Cast Carbon Steel Research Articles

STUDY OF THE INFLUENCE OF THE Si/Mn CONTENT RATIO ON THE DENDRITIC STRUCTURE OF STEELS FOR RAILWAY AXLES

Purpose. Investigation of the effect of different total concentration and ratio of Si and Mn content on the dendritic structure and segregation inhomogeneity of cast carbon steel and its transformation after hot plastic deformation.
 Methods of research. To determine the effect of the content of Si and Mn, experimental ingots with a variable chemical composition within the grade were made for three steel grades used for the manufacture of railway axles – grade OS according to DSTU 31334, F according to AAR M 101 and EA1N according to EN 13261. To determine the dendritic structure microstructural analysis was used after etching in sodium picrate.
 Results. A comparative analysis of the microstructure of the experimental heats of steels with a variable chemical composition has been carried out. The ratio of content in steel Si and Mn in the cast state and after deformation is established. A significant effect of the total deoxidation in steel on the formation of microhardness inhomogeneity over the cross section of a carbon steel ingot and microinhomogeneity of the structure of individual sections is shown. It was found that after deformation, the central zones turned out to be the most worked out (especially for steel with a chemical composition within the EA1N grade, characterized by an increased content of Mn).
 Scientific novelty. The study of the influence of fluctuations in the content of the basic elements of carbon steel leads to the development of ideas about the formation of a dendritic structure and segregation heterogeneity in railway axle steels.
 Рractical value. Knowledge of the principles of segregation formation is necessary to determine further modes of deformation and heat treatment not only for continuously cast billets or ingots, but also for final products.

Analysis of fatigue characteristics on camshaft using finite element analysis

Camshaft plays an important role in the internal combustion engine, where it regulates the opening and closing time of the valves to allow fuel and air mixture to enter the engine and exhaust. The study aims to analyze the fatigue characteristics of the camshaft made from gray cast iron and cast carbon steel. SolidWorks and ANSYS Workbench were used to design and predict the lifespan of the camshaft. The modelled camshaft was used to analyze the fatigue properties. Modal analysis was performed to evaluate the deflections and natural frequency of the camshaft while static structural analysis used to evaluate the total deformation, maximum stress, and safety factor. Appropriate mesh size was used where the component was divided into several discrete parts or finite elements. The camshaft was assigned with boundary conditions such as fixed support and moment. Dunkerley’s approach was used to compare simulated natural frequencies to theoretical values. The resulting S-N curve plots the alternating stress on the camshaft against the number of cycles required to fail. Cast carbon steel was suggested to be the more desirable material since it can withstand 260 MPa of stress for 10 million cycles, whereas gray cast iron can endure only 140 MPa.

Changes in Microstructure and Abrasion Resistance during Miller Test of Hadfield High-Manganese Cast Steel after the Formation of Vanadium Carbides in Alloy Matrix.

Hadfield cast steel is characterized by high wear resistance, but this is only when it is subjected to the effect of dynamic loads. During unloaded abrasion, e.g., sand abrasion, its wear resistance is very low and comparable to the wear of carbon cast steel. To increase the wear resistance of this alloy for operation under the conditions of low pressure or low stress, primary vanadium carbides were produced by the metallurgical process to obtain a two-phase structure after alloy solidification. Compared to samples made of Hadfield cast steel, the primary, very hard carbides, evenly distributed in an austenitic or austenitic-martensitic matrix, increase (at least three times) the wear resistance of samples tested in an abrasive mixture of silicon carbide and water. The changes in microstructure and hardness obtained in alloys after heat treatment (quenching at 1000–1150 °C in water and tempering at 600 °C) are presented. The bulk hardness of the matrix ranged from 370 HV to 660 HV. After heat treatment, the secondary, dispersed vanadium carbides, precipitated in the alloy matrix.

