rápido da austenita, grafita nodular de pequenas dimensões e de fases complexas em contornos de grãos martensíticos.
Abstract: This work analyses the thixoability, the viability of actual production of thixotropic semi-solid of ferritic nodular cast iron ASTM A536 60-40-18, as well as the phase transformations taking place in the process. Thixoability evaluation is made through thermal analysis by Differential Thermal Analysis (DTA) and Differential Scanning Calorimetry (DSC) tests in different conditions (cycle type and heating/cooling rate), and also through thermodynamic simulations using THERMOCALC® software. Related to these analysis it is evaluated the influence of tests conditions on transformations temperatures and ranges; results are compared to those obtained by simulation. Phase transformations are discussed and a specific phase diagram for the alloy investigated is proposed. Liquid fraction sensitivities with temperature (dFL/dT) are determined, and thixoforming windows are suggested. Results indicate that a thixoforming window in the order of 20°C are available; in this range a eutectic transformation takes place and the liquid fraction can be controlled. Beyond the eutectic temperature liquid fraction increases significantly with temperature variation and processing control can not be assured. Thixoforming windows depend on heat transfer rates: higher the rate, higher the eutectic range and the thixoforming window. To analyse the viability of actually producing thixotropic slurries by partial melting, samples were heated to temperatures within the thixoforming windows previously suggested. Resulting microstructures were analysed by optical and electronic microscopy, X-R diffraction and EDS microanalysis. Results show the feasibility of producing thixotropic semi-solid of the studied nodular iron, in spite of its narrow thixoforming field; treatment temperature influences the size and amount of graphite nodules in the matrix. Higher temperatures can lead to fast dissolution of graphite, jeopardizing the ductility of the material. Thixocast product presents, at room temperature, small nodules of graphite in a martensitic matrix and a complex phase in grain boundaries.
Doutorado
Materiais e Processos de Fabricação
Doutor em Engenharia Mecânica
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Bourdie, Jacques. "Sphéroïdisation du graphite - Cas de la fonte centrifugée." Thesis, Toulouse, INPT, 2017. http://www.theses.fr/2017INPT0117/document.
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Les fontes de fer sont des matériaux largement utilisés dans de nombreux domaines allant de l’industrie automobile au secteur de l’énergie en passant par la fabrication des tuyaux d’adduction d’eau. Du fait de la teneur en carbone élevée de ces alliages, du graphite et/ou des carbures de fer précipitent pendant la solidification. Les propriétés finales des pièces dépendent alors de la nature de la matrice, de la présence ou non de carbures et surtout de la forme du graphite. Celui-ci peut cristalliser sous la forme de lamelles, de sphères ou de particules de formes intermédiaires. Les éléments présents à l’état de traces dans le bain de fonte liquide influencent de manière considérable la croissance du graphite et conditionnent sa forme finale. Leur moyen d’action ainsi que le mécanisme de croissance du graphite sphéroïdal sont encore un sujet de débat et cette thèse a pour objectif de contribuer à la compréhension des phénomènes mis en jeu. Les échantillons utilisés ont été élaborés selon le procédé de coulée par centrifugation, son influence sur les mécanismes étudiés est d’ailleurs au cœur de ce projet. Les différents essais et analyses réalisés prouvent que la structure des nodules observés dans les échantillons centrifugés est la même que dans le cas des pièces moulées en sable. De plus, les éléments traces montrent une action similaire lors de la solidification et pendant la croissance en phase solide durant le traitement thermique destiné à éliminer les carbures. Ces résultats suggèrent que le mécanisme de croissance du graphite sphéroïdal est le même lors de la croissance à partir du liquide ou en phase solide par décomposition des carbures. Une proposition est d’ailleurs faite pour expliquer le développement des nodules par une germination continue du graphite sur les plans de base conjuguée à une croissance selon les directions prismatiques. Un modèle mathématique associé à ce mécanisme est présenté et son application au procédé de centrifugation donne des résultats en accord avec les observations expérimentalesCast irons are widely used in the foundry industries for applications mainly in the automotive, energy and pipes industries. Because of the high carbon content, graphite and/or iron carbides appear during solidification. The properties of the casting depend on the nature of the matrix, the presence or not of carbides and the shape of the graphite. It can crystallise under the form of lamellae, spheroids or particles with an intermediate shape. Trace elements present in the melt strongly influence graphite growth and shape. Their action and the growth mechanism of the spheroidal graphite are still under debate and the aim of this project is to contribute to the understanding of these phenomena. The samples have been cooled by the centrifugal casting process whose influence on