Si and Ni As Alloying Elements To Vary Carbon Equivalent of Austenitic Ductile Cast Iron - Microstructure and Mechanical Properties-2
Si and Ni As Alloying Elements To Vary Carbon Equivalent of Austenitic Ductile Cast Iron - Microstructure and Mechanical Properties-2
Si and Ni As Alloying Elements To Vary Carbon Equivalent of Austenitic Ductile Cast Iron - Microstructure and Mechanical Properties-2
a r t i c l e
i n f o
Article history:
Received 16 September 2008
Received in revised form 14 October 2008
Accepted 15 October 2008
Keywords:
Austenitic ductile iron
Carbon equivalent
Microstructure
Mechanical properties
Alloying elements
a b s t r a c t
Successful casting of three groups of austenitic ductile irons was achieved covering a carbon equivalent
(CE) range from 3.51% to 5.04%. The three groups implied the change of C, Si or Ni contents to control
the CE%. In case of using Ni element to vary CE%, austenitic ductile iron could be obtained starting from
13.5% up to 34.7% Ni. Generally, the microstructure consisted of graphite nodules embedded in austenitic
matrix. Nodule characteristics were affected by the variation of CE%. Nodularity was almost 100% for all
tested specimens. Slight decrease in hardness and tensile strength ( u ) was observed with increasing the
CE%. 0.2% proof stress ( 0.2 ) showed almost a constant value with increasing CE%. Tensile elongation was
mainly increased with increasing CE% with different degrees owing to the alloying element (C, Si or Ni).
2008 Elsevier B.V. All rights reserved.
1. Introduction
Austenitic ductile cast irons are series of cast irons that contain nickel from 18 up to 36 mass%, having been treated with
magnesium to bring about the formation of nodular graphite
[1]. It contains sufcient nickel to produce an austenitic matrix
structure similar to that of austenitic stainless steel. These irons
have tensile strength ranging from 3870 to 5620 MPa, elongation
from 4% up to 40% and Brinell hardness ranging from 1110 to
1710 MPa [16]. These high nickel alloyed ductile cast irons are
made in a number of different compositions to produce the desired
properties [13,713]. While conventional foundry practices are
used for the production of Ni-resist ductile iron castings, special
precautions, not normally used, must be taken into consideration.
Treating and gating practices, and pouring temperature must be
modied considerably from those used in conventional ductile iron
production. For this reason, design engineers and Ni-resist ductile
cast iron producers should review proposed casting designs if minimum cost and maximum product reliability are to be obtained
[1]. Numerous data have been published about the production,
microstructure and mechanical properties of austempered ductile cast iron (ADI) [17,1419] and conventional ductile iron
[17,2031]. Few information [13,713] do exist for the produc-
2. Experimental procedure
Three heats (A, B and C) were prepared in a 90 kg high frequency
(1000 Hz) induction furnace. Charges were low sulphur, low manganese, and low phosphor pig iron (Sorel metal) and steel scrap (cf.
Table 1). Necessary amounts of Si, C and Ni were added to yield a Sicontent 1.635.31 mass%, C-content 2.13.5 mass%, and Ni-content
4.9934.70 mass%. Melts were superheated to 17731823 K. Magnesium treatment and inoculation were performed using the
Sandwich Technique [1] for producing ductile cast iron. The ferrosilicon alloy containing 10% Mg was used in the spheroidising
treatment. The heats were inoculated with 0.5 mass% of the charge
with FeSi alloy (65% Si). The grain size of inoculants ranged from 1.5
to 3 mm. Pure Ni was melted with raw materials to get austenitic
ductile iron in the as cast condition. Table 2 lists the actual chemical composition of all heats involved in this study. The melt was
poured at a temperature ranging from 1620 to 1640 K into two different moulds to produce specimens for both chemical analysis and
tests. A half-inch Y-block sand mould was used (cf. Fig. 1). Carbon
82
Table 1
Chemical composition of the raw materials used to produce austenitic ductile cast
iron in the present study.