Influence of thermal cycles of repair electroslag welding on the structure and mechanical properties of joints of cast medium carbon steels

The results of the study of the effect of thermal cycles during multi-pass electroslag welding on mechanical properties of the weld metal and the heat affected zone (HAZ) are presented. It is shown that one of the ways to approximate the mechanical properties of the welded joint to the properties of the base metal without high-temperature heat treatment is to perform electroslag welding not in one but in several passes, when the heat released during each adjacent pass affects the previously welded sections, producing their partial heat treatment, improving the mechanical properties. Analysis of thermal cycles showed that the cooling rate of the metal HAZ of each weld within the temperature range 600...500°C (w6/5) does not exceed critical values for 35L steel type, and also decreases with the welds overlapping, i.e., the danger of martensite formation in this zone is absent. It has been established that the effect of automatic heat treatment of welds results in the structure recrystallization, contributing to grain refinement in the overheating area of the heat transfer zone and weld metal and significant improvement of the mechanical properties. The results of impact bending tests (KCU) of the welded joints showed that the toughness impact in the areas of the weld metal, which have undergone the accompanying heat treatment, exceeds that one of the base metal, as well as the regulatory requirements, by 2...4 times.

COMPLEX OF MATHEMATICAL MODELS AND METHODS TO CALCULATE PRESSURE EFFECT ON SULFIDE DISTRIBUTION IN STEEL

Primary objective is to develop computational method to analyze digital pictures of sulfide prints, helping obtain qualitative image characteristics, and to formulate mathematical model of the distribution of sulphide inclusions to determine specific features of the pressure effect on the macrostructure formation of carbon steel castings flooded into the uncooled mold.
 The research was carried out using images of sulfide prints of templates cut of steel cylindrical castings; L500 steel was applied. The castings result from industrial tests of a method of gas-dynamic effect on the fusion in the foundry forms under the conditions of a casthouse of Dnipropetrovsk aggregate plant PJSC. Digital pictures of sulfide prints, obtained in terms of the increased rate of gas pressure and maximum pressure, were binarized; defective fra gments were removed; and zoning took place. The developed computational method has been applied for fragments of images, representing different zones; data arrays have been received containing sizes and amounts of inclusions in the fragment.
 The developed computational method to analyze digital images of sulfide prints has been implemented. ASImprints software support has helped obtain qualitative characteristics of images; namely, distribution of amount of the certain-size sulfide inclusions. 
 The computational method to analyze digital images of sulfide prints has made it possible to study the set of patterns of sulfide prints. The dependences have been obtained, describing specific features of sulfide inclusion distribution while varying gas-dynamic pressure method in terms of fusion in the casting form. It has been demonstrated that the distribution describes effectively the power-series distribution to compare with the exponential one. Mathematical model of the power-series distribution parameter dependence upon pressure has been developed. Deviation of the distribution parameters in terms of the experimental values and the model values has been evaluated. 
 The research demonstrates the ways to apply an algorithm of simple recursive casting for quantitative analysis of digital images of sulfide prints. Use of ASImprints, being software implementation of the computational method to analyze digital images of sulfide prints making it possible to obtain qualitative characteristics of images, has helped identify that the increased pressure within a casting-device for gas injection system results in the increased specific amount of inclusions and the decreased specific zone of sulfide inclusions respectively. It has been defined that exponential function describes reliably the nature of sulfide inclusion distribution in the digital image of sulfide print. The research has demonstrated that fragments of a sulfide print, belonging to one zone, are statistically homogeneous. Thus, it is possible to analyze quantitively digital image zone of a sulfide print on its fragment. Mathematical model of dependence of sulfide inclusion distribution in carbon-steel castings in terms of gas-dynamic effect on fusion solidifying in a mold has been developed. The model may be applied to predict sulfide inclusion distribution within the selected zones of cross section of the cylindrical castings solidifying in the uncooled mold in terms of the preset mode of gas-dynamic effect.
 Keywords: gas-dynamic effect, pressure, solidification, casting, steel, 35 Л, mold, macrostructure, sulfides, inclusions, template, sulfide print, distribution, polynomial, parameters, prediction, software implementation, ASImprints

Pengembangan Alat Bantu Arbor untuk Pembuatan Roda Gigi pada Mesin Frais Vertikal

The machining process is included in the classification of metal cutting processes, which are used to change the shape of metal or non-metallic product by cutting, peeling or separating. One of the machines used in this cutting process is a vertical type milling machine. This machine functions to make a product, one of which was a gear. The supporting equipment needed to make this gear was a vertical arbor tool. The material used in the manufacture of this product was a cast carbon steel type using the design method for manufacturing and assembly (DFMA), which began by examining and identifying needs, conceptualizing and designing products and making these products tailored to the dimensional specifications of standard and common cutter modules in the market. The results of the manufacture of this tool were directly tested for the manufacture of gears of various sizes and produced products whose deviations were within the tolerance of the measuring instrument, namely in the range 0 to 2%. In addition, the von Mises stress simulation at an engine speed of 150 Rpm, 450 Rpm and 750 Rpm and the resulting maximum stress was still below the yield limit, so it was safe to use.