the studied mechanisms is the focus of this project. The different analyses that have been carried out show that the structure of the nodules is the same in centrifugated and sand mold castings. Moreover, the trace elements exhibit a similar action during solidification and solid state growth during heat-treatment for carbide dissolution. These results suggest that the growth mechanism of spheroidal graphite is the same during growth from the liquid and by solid state decomposition of carbides. A schematic is proposed to explain the growth of the nodules by a continuous nucleation on the basal surface of the graphite coupled to a growth along the prismatic directions. A mathematical model associated to this mechanism is presented and its application to the centrifugal casting process gives results in good agreement with experimental observations
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Molina, Griggs Alejandro José. "Laser Metal Powder Deposition of Austenitic Stainless Steel on Spheroidal Graphite Cast Iron : A corrosion resistant coating for the Food & Beverage Industry." Thesis, Högskolan Väst, Avdelningen för svetsteknologi (SV), 2018. http://urn.kb.se/resolve?urn=urn:nbn:se:hv:diva-13016.
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Spheroidal graphite cast iron is a material widely used in the industry for the manufacturing of all kind of covers and protective casings thanks to its good combination of mechanical properties, processability and cost. When cast iron components are put into service in corrosive environments the most common approach to protect the components is painting them. The protective painting has been found to flake off with time when aggressive washing procedures, such as the ones used in the Food & Beverage industry, are applied several times. In this project, the coating of cast iron with a corrosion resistant AISI 316L stainless steel by Laser Metal Powder Deposition has been studied as an alternative protection against corrosion. Several samples with different combinations of substrate preparation, number of layers and surface conditions were produced and analysed by optical microscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy, wash down tests and salt spray chamber corrosion tests. Main results show that the diffusion of carbon from the carbon-rich cast iron to the stainless steel coating, which would have a negative effect on the corrosion resistant properties, was significantly low as a result of the low penetration and dilution achieved during the laser metal powder deposition process. The deposited stainless steel coatings successfully protected the substrate during the corrosion tests and the integrity of the coatings is not expected to fail during the washing producers applied in the industry.
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Tinoco, José. "On the Spray Forming of Metals, the Formation of Porosity and the Heat Evolution during Solidification." Doctoral thesis, KTH, Casting of Metals, 2003. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-3636.
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This thesis deals with the heat evolution duringsolidification and its relation to the formation of porosity.It intends to improve the current understanding of theformation of porosity in cast materials with special interestin nodular cast iron and the spray forming process. Twodifferent systems, a Fe-based alloy, Cast iron, and a Ni-basedalloy, Inconel 625, are examined. The effect on the heatevolution of the morphology and the processing parameters inspray forming are treated.
An evaluation of the microstructural features, segregationbehavior and physical properties such as latent heat of fusionis performed byusing thermal analysis under cooling ratesranging from 0.1 to 104 K/s. In order to achieve this amodified differential thermal analysis (DTA) equipment, amirror furnace and levitation casting are used. Results arepresented in terms of the fraction of solidified, the coolingrate and the microstructure observed. The measured latent heatof fusion is not constant throughout the solidificationprocess. Variations in morphology and cooling rate affect therelease of the latent heat.
A thermodynamic model is used to describe the experimentalobservations and to explain the formation of pores in nodularcast iron by taking into consideration the formation of latticedefects during the liquid/solid transformation. In this casethe formation of porosity is regarded as a consequence ofchanges in the volume fraction ratio graphite/ during thesolidification process.
A numerical model of the spray forming process is developedby means of CFD modelling and compared with experimentalmeasurements performed in an industrial facility. Stagnationpressure measurements provided information about the gas flowvelocity and an analysis of the overspray powder providedinformation about the particle thermal history. Evaluation ofthe deposit was also performed. It is observed that the processconditions in spray forming promote non-equilibriumsolidification even though solidification at the deposit occursat a lower rate. In this case the porosity formed near theinterface substrate/deposit depends largely on the substratetemperature. The presence of certain reactive elements, such astitanium, affects the porosity levels in the rest of thedeposit.
