Effect of chromium-to-carbon ratio and carbide volume fraction on the three-body abrasion wear and corrosion behaviour of high chromium white cast iron

Simulation study on heat transfer behavior of blast furnace cast iron cooling stave after damage

This article presents a dataset generated from a cylindrical plunge grinding process conducted in an industrial piston ring manufacturing environment. The data aim to support studies focused on process capability, variability, robustness, parameter optimization, and modelling approaches in grinding research. The experimental conditions were defined following a Central Composite Design for k = 4 factors and axial distance ρ=1.5, which established the levels of Wheel infeed rate, Dressing speed, Grinding wheel peripheral speed, and Dressing depth. These parameter combinations were carried out on the shop floor under real production constraints, ensuring that the collected measurements represent industrial operating conditions rather than laboratory simulations. Two external noise factors were considered during data collection, consisting of the different mandrels and the position of the piston ring within the production package. These noise sources reflect variations commonly encountered in manufacturing and allow researchers to investigate the robustness and sensitivity of dimensional responses. A CCD with thirty runs, being sixteen factorial points, eight axial points, and six center points, organized in two blocks of experiments, was performed, associated with four noise combinations, defined according to an experimental plan. For every condition, ten repeated measurements, represented by ten piston rings sampled from the package and assembled in different mandrels, were acquired using the dimensional control fixture routinely employed in the industry, forming a dataset of 1200 runs. This procedure ensured consistency with existing quality inspection practices and provided a rich structure suitable for repeatability and uncertainty analyses. The dataset includes raw measurements, process parameters, and experimental identifiers that enable multilevel exploration of machining performance. Its structure supports diverse analytical applications, including modelling of process capability, variability, evaluation of noise effects, optimization of input parameters, statistical analysis of repeated measures, and the development or validation of data-driven and machine learning methods. Owing to its industrial origin, the dataset offers realistic variability patterns and is relevant for comparative studies, benchmarking activities, and the development of predictive or robust design frameworks in manufacturing research.

An investigation into the uncertainties in the crack resistance curves of nodular cast iron

Numerous methods have been suggested to quantify fatigue-initiating defect size on fracture surfaces, the most prevalent are based on the Murakami-Endo a r e a -parameter. However, there is an ambiguity in how to systemically determine defect areas. For instance, in literature on high-cycle fatigue of ductile cast irons the several different methods have been suggested: i) the traced contour, ii) the convex hull, iii) the minimum circumscribed circle, and iv) the minimum bounding rectangle. This work focuses on comparing and evaluating these methods by assessing the fatigue-initiating defect area distributions, and the influence on fatigue assessment using the a r e a -parameter. To this end, very high cycle fatigue data on ductile cast irons with different microstructures is used, where complex shaped defects are the root-cause for fatigue failures. It is shown that there is a significant difference in the area distributions, originating from the applied area measurement method. In addition, to enable and include fatigue assessment of high strength ausferritic ductile irons, two improved Murakami-Endo type models are proposed, which show satisfactory prediction capabilities over a wide range of ductile cast iron microstructures. To further evaluate the different area measurement methods, the suggested models are validated against ductile cast iron high-cycle fatigue data from literature having artificial defects and notches. Finally, it is concluded that the traced contour defect measurement method yields the best agreement between artificial and natural defects, and overall, the least prediction errors. • Several defect area measurement methods compared. • Extended fatigue strength prediction models for ductile cast iron. • Evaluation of influence on area distributions and fatigue assessment.

Field evidence for the impact of aged cast iron pipes on emerging DBPs in drinking water distribution systems.

Navigating the narrow processing window: Toward stable and high-quality direct chill casting of large-size Al Alloys via integrated simulation, machine learning, and experiment

Under conditions of depletion of natural resources and increasing volumes of techno-genic waste from metallurgical and alumina production, the development of technologies for the integrated processing of sludges with the extraction of valuable components becomes highly relevant. This study proposes a method for the combined processing of red mud and dump sludge to obtain pig iron, a rare earth element concentrate, and titanium dioxide. The reduction smelting of a briquetted charge composed of sludge mixtures was carried out in a muffle furnace at 1350–1400 °C with the addition of a reducing agent. Magnetic separation of cast iron slag made it possible to reduce the iron content in the non-magnetic fraction and increase the concentration of REEs. As a result of nitric acid leaching of the non-magnetic slag fraction, followed by neutralization and calcination of the titanium-containing precipitate, a rare earth element concentrate and titanium dioxide containing 96.5% TiO2 were obtained. The developed method ensures the utilization of technogenic raw materials and contributes to the creation of an additional resource base for the production of strategically important materials.