Table 3
Effect of CE% on nodule-characteristics of all groups of austenitic ductile cast iron
produced in the present study.
Raw materials
Group
symbol
Heat no.
CE%
Nodule count
nodule (mm2 )
Nodule size
(m)
Nodularity
(%)
A1
A2
A3
A4
A5
A6
A7
A8
3.51
3.69
3.91
4.1
4.34
4.55
4.67
5.04
80
125
125
125
70
220
220
220
15
28
25
25
20
25
25
25
80
100
100
100
100
100
100
100
B1
B2
B3
B4
B5
B6
B7
B8
3.86
4
4.16
4.28
4.38
4.46
4.59
4.64
130
160
200
200
225
225
225
250
28
25
25
25
22
22
22
20
100
100
100
100
100
100
100
100
C1
C2
C3
C4
C5
C6
C7
C8
3.7
3.79
3.9
4
4.15
4.26
4.49
4.8
125
200
250
180
200
250
250
250
28
10
15
15
15
15
15
15
100
100
100
100
100
100
100
100
Sorel metal
Steel scrap
Ferrosilicon
Carboriser
Nickel
Composition%
C
Si
Mn
Ni
Fe
4.0
0.16
0.0
100.0
0.0
0.1
0.15
65.0
0.0
0.0
0.1
0.6
0.0
0.0
0.0
0.02
0.02
0.0
0.0
0.0
0.03
0.03
0.0
0.0
0.0
0.0
0.0
0.0
0.0
99
Balance
Balance
Balance
0.0
Balance
Table 2
Chemical composition of all heats of austenitic ductile cast iron produced in the
present study.
Group symbol
Heat no.
Composition
C
Si
Ni
Mn
Mg
A1
A2
A3
A4
A5
A6
A7
A8
2.11
2.31
2.53
2.71
2.95
3.16
3.29
3.42
2.12
2.07
2.11
2.08
2.12
2.14
2.08
2.16
19.77
19.44
19.41
19.70
19.54
19.41
19.52
20.02
1.40
1.40
1.40
1.40
1.40
1.40
1.40
1.40
0.043
0.041
0.045
0.050
0.045
0.053
0.048
0.059
B1
B2
B3
B4
B5
B6
B7
B8
2.50
2.53
2.52
2.56
2.54
2.51
2.53
2.50
1.63
2.17
2.76
3.32
3.89
4.41
4.92
5.31
21.54
21.59
21.90
21.67
21.86
21.87
21.65
21.58
1.34
1.33
1.32
1.33
1.34
1.34
1.33
1.33
0.047
0.040
0.042
0.049
0.051
0.049
0.038
0.036
C1
C2
C3
C4
C5
C6
C7
C8
2.90
2.85
2.79
2.80
2.83
2.78
2.77
2.91
1.86
1.82
1.84
1.85
1.75
1.79
1.85
1.83
4.99
9.09
13.50
16.10
19.80
23.90
30.40
34.70
1.77
1.72
1.48
1.56
1.71
1.60
1.59
1.39
0.045
0.069
0.061
0.065
0.051
0.063
0.067
0.062
83
Fig. 2. As-polished microstructure of austenitic ductile cast iron with different %CE ranging from 3.51 to 5.04. Group A: different C% ranging from 2.11 to 3.42.
84
Fig. 3. As-polished microstructure of austenitic ductile cast iron with different %CE ranging from 3.86 to 4.64. Group B with different Si% ranging from 2.50 to 5.31.
85
Fig. 4. As-polished microstructure of austenitic ductile cast iron with different %CE ranging from 3.70 to 4.80. Group C with different Ni% ranging from 4.99 to 34.70.
86
Fig. 5. Effect of variation of %CE ranging from 3.51 to 5.04 on the microstructure of austenitic ductile cast iron etched with 0.5 nital. Group A with different C% ranging from
2.11 to 3.42.
