Cast Carbon Steel Research Articles

Development of geometry-driven quantitative prediction for shrinkage porosity in T-junction of steel sand castings

Shrinkage porosity poses a significant challenge in metal casting processes, impacting both productivity and energy efficiency, especially when dealing with components that are not accepted or reprocessed. Addressing this issue requires proactive measures, and predictive techniques play a crucial role in minimizing its occurrence. Among these methods, the Criterion Function stands out as a valuable empirical model extensively explored in the literature. By intricately linking solidification processes to the development of shrinkage porosity, the Criterion Function leverages key process parameters, including thermal gradient, molten metal velocity during solidification, and cooling rate, to offer predictive insights into the location and presence of porosity. However, a criterion function is needed that also considers the effect of geometric variations as well as the size of the defect (shrinkage porosity). In this study, a casting with three T-joints was taken as a benchmark shape to develop a geometry-based quantitative prediction model for plain carbon steel castings. Real experimental results were combined with solidification simulation results to produce reliable data, which were then used to extrapolate the results. The developed quantitative prediction model, which includes the effect of geometric changes, has been validated and proven effective in predicting shrinkage porosity.

Analysis of Fragmentation Phenomenon of Composite Layers of Fe-TiC Type Obtained “in situ” in Steel Casting

A method for fabrication of a composite layer on the surface of a steel casting using coating containing TiC substrates was presented. The reaction of the synthesis of the ceramic phase was based on the SHS method (Self-propagating High-temperature Synthesis) and was triggered by the heat of molten steel. High hardness titanium carbide ceramic phases were obtained, which strengthened the base material improving its performance properties presented in this article. Microstructural examinations carried out by light microscopy (LM) on the in-situ produced composite layers showed that the layers were the products of reaction of the TiC synthesis – the phenomenon called “fragmentation” by the authors of study. The examinations carried out by scanning electron microscopy (SEM) have revealed the presence of spheroidal precipitated and free of impurities. The presence of titanium carbide was twofold increase in hardness in the area of the composite layer as compared to the base alloy which was carbon cast steel.

Comparative Analysis of Piston Rings Made with Aluminum Titanium Carbide (AlTiC-75-2) and Carbon Cast Steel (AISI 1540) Materials Using Numerical Method

Aim: The main purpose of this study is to perform a comparative analysis of piston rings made with aluminum titanium carbide (AlTiC-75-2) and carbon cast steel (AISI 1540) materials using numerical method. Study Design: Numerical methods. Materials and Methods: The 3D piston rings were modelled with SOLIDWORDS version 2019 and imported to ANSYS 2020 RI environment for simulation and analysis. Results: The study revealed that AISI 1540 and AlTiC-75-2 had maximum deformations of 1.0356 mm and 1.0773 mm, respectively. Also, when the equivalent elastic strains of the piston rings were compared, it was revealed that, the maximum and minimum elastic strain of the AlTiC-75-2 piston was 4.8826e-3 and 2.2581e-5, respectively, whiles the maximum and minimum elastic strain of AISI 1540 was 2.1878e-5 and 2.1878e-5 respectively. Numerical results further showed that AISI 1540 piston suffered the least elastic strain while the AlTiC piston ring endured more elastic strain. Furthermore, results showed that the maximum Von Mises stresses induced in AlTiC-75-2 and AISI 1540 piston rings were 915.2 MPa and 911.27 MPa, respectively, which implies that stresses induced in both rings were beneath the compressive yield strengths of the individual materials, therefore both rings could withstand the load imposed. Conclusion: Result shows that the AISI 1540 ring has high minimum value than AlTiC which makes it more suitable material in terms of failure as against AlTiC-75-2 with a low minimum safety factor of 0.094187 as against 0.10182 for carbon cast steel. The study therefore recommends that AlTiC-75-2 should be considered as one of the most suitable materials for piston ring design.

Cause of bending fracture in high-strength fasteners and heredity of surface recarburization in high carbon steel

In this work, the cause of bending fracture in high-strength fasteners after electroplating was investigated and the heredity of surface recarburization from continuously cast high carbon steel blooms to the final fastener products was explored. The fracture surface of the fasteners displayed intergranular cracking and numerous intergranular facets accompanied by ductile tearing. Hydrogen-induced stepwise cracks were identified near fracture zones, indicative of hydrogen embrittlement. The surface decarburized layer on the fasteners featured a significant number of fine partial decarburization grains and a high carbon content, resulting in low electrical conductivity. The observed dense coating, possibly induced by the poor conductivity of the decarburized layer, could elevate the hydrogen content in the substrate, ultimately resulting in hydrogen embrittlement. Additionally, the surface carbon pick-up at the corners of the blooms could be inherited by the rolled billet. The extensive deformation experienced during the hot rolling process resulted in the uniform distribution of recarburization on the surface of both the wire rod and spheroidized wire rod. Consequently, this recarburization contributed to a low degree of decarburization on the surface of the fasteners. Simulation results obtained through DICTRA also indicated that the recarburization on the surfaces of various samples could not be eliminated during the heat treatment process.

Finite Element Analysis of a Robotic Arm for Electronic Devices Transportation: Design and Simulation

Automation of various routine operations using the robotics arm in industrial automation is crucial for bridging innovative systems and production procedures, thereby speeding up the manufacturing process by reducing overall cycle times. In this work, Finite Element Method (FEM) is used to simulate a robotic arm for handling electronic printers to foster their transportation. The analysis considers different loads and materials which include AISI 304, cast carbon steel, aluminium alloy 1060, malleable cast iron and AISI 1020. The effects of discrete particulate mechanical properties, concerning material, load zone and design configuration parameters were revealed. The remarkable result of these simulations shows displacement, tensile and compressive strain distribution values as a conclusion of the better capacity for anticipated lightweight operation using aluminium alloy 1060 robotic arm transporting device. In addition, the current simulations give a profound picture of how materials are selected to maximize the operational process.

Reliability Prediction of Wrought Carbon Steel Castings under Fatigue Loading Using Coupled Mold Optimization and Finite Element Simulation

Reliability Prediction of Wrought Carbon Steel Castings under Fatigue Loading Using Coupled Mold Optimization and Finite Element Simulation

Numerical Investigation of the Thermal Effect of Material Variations on the Brake Disc

Braking is one of the most critical systems for ensuring the safe driving performance of motor vehicles. Among the components that constitute the braking system, the disc is the one with the highest risk of wear. When the braking system is engaged, the physical contact between the brake pad and the disc leads to the generation of high pressure and high temperature. This released heat shortens the material's lifespan. The wearing or fracturing of the brake disc can result in a significant safety vulnerability. Therefore, it is desired for the discs to have better heat dissipation to increase their longevity. In this study, two different designs of brake discs were first examined thermally using the computational fluid dynamics (CFD) method. Subsequently, numerical analyses were conducted under the same boundary conditions by selecting the disc geometry with superior heat dissipation performance and using different materials. The results obtained from the analyses were compared and interpreted. The materials utilized in the study were grey cast iron, carbon steel, stainless steel, and carbon-carbon composite. As a result, it was observed that the carbon-carbon composite exhibited higher resistance to elevated temperatures.

Numerical and Experimental Study on Carbon Segregation in Shaped Billet of Medium Carbon Steel with Combined Electromagnetic Stirring

Carbon segregation is the major and classical internal defect in the continuous casting process of carbon steel. Based on the combined electromagnetic stirring equipment for new billet in a steel plant, China, the influence of combined electromagnetic stirring (M-EMS + F-EMS) on the carbon segregation of 300 mm × 340 mm special-shaped billet was studied via numerical simulation and on-site industrialization tests. The Lorentz force and carbon solute distribution were simulated under different EMS parameters. The formation mechanism of the carbon segregation of medium carbon steel with different combined electromagnetic stirring processes was analyzed. The results show that: (1) with the combined action of “solute flushing” effect and gravity, the carbon concentration in the loose side of the medium carbon steel casting billet is gradually lower than the fixed side, while the carbon concentration on the fixed side gradually accumulates more; and (2) under the action of combined electromagnetic stirring, the segregation index of casting billet could be controlled to remain between 0.96–1.05 and shows an increasing change in solidification from the skin to the center. When the current and frequency of M-EMS are 250 A and 2.0 Hz and the F-EMS are 180 A and 8.0 Hz, the carbon segregation defects in the special-shaped (300 mm × 340 mm) casting billet can be significantly improved.

The technology of arc welding of dissimilar steels

Arc narrow gap welding of the 35L carbon cast steel (cast carbon steel J03502, grade 1) and the 110G13L high-manganese steel (austenitic manganese steel, ASTM A128) is performed using chromium-nickel-manganese wires in a shielding gas mixture (GOST R ISO 14175–2010 – M21). The welded samples are examined by different methods including optical metallography, hardness measurement, and mechanical tests. The weld metal structure along the weld height in the welded samples proves to be fairly uniform, namely austenite with ferrite inclusions. The experiment results show that the mechanical properties of the weld metal correspond to the intermediate values for the joined steels. The developed technology has made it possible to produce a welded joint with high mechanical properties and a ductile structure.

Liquefaction Controlling Components and Their Effect on Carbon-Free Mold Powders

In the continuous casting of ultra-low carbon steels, recarburization from the mold powder negatively affects steel quality. Therefore, to develop mold powders without free carbon, different carbides or nitrides have been proposed and evaluated in laboratory and field studies. Among these, SiC and Si3N4 were selected for the present study. Additionally, thermodynamic calculations were performed to quantitatively describe their effect on the melting behavior of the mold powder. To verify the results under high heating rates, mixtures of raw material components were placed in a steel crucible with a lid, inserted into a furnace preheated to different temperatures, and investigated mineralogically. The results agreed with those of the thermodynamic calculations. Moreover, the results suggested that Si3N4 and SiC were suitable raw material components and alternatives to carbon in the mold powder. They prevented solid–solid reactions between raw material components to form new phases and were still found at the temperature of 1200 °C. Consequently, the CaO/SiO2 ratio was higher before oxidation and affected the liquid-phase formation. The addition of antioxidants reduced the liquefaction-controlling effect of SiC. Additionally, the study shows that the sample preparation impacts the phase formation: granules facilitate phase formation due to a higher contact of reactants, further they show earlier melting close to their surface as sodium content is increased there by the spray drying procedure.

Finite Element Analysis of Spur Gear

Abstract: Gear drive is crucial in control transmission businesses, as they are subjected to fluctuating loads, creating bowing and compressive stresses. Analyzing these stresses is crucial for safety operation and weight reduction. Gears are analyzed using AUTO CAD and ANSYS for inactive and modular examinations, considering materials like cast iron, carbon steel, brass, and copper

Estimation of the segregation in a high carbon cast steel by thermoelectric power means

This research study proposes the hot-cold tip thermoelectric power (TEP) method to estimate alloying elements segregation and the microstructure variation of high carbon steel cast in a mold. Optical Emission Spectrometry (OES) showed a higher concentration of carbon, nickel, chromium and aluminum at the ingot center. That elemental saturation produced an increase in perlite content as well as hardness. The non-destructive technique of thermoelectric power was applied varying the hot tip temperature (40 oC, 50 oC, 60 oC, 70 oC), where higher temperature values showed to be more sensitive to segregation and microstructural changes. The statistical analysis showed that the thermoelectric power technique is more sensitive to detect the nickel and chromium concentration changes.

Estimation of the Segregation in a High Carbon Cast Steel by Thermoelectric Power Means

Estimation of the Segregation in a High Carbon Cast Steel by Thermoelectric Power Means

A CASE STUDY ON THERMAL ANALYSIS OF THE DISC BRAKE USED FOR HEAVY-DUTY CARS

The brake system converts kinetic energy into thermal energy, resulting in a rise in the temperatures of the disc brake due to the friction caused by the pressure brake between the turntable and the brake pads. This study aimed to investigate the thermal analysis of the disc brake used for heavy-duty cars. The study focuses on designing the ventilated brake disc for a particular Mitsubishi Pajero car through modeling software and observing the performances of two materials such as grey cast iron and cast carbon steel. Holes were also included on the surface of the rotor to speed up heat dissipation during and after braking. By utilising SimulationXpress and ANSYS Workbench, stress and thermal behaviour were analysed to choose a material that would perform better and reduce the damage brought on by high temperatures. It was observed that cast carbon steel with 30 vanes showed better performance for stress analysis. The transient thermal analysis for solid and drill disc brakes using cast carbon steel showed that the disc brake with holes performs better, even reducing vanes from 36 to 30. The study proves that a drilled disc with 30 vanes and made of cast carbon steel is the better choice for performance and heat dissipation.

Stress and deflection analysis of trench back-filling dozer blades using FEM

The objective of this paper is to improve the dozer's sharp edges in soil refilling applications based on limited component technique. The re-enactment strategy is achieved by involving computer-aided design programming for the pressure and redirection examination. The different terminology of dozer edges is mathematically obliged with the readiness of the model and the execution is successfully achieved from the real-time experimental conditions with given boundary conditions. The energy obliged for the dozer cutting edge applications with 35Hp power inlaying machine and assessed powers acting at the soil-instrument interface. The proposed work brings about recognizing adequate resilience in changing the elements of dozer edge segments and improving the overabundance of machine weight in a strong area. Furthermore, to raise the heaviness of the sharp edge for a solid strength different material such as EN24, Grey Cast Iron, Carbon Steel, and NIMONIC 80a were considered in this research. Based on the outcomes a recommendation is suggested as a suitable material.

ПРОЕКТИРОВАНИЕ УСТАНОВКИ ПО ПЕРЕРАБОТКЕ МЕДИЦИНСКИХ ОТХОДОВ ТЕРМОХИМИЧЕСКИМ МЕТОДОМ

The article deals with issues related to the development of the design of a medical waste processing machine based on the thermochemical method, special attention is paid to the cutting equipment used in the machine. The problem statement is formulated as follows: to design a machine that allows realizing the possibility of processing medical waste by the thermochemical method; offer design options for the cutting equipment of the machine and justify the choice of knife material based on finite element modeling. The design of the machine is proposed, consisting of a base on which an electric motor is located, the movement from which is transmitted by means of a V-belt transmission to the tooling drive. Processing and disinfection of medical waste is carried out in a sterilization chamber. The sterilization chamber and the tank associated with it are structurally the most complex. The main structural elements of the tank are the base, the sterilization container and the lid. Direct processing of medical waste is carried out by rotating the rotary assembly with tooling. In the proposed machine tooling includes four movable horizontal and two vertical knives. During the processing of medical waste, the working surfaces of horizontal knives are exposed to a number of factors that lead to their intensive wear. The article offers several designs of knives to increase their durability. In order to check the correctness of the choice of material and the influence of operating conditions, a FE model was developed for the process of heating a knife under the action of a friction force caused by polyethylene chips descending along the front surface. Calculations were made for two knife materials: carbon steel and gray cast iron. The simulation results showed that, according to a number of criteria, gray cast iron is the most preferred knife material. The use of cast iron will ensure the rapid achievement of the required temperature in the sterilization chamber, and lower internal stresses will reduce the likelihood of knife breakage. To improve the reliability of the machine, design options for movable knives that are subject to the most intense wear are given.

ALAT BANTU UNTUK PEMBUATAN ULIR LUAR DAN ULIR DALAM

The machining process is the process in which different products are made especially from metal and it is often used in both small and large industries. One of the products of the machining process is threaded products and there is an ongoing increase in the use of these products because of their ease of maintenance and assembly to a complete product. The manufacturing of these products can be done by several methods e.g., by using machine tools or hand taps. In line with that, to manufacture these products in large volumes and to achieve high production speeds, special supporting tools are required. The design of the supporting tools is evolving continuously because a single tool cannot fulfill the entire manufacturing process. To design and manufacture supporting tools, apart from the design, the safety and comfort aspects of work are also taken into account. The methodology for the manufacturing of this product is to use the design for manufacturing and assembly (DFMA) method, which starts with reviewing and identifying needs, designing and making these tools that are adapted to the standard tap/one dimension specifications and the type of material used is cast carbon steel. Based on the study of von misses for 32 N, 64 N, and 94 N loads, the results were 1.807 e+05, 3.614e+05 N/m2, 5.646e+03 N/m2, and this value is still below the stress value. The yield is 2.48168e+008 N/m2, therefore the type of material used is very safe for the manufacture of this product.

Microstructure Refinement by Austenizing and Tempering in Low Alloy Carbon Steel Casting

Requirements for high service life and mechanical strength of components undergoing cyclic deformation and abrasive resistant, identification of quantitative relationships between material properties and its microstructure very important. In the previous study, Hardness and toughness properties are usually obtained by combining quenching and tempering. The other studies, to increase the hardness by adding Cr on the material. The application of heat treatment in austenizing can provide a microstructure change with refining carbides. In this study, 2.085Cr 2.418Ni low carbon steel casting were heat treated with a reheated in various temperature without quenching. The changes in the microstructure in the last step after passing through the temperature experienced respectively 750 ° C, 650 ° C and 350 ° C were very significant. The phase that appears is tempered martensit surrounding refinement fine tempered martensite and decreasing hardness from 496 HvN to 257 HvN.

Quenching of EN-8 Medium Carbon Steel in Salt Bath of Different Concentrations

Heat treatment of metals and alloys is an important operation in the final fabrication of several engineering parts. Heat treatment and microstructure studies have always been a wide area of research for mechanical and metallurgical engineers. The application of different quenchants for cooling process has further has widened the scope of quenching. This experimental work is concentrated on the microstructure of EN-8 medium carbon steel cast samples when heat treated at different temperatures and quenched in different types of quenchants. The properties of this steel got affected due to sudden quenching. The microstructure of the steel was analysed and it was subjected to Rockwell hardness tests. Increase in hardness value of the samples was determined. The change in microstructure was studied.

A Study on a Cast Steel Reinforced with WC-Metal Matrix Composite.

This study seeks to investigate the local reinforcement of low carbon cast steel specimens with WC–metal matrix composites (WC–MMCs), to obtain a new material effective in competing with hard alloy steels. For this purpose, a powder compact of tungsten carbide (WC) and iron (Fe) was prepared and placed in the mold cavity before casting. The reactions that occurred with the molten steel led to the formation of the WC–MMC and, consequently, to the local reinforcement of the steel. The microstructure of the WC–MMC reinforcement was characterized by scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS), X-ray diffraction (XRD), and electron backscatter diffraction (EBSD). The results showed a microstructural variation throughout the depth of the reinforcement. In the surface region, most of the original WC particles retain their polygonal morphology, but towards the base metal, the dissolution of the WC particles increased with the formation of (Fe,W)6C carbides. Closer to the base metal, dendritic eutectic carbides of (Fe,W)6C and fine (Fe,W)23C6 precipitates in a matrix of martensite were formed. The mechanical properties of the reinforcement were evaluated by hardness and ball-cratering abrasion tests. The results revealed a significant increase in hardness, being three times harder than the base metal, and a decrease of 39% in the wear rate.