Keywords:Thermal Analysis, Nodular Cast Iron, Inconel625, CFD, Flow Assesment, Multiphase Flow, Spray Deposition,Microporosity, Superalloys
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Yang, Rong Zhong, and 楊榮忠. "The influence of graphite nodules and size on austenitization of ductile cast iron." Thesis, 1995. http://ndltd.ncl.edu.tw/handle/09428823973116950194.
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吳慶郎. "Simulation of solidification in eutectic nodular cast iron system." Thesis, 1988. http://ndltd.ncl.edu.tw/handle/59909604391109681403.
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Sun, Chi-Hung, and 孫啟宏. "A Study on Metal Mold Centrifugal Casting of Compacted Graphite Cast Iron and Compacted Graphite Cast Iron Based Composites with TiC." Thesis, 2001. http://ndltd.ncl.edu.tw/handle/16789614195744638932.
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碩士義守大學
材料科學與工程學系
89
Abstract The effect of process parameters, which include the amounts of spheroidizer (0.19~0.94wt%), the amount of inoculator (0.4~1.0wt%), the times gravity (70~110G), the pouring temperature (1350~1420℃),and the CE value (4.08~4.52%), on the microstructures and mechanical properties of centrifugally cast compacted graphite iron were studied. This data base were applied to develop compacted graphite iron based composite with concentration gradient distribution of TiC particles on the inner surface layer. Some process parameters will be investigated. They are titanium content (0~0.54wt%), the times gravity (70~110G), the pouring temperature (1349~1394℃), and the amount of inoculator (1.0~1.4wt%). The effect of process parameters on the amounts of TiC , microstructures and mechanical properties were investigated. The results showed that the good compacted graphite shape can be obtained in the residual Mg content between 0.013~0.023wt%. When the residual Mg content at 0.018wt%, we can obtain the best vermicular graphite shape. The amount of carbide increases with increaseing times gravity. The tendency of carbide formation decreases with inccresing CE value. On the other hand, the amounts of ferrite , ductility, and tonghness have opposite tendency with CE values. The results also revealed that the distribution of TiC particles in the radial direction is in the order of interior region > outside region . For the mechanical properties, the tensile strength increases with increasing the times gravity, but the tendency of ductility is contrary. The tensile strength decreases with increasing the amount of inoculator.
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Tai, Huang Kuo, and 黃國泰. "The Study of Compacted Graphite Cast Iron Process Stability." Thesis, 2001. http://ndltd.ncl.edu.tw/handle/44331479904180955780.
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碩士國立臺灣師範大學
工業教育研究所
90
ABSTRACT This paper is mainly focusing on the study of the amount of the three kinds of spheroidizing, KC alloys、CG alloys、Rare earths that is needed to produce the compacted graphite cast iron, and on the study of the stability in the process of producing optical microscope observation and mechanical property under as identical condition as possible. Besides, this paper will do the comparison between the stability of the two base structures under two different speed of annealing. The results shows that the amount needed to produce the compacted graphite cast iron is 0.8% with CG alloy-spheroidizing, 0.3% with KC alloy-spheroidizing, 0.8% with Rare earths; and what’s more, the above three kinds of spheroidizing have to add 0.2% dose of inoculation. According to the gauging, the coefficient of variance of the compacted rate of graphite is 44.98, and the standard deviation of it is 6.71, which is the smallest. In addition, the average figure of the eight-time experiment is 88.13% so to add KC alloys can make the process of producing the compacted graphite cast iron most stable. From the results of the experiment, CG alloys can produce better mechanical quality of the compacted graphite cast iron, and have more stable process of producing it. When the compacted graphite cast iron is under the process of the annealing, neither the temperature quenching down to 260°C in the stove before quenching in the air nor quenching the temperature directly in the air will have influence on getting the complete ferrite structure.
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Javaid, Amjad. "Morphological features of spheroidal graphite in ductile cast iron." 1989. http://catalog.hathitrust.org/api/volumes/oclc/20078809.html.