Comparison on corrosion performance of waste-based multi-hybrid structure high carbon steel and high Cr cast steel

Series of protective layer on high C steel have been successfully developed through transforming various wastes. While high Cr cast steel (HCCS) offers excellent properties of toughness, hardness and corrosion resistance. In this research, the focus on characterisation methods of HCCS were conducted by SEM/EDS, TEM, XRD, Tafel and EIS curves. Results have revealed that modified surface high C steel performed higher corrosion resistance than 16.0–16.5%Cr steel. This finding has opened the new context of using wastes as a source for producing protective layer on the surface of high C steel that integrated profitability of steel products, thus, minimising production cost.

Особливості виробництва високоякісної вуглецевої литої сталі в індукційних тигельних електропечах малої ємності

Особливості виробництва високоякісної вуглецевої литої сталі в індукційних тигельних електропечах малої ємності

Application of “flat’ closed-bottom submerged nuzzles for decreasing rejections of slabs because of longitudinal cracks

In the process of steel continuous casting it was discovered, that due to relatively small distance between a submerged nuzzle and a mold walls, formation of “scull crust” takes place in the area of small and big radius of the billet. It resulted in deterioration of heat-away in mold, conditions are formed for origination of longitudinal cracks following its further opening in the CCM secondary cooling zone. To decrease the number of rejections continuously casted slab billets due to existence of longitudinal cracks, it was proposed to use “flat” closed-bottom submerged nuzzles. It was shown, that in contrast to cylindrical form of a series closed-bottom submerged nuzzle, the proposed one has rectangular section with chamfered butt facet in the are of nuzzle submerging into the mold melt, which enables to ensure better fluidity of slag-forming mixture between the nuzzle and the mold walls. This effect results in onsiderable improving evenness of heat-away. To confirm the effectiveness of the pilot submerged nuzzles application, in 2019 their pilot-industrial tests were accomplished in the campaign of casting of carbon and peritectic steels to produce 200 mm thick slabs at CCM No. 4. In the process of the tests when casting various steels, the same slag-forming mixtures were used. As a result of the tests the decrease of rejections of continuously casted slabs due to longitudinal cracks formation was confirmed.

Varying of horse power and torque in two wheeler’s by using sprockets

The objective of this project is to vary the horse power and torque completely in motor bikes by using sprockets. Normally, sprockets can be manufactured based on the specifications of bike. This Project describes that the two sprockets with different dimensions used to vary the horse power and torque. Normally, the torque and Horse power can be defined as the ratio of output teeth to the input teeth. If the result value is between 2 and 2.5, then the Sprocket is designed for Purely Horse Power and when the result value is greater than 3, then it is surely produce high Torque. Whether the speed may be based on Horse Power or Torque. For Instance, if a 200 cc bike has a necessity to ride in a hills. The bike must be run in second or third gear. During second and third gear the engine needs more torque. A sprocket made for a horse power cannot produce sufficient torque to ride in a hills and fuel consumption is high. To overcome this problem, an input shaft which contains two sprockets of which one is purely for horse power and another one is purely for Torque. And the derailleur is introduced to shift the roller chain. Normally, Sprockets are made up of Cast Iron and Carbon Steels. In this work, instead of Cast Iron Sprocket, it is made up of 4140 Alloy Steel is used for Torque. A virtual model of Sprocket is designed by using CATIA 2018. Model is imported in ANSYS 15.0. The model has been analyzed and results have been recorded.