Industrial textile wastewater containing synthetic dyes cause serious environmental and health risk, whereas ductile cast iron (DCI) foundries generate over 500 000 tons of waste annually. This study utilizes DCI solid waste as an adsorbent to remove the crystal violet (CV) dye from wastewater. Techniques (XRF, XRD, BET, SEM-EDX, FTIR, TGA-DTG, zeta potential) proved that the waste contains 88.0 wt% periclase (MgO) with nanoscale, high surface area, and abundant surface hydroxyl groups. Response surface methodology showed that the most significant parameters were the adsorbent dose and time contact. The optimal conditions give 93.7% removal efficiency at initial concentration: 38.7 mg L-1, adsorbent dose: 6.2 g L-1, shaking rate: 150 rpm, and contact time: 30 min. The isotherm model was the Freundlich model suggesting surface heterogeneity with dispersed binding energies; multilayer coverage supports this, but the Freundlich fit by itself cannot establish it. The maximum physisorption capacity was 116.85 mg g-1, and the mean free energy, E = 3.34 kJ mol-1. Kinetic study demonstrated that the reaction follows pseudo-first-order kinetics (k 1 = 0.1654 min-1) and showed three diffusion phases: the external film diffusion (0-30 min), the intraparticle diffusion (30-120 min), and the equilibration phase (>120 min). The thermodynamic investigation showed that the adsorption is an endothermic process (ΔH° = +22.15 kJ mol-1), accompanied by a positive entropy change (ΔS° = +85.3 J mol-1 K-1) and a negative Gibbs free energy change (ΔG° = -2.94 to -5.68 kJ mol-1), which means spontaneous, entropy-driven physisorption. Post-adsorption XRD showed that MgO was hydroxylated to Mg(OH)2. The pH optimization revealed maximum removal at pH 7-9. The regeneration technique employing acid and thermal methods yielded a desorption efficiency rate of 95.4%, a cumulative adsorption capacity recovery rate of 78.5% following 15 cycles, and magnesium release lower than all permissible standards (USEPA, WHO, Egyptian Law 4/1994). The initial techno-economic analysis yields a unit treatment cost of approximately $1.09 m-3 for a hypothetical 1000 m3 d-1 plant; nevertheless, further confirmation based on scale up and continuous flow operation is essential prior to actual commercialization. This study proves that DCI solid waste is not only economically feasible but also environmentally adsorbent in the context of a circular economy.

Abstract This study investigates iron use and production at the Zhuoerkut site, an important frontier city associated with the Western Regions Protectorate of the Han dynasty in southern Xinjiang. Metallographic and compositional analyses were conducted on iron artifacts and slags excavated from the site. Most of the analyzed iron artifacts display characteristics of white cast iron, while one sample shows the feature of incompletely annealed malleable cast iron. Chemical analysis of this sample reveals unusually high phosphorus and sulphur contents, which may indicate the use of mineral fuel during smelting, a practice documented in Xinjiang but uncommon in inland Han China. The slag assemblage suggests the presence of multiple metallurgical activities. Some slags are consistent with smithing residues, while others are broadly compatible with bloomery smelting. Overall, the evidence indicates a technologically diverse iron assemblage shaped by regional supply networks, local production practices and frontier environmental conditions.

Fabrication and characterization of ZTA/high-chromium cast iron composites via Al–Fe3O4 self-exothermic powder-assisted infiltration

Anti-corrosive structural integrity and morphology of DLC/AlCrN coated grey cast iron under high temperature

• Pore–notch competition quantified using energy-based stressed volume and strain energy. • Pearlitic and high-silicon ferritic irons show fatigue reversal with notch severity. • Computed tomography and extreme-value statistics inform defect-sensitive fatigue. • High-silicon ferritic iron shows greater pore tolerance in blunt, large stressed volumes. • Simplified strain-energy method enables fatigue design without tomography or FE. Heavy-section castings of ductile cast iron (DCI) unavoidably contain micro shrinkage porosity due to non-uniform, slow cooling, and service components also feature geometric stress raisers. This study quantifies how these two realities—intrinsic defects and notches—jointly control fatigue resistance and formalizes a design approach that accounts for their interaction. We compare a pearlitic EN-GJS-600–3 (GJS-600–3) and a high-silicon solid solution strengthened ferritic (HSi) DCI, which exhibit different matrix ductility and distinct pore populations. Pore size distributions are characterized (via X-ray computed tomography