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Thesis (M.S.)--University of Wisconsin--Madison, 1989.Typescript. eContent provider-neutral record in process. Description based on print version record. Includes bibliographical references (leaves 108-113).
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Hu, Chen-Yu, and 胡鎮宇. "Production of Graphite from Catalytic Liquid Cast Iron Bath." Thesis, 2018. http://ndltd.ncl.edu.tw/handle/f987bp.
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碩士國立清華大學
材料科學工程學系
106
Via the use of iron-carbon phase diagram and the theory of graphitization of carbon in cast irons, this study investigates an innovative method for continuously, effectively and efficiently, as well as environment-friendly producing graphite in a catalytic cast iron bath. It is concluded that the transformation from amorphous carbon to graphite via the method is available, and the degree of graphitization (DOG) described in this study reaches a high value of more than 93% like that of Acheson’s. Furthermore, the DOG is process-controlled and is independent of carbon source in the hypereutectic catalytic cast iron melt. The observance of graphite flotation in liquid catalytic cast iron bath manifests the production of graphite is achievable by the fluidized bed method. The first part of this study describes the inductive melting (IM) of alloys of iron, carbon, and silicon at 1600oC for full melting; holding at temperatures higher than the eutectic temperature of 1500oC for 4 h for graphitization of carbon; and then lower the temperature to 25oC for test specimens. The IM specimens, being XRD and OM-checked firstly, are further pickled to obtain graphite that is also XRD-, OM- and ICP-analyzed to compare with graphite obtained from nodular cast iron and gray cast iron. The second part is about the vacuum arc re-melting (VAR) experiment of the specimens that are obtained in the first part. The effects of the number of VAR process and the addition of synthetic graphite on the DOG are checked with OM. The graphite samples of VAR specimens after pickled are checked with graphite production yield analysis, XRD for the comparison of the DOG, and ICP for the composition analysis.
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簡絲男. "A Study on the Resonant Vibration Characteristic of As-Cast Spheroidal Graphite Cast Iron." Thesis, 1999. http://ndltd.ncl.edu.tw/handle/54420264935403337707.
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碩士國立成功大學
材料科學及工程學系
87
Spheroidal graphite (SG) cast iron has been used in many automobile components. During application, resonant vibration may occur and cause failure. A lot of these automobile components are used in as-cast condition, so systematic exploration of the resonant vibration characteristics of as-cast SG cast iron is necessary. In addition, the resonant vibration test can also be applied to separate the sprue and workpiece in investment casting. The as-cast SG cast iron of 3.6wt%C-2.9wt%Si was used in this study. By varying the cooling rate after solidification, different matrix structures (pearlite components) were available, which aimed to study the effect of matrix structures on resonant vibration characteristics. During resonant vibration, the variation of deflection amplitude vs. vibration cycles could be divided into three stage. Firstly, the deflection amplitude maintain about constant for a certain period of vibration cycles (stage I). Then, the deflection amplitude decreases significantly with increasing vibration cycles. In the third stage, the deflection amplitude maintains about constant again, but significantly lower than the deflection amplitude of stage I. The above mentioned feature of three-stages behavior is related to the result of crack initiation and propagation. Mostly, microcracks initiate from the interface between graphite nodules and matrix, and fewer microcracks initiated from the inclusions in eutectic cell wall. Microcracks propagated to link each other and finally become major cracks with increasing vibration cycles. The process of crack initiation and linking were proceeding during the stage I period. After the formation of major cracks, the major cracks propagate through the thickness direction, then the effectic elastic modulus of specimen was reduced. Due to the drop of elastic modulus, the deflection amplitude decreased significantly as shown the feature of "stage II". In stage 3, the lower of deflection amplitude and cracking rate makes another plateau region. The experimental results showed that the increment of pearlite contents would slightly increase the resonant frequency of specimen. The damping capacity decreases with increasing pearlite content and so does deflection amplitude. After initiation, the cracks propagated in. The cracks propagated in the pearlite matrix along two paths. Sometimes it goes along the cementite platelets and sometimes through cementite platelets. Mostly, cracks propagated transgranularly in ferrite matrix, but fewer intergranular fracture near the bull''s-eye region is also observed by SEM. As the crack extends, the deflection and brunching occur on the grain boundaries of ferrite, the interface between ferrite and pearlite and the cementite platelets with different orientation. Thus, the driving force for crack propagation is reduced. Although the pearlite content can cause the deflection amplitude under resonant, to increase the crack propagates in the pearlite with higher degree of deflection and branching and the pearlite can retard crack extension. Therefore, the resonant vibration life can be improved with increasing the pearlite content.