Structure and Properties of Carbon Steel Cast by the Ablation Process

Ablation casting is a relatively new casting technique which can improve the mechanical properties of castings. In this paper, the microstructure and mechanical properties of plain carbon steel castings produced by conventional casting and ablation casting techniques were compared. It was found that ablation increased the ultimate strength from 638 to 1094 MPa and tensile elongation increased from approximately 13 to 16% as a result of severe microstructural changes from ferrite and pearlite to acicular ferrite, bainite, and martensite. Ablation increased the core hardness of the casting from 182 to 467 HB and the surface hardness from 205 to 508 HB.

Conversion of cast carbon steel into composite material

Experimental estimates of the strength properties of a composite material based on carbon steel 45, created by piercing matrix steel in the mode of superdeep penetration by streams of powder particles, have been performed. Pulsed dynamic action by streams of powder particles and subsequent heat treatment converts steel into a fiber composite material.

Pengaruh temperatur terhadap struktur mikro dan sifat mekanik dalam proses fussion brazing Ni-Hard 4 dengan S45C menggunakan CuZn 35 sebagai logam pengisi.

This research was conducted on white cast iron (Ni-Hard 4) and medium carbon steel (S45C) cast iron materials using a thin brass plate (CuZn 35) 0.3 mm as filler metal by heating at temperatures of 850 to 1050 0 C for 120 minutes with a pressure of 2 Mpa in the muffle furnace. The effect of temperature on the microstructure was observed using an optical microscope and scanning electron microscopy equipped with energy dispersive X-ray system (EDS) to determine the chemical composition that occurred between the three meterial layers. The thickness of the interface layer increases with increasing holding temperature. The highest shear strength (79.86 Mpa) was obtained at a temperature of 950 0 C.

Mechanical properties of a carbide-free bainitic cast steel with dispersed free ferrite

ABSTRACTA high silicon, medium carbon cast steel was designed and heat-treated in order to develop microstructures composed of carbide-free bainite and small amounts of free ferrite, with the aim of obtaining high strength cast steels with improved ductility. Because of microsegregation, it was observed that ferrite present in partially austenitised samples is mostly present at the highly alloyed zones, creating an interconnected network even for low proportions of this phase. Despite the coarse solidification structure and marked microsegregation in the cast steel, the mechanical properties obtained for both fully bainitic and bainitic-ferritic microstructures largely satisfy the minimum standard requirements for high strength cast steels and are similar to those reported for wrought steels of similar microstructures.

Production, Structurization, and Properties of Wear-Resistant ‘Iron–Carbon Alloy–Granular Hardmetal Reinforcement’ Materials

The production, structurization, and resultant properties of metal matrix ‘iron–carbon alloy–granular hardmetal reinforcement’ materials are studied. The vacuum suction method ensures almost complete filling of interparticle voids with molten metals and results in composites containing hardmetal reinforcement with 0.17–0.7 mm particles. The composites show the microstructure that has no pronounced transition zone at the hardmetal–metal interface and has a ‘granular’ austenitic cast iron matrix and a significant amount of lamellar graphite. The mechanical properties and abrasive impact wear resistance of the white cast iron and carbon steel materials are examined. The optimum combination of properties is exhibited by the composite consisting of steel 45 and 60 vol.% KKhNF15 hardmetal.

Influence of Impeller Diameter on the Performance of Centrifugal pumps.

The impeller is the most important part of the centrifugal pump because it determines the flow or efficiency of the pump. The design of the impeller and its diameter are very essential when considering pump efficiency. The capacity of the pump is determined from the impeller vanes and channels. The three types of impellers include open impeller, enclosed impeller and semi-open impeller are each designed for a specific application. Impellers are made of cast iron or carbon steel and special alloys depending on their application. The research involves the study of the application of impellers in the centrifugal pumps used by Rand Water Company in Johannesburg. The paper considers how variations in the impeller diameter affect the performance of the centrifugal pump. Simulations were conducted at different diameters of the impeller. The impeller was modelled using AutoCAD and simulated using ANSYS software to determine the performance of the centrifugal pump on different diameters. Calculations were done to compare the results of simulation of the different diameters of 2000mm, 2200mm, and 2400mm. The results show that changing the diameter of a pump impeller affects the flow, head and input brake horsepower of the pump in different proportions. The centrifugal pump gives a high flow rate as the diameter of the impeller increases.

Properties and fracture splitting of cast steel matrix composites

To break through current limitations of fracture splitting materials for connecting rods, a bimetallic compound as a fracture splitting material was studied. The bimetallic sample was produced by investment casting, and interface performance tests and splitting tests were conducted. At a casting temperature of 1600 °C for 0.25 wt. % C cast carbon steel, the preheating temperature of T10A was 500 °C, and the thickness of T10A was in the range of 2–3 mm. The 0.25 wt. % C cast carbon steel and T10A were fully combined in the interface. The appearance of the fracture zone was a flat cleavage fracture, which would facilitate meshing of the cracked surface if the specimen were assembled and improve the quality of fracture splitting.

Effect of Shot Peening Time on fatigue and corrosion fatigue life for A27 cast carbon Steel

A 27 cast carbon steel, which was used in induced draft fan blades of Nasiriyah thermal electricity station was chose to actualize the aim of this paper by studying the effect of shot peening time on dry and corrosion fatigue life. .Many specimens from the metal choice for tensile and fatigue tests were equipped according to ASTM (E8/E8M-09) some of preparing specimens were subjected to shot peening by steel ball in diameter 2.25 mm for different time (10, 20, 30) minute. Hardness, residual stress, surface roughness , dry fatigue and corrosion fatigue were tested. The result showed an improvement in the tensile strength for shot peening comparing with the base metal. The tensile strength of the shot peening metal at 20 minute was higher than the tensile strength of the shot peening at 10,30 minute. Also shot peening contributed in improvement fatigue life but the best time was 20 minute and this improvement witness decay in fatigue life by corrosion fatigue test due the effect of environment in addition of cyclic loads.

Development of the organization of rational schemes for the use of technogenic waste in the processes of off-treatment of steel intermediate

The results of the experimental verification of the efficiency of complex out-of-furnace treatment of low carbon steel using a test mixture based on man-made waste, which is fed partly to the melting unit at the end of the oxidation period of melting and partly by pouring under a stream of liquid metal. is the use of slag-forming materials obtained by joint heat treatment of mixtures of components containing the above mentioned oxides and carbonaceous material of vegetable origin. Their weight ratio in the initial mixture is determined by the purpose and properties of the finished product. The positive technological effects that are achieved by applying the developed method of after-treatment will in future provide favorable conditions for the effective conduct of microalloying, modification, vacuuming and stable casting of low-quality and ultra-low carbon steel. A slight decrease in the temperature of the steel intermediate in the implementation of the method is about 10 - 15 ° C, which is easily compensated for the installation of the ladle, and a slight increase in electricity consumption is compensated by the effects achieved in the processing of low-carbon steel intermediate. Obtaining a higher degree of desulfurization and deoxidation of steel, as well as reducing the contamination of Al2O3 steel and improving the ecological purity of the process can be achieved by reducing the composition of the SHS used in the first stage of processing, the amount of slag aluminothermal production of ferromanganese and complete exclusion of melting, melting weight ratios of powdered waste production of lime, aluminum-thermal slag production of ferromanganese, sludge neutralization of electrocorundum and carbide cr emnia.

Design and Topology Optimization of 3D-Printed Wax Patterns for Rapid Investment Casting

Abstract Traditional investment casting (IC), also known as lost-wax casting, suffers from high tooling cost and long lead-time during fabrication of wax patterns. In recent years, rapid investment casting (RIC) based on AM has become widely accepted in casting foundries due to rapid production of patterns without any tooling requirements. Direct AM production of wax patterns is not only cost-efficient for low volume production but also capable of creating freeform and highly complex geometries that are otherwise extremely difficult or too expensive to cast conventionally. Such advantages provide unlimited opportunities in the cast part design and enable the use of advanced design tools especially advanced optimization tools like topology optimization (TO). In this study, knowledge-based design guidelines for rapid investment casting are developed through streamlined integration of TO with design for investment casting and design for AM principles. Specifically, TO routine based on Solid Isotropic Material with Penalization (SIMP) method using Abaqus Topology Optimization Module (ATOM) has been developed for both material extrusion and investment casting constraints. Part design optimization is demonstrated for this new technique and is validated by a case study using heat-treated ASTM A216 WCB cast carbon steel parts. AM patterns for investment casting are produced using commercially available wax filaments. Wax material extrusion parameters are identified for optimal AM accuracy and surface finish.