87
Fig. 6. Effect of variation of %CE ranging from 3.86 to 4.64 on the microstructure of austenitic ductile cast iron. Etched with nital 0.5. Group B with different Si% ranging from
2.50 to 5.31.
Table 4
Summary of the properties of austenitic ductile cast iron available in a narrow range
of CE% ASTM A439 [3].
Grade
CE%
0.2 (MPa)
u (MPa)
Elongation%
HB (MPa)
D2
D2B
D2C
D3
D3A
D4
D5
D5B
D5S
4.44
4.44
4.37
4.33
4.92
4.33
4.31
4.31
3.17
207
207
183
207
207
NA
207
207
207
400
400
400
379
379
414
379
379
449
8
7
20
6
10
NA
20
6
10
13902020
14802120
12101710
13902020
13101930
20202730
13101850
13901930
13101930
shows that as CE% increases the u decreases slightly for all heats.
u for heats of group A is higher than its value for heats of groups
B and C. This is believed to stem from the higher C-content in
the former. The higher u of heats of group B compared to that
of group C refers to the higher Si-content in the former. Again,
the results of the two heats C1 and C2, although shown on the diagram, however, are not comparable with other points since they
revealed pearlite and martensite in their matrices (not austenitic
ductile iron). Additionally, these two specic heats, C1 and C2, had
low Ni-content (less than 13.5%Ni) (cf. Table 2). The decrease in u
is related to the amount of iron carbide (hard phase) and austenite
(soft phase) in the matrices. The u values obtained in the present
study agree with those reported in the literature in the common
range of CE% [15]. However, the present research covered a wider
range of CE% than that reported in the literature.
88
Fig. 7. Effect of variation of %CE ranging from 3.70 to 4.80 on the microstructure of austenitic ductile cast iron etched with 0.5 nital. Group C with different Ni% ranging from
4.99 to 34.70.
Fig. 8. Variation of hardness HV with %CE of austenitic ductile cast iron of all groups
(A, B and C). *This graph implies two alloys of pearliticmartensitic DI of group C.
Fig. 9. Variation of ultimate tensile strength with %CE of austenitic ductile cast iron
of all groups (A, B and C). *This graph implies two alloys of pearliticmartensitic DI
of group C.
89
(1) Successful production of austenitic ductile cast iron covering a wide range of carbon equivalent (3.515.04%). This was
achieved using; carbon, silicon or nickel as alloying elements.
The present results are generally in consistence with those
reported in the literature in the common CE% range. However,
the present research lled the gaps that do exist in the literature.
(2) Successful casting procedure produced austenitic ductile iron
for a heat with only 13.5 mass%Ni. Therefore, a promising
cheaper production cost will be available less than that
presently used (more than 18 mass%Ni).
(3) The microstructure of the produced austenitic ductile cast iron
consisted of graphite nodules embedded in austenitic matrix.
The nodule characteristics were affected by the change of CE%.
(4) Slight decrease in hardness, tensile strength, and 0.2% proof
stress with increasing CE% was observed. On the other hand,
a slight increase in ductility was observed with increasing the
CE%.
References
Fig. 10. Variation of 0.2 proof stress with %CE of austenitic ductile cast iron of all
groups (A, B and C). *This graph implies two alloys of pearliticmartensitic DI of
group C.
Fig. 11. Variation of elongation% with %CE of austenitic ductile cast iron of all groups
(A, B and C). *This graph implies two alloys of pearliticmartensitic DI of group C.
3.3.4. Elongation%
Fig. 11 delineates the effect of CE% on elongation of austenitic
ductile cast iron for all heats produced in the present study. The
elongation of all the heats of groups A and B has the trend of
slight increase with increasing CE%. Elongation of the heats of group
B is generally higher than that of group A; this maybe due to
higher Si-content which prevents the formation of any carbides
and increases the amount of soft phase (austenite). The increase in
Ni-content in the third group C resulted in a slight decrease in
ductility as can be seen in Fig. 11.
4. Conclusions
The goals, of the present investigation, have been successfully
achieved implying:
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