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Pires, António Jorge Ferreira. "Use of Thermal Analysis for Evaluation Of Inoculation Efficiency In Nodular Cast Iron." Dissertação, 2020. https://hdl.handle.net/10216/129259.
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Pires, António Jorge Ferreira. "Use of Thermal Analysis for Evaluation Of Inoculation Efficiency In Nodular Cast Iron." Master's thesis, 2020. https://hdl.handle.net/10216/129259.
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Wu, Kuo-Lung, and 吳國龍. "Study on Erosion Wear of Spheroidal Graphite Cast Iron Pipes." Thesis, 2005. http://ndltd.ncl.edu.tw/handle/ktpbnu.
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碩士國立臺北科技大學
材料及資源工程系所
94
Spheroidal graphite cast iron has been widely used in many structure fields of industry due to its superior mechanical properties. This research takes three kinds of commercial spheroidal graphite cast iron pipes, centrifugal casting pipe, centrifugal casting pipe with annealing treatment and sand casting fitting, which were to undergo solid erosion test using angular Al2O3 particles. The purpose of this research is to study the effect of erosion on spheroidal graphite cast iron pipes and fitting which possess various microstructures and mechanical properties due to the different manufacturing processes and heat treatment. The experimental results showed that the microstructure of centrifugal casting pipe consists of larger amount of cementite because of the fast cooling rate and higher degree of overcooling, resisting in the improvement of hardness and erosion resistance. Centrifugal casting pipe with annealing treatment, turning its microstructure into full of ferrite by carbon atom diffusing to nodular graphite and ferrite, is least resistant to erosion with the highest erosion rate and the maximum erosion depth. The microstructure of sand casting fitting is mixed with pearlite and ferrite, with the mechanical property just laying between the other two pipes, which makes the erosion rate and erosion depth follow the same trend. The max. erosion rate occurred at incident angle 30°∼45°according to different solid erosion particle amounts, and the deepest erosion depth occurred consistently at incident angle 60°, for the three comparison specimens. The test also reveals that the failure mechanism of spheroidal graphite cast iron pipes and fitting tend to be ductile-brittle fracture.
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Lin, Cheng, and 林晟. "The Study on Rare Earth Element (Ce) Decay in Thin Casting Nodular Cast Iron." Thesis, 2009. http://ndltd.ncl.edu.tw/handle/y3y96u.
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碩士國立臺北科技大學
材料科學與工程研究所
97
The main propose of this thesis is to investigate the influence of metallographic on cast iron which have trace element. It could offer producer a feasible way and recognize the trace element to use it. The variable in the experiment include trace element type, quantity, reaction time and spheroidizing methods. And quantity of inoculation, size of inoculation and inoculate methods. In the experiment to make Nodular Cast Iron is use rare earth element (Ce) which pure rate above 99% to be nodularizer add into molten iron (FCD-450). Then inoculate with FeSi. Experiment temperature are within 1400 to 1500℃ in every furnace lot, and test pour out at different time. We use sand box to be cast mold which thin wall type in every factory, in order to know Thin Wall Nodular Cast Iron spheroidizing rate influence by nodularizer decay. We know produce procedure of Nodular Cast Iron, melting → spheroidizing → inoculation → casting → sampling. Spheroidizing and inoculation reaction are perform in ladel. Due to this experiment principal issue is nodularizer decay time in molten iron, molten iron pour out at different time, so we need to adjust procedure to match experiment demand. Experiment result shows that use cerium 3% to replace magnesium to be nodularizer, and add inoculate FeSi 1.5%. When spheroidizing 15~20 min., we can obtain Thin Casting Nodular Cast Iron nodularity 90%. when spheroidizing at a long time later, nodularity below 50%, to replace vermicular and flat piece graphite. In addition, this article is directed to manufacturing process about use cerium to replace magnesium to manufacture Thin Casting Nodular Cast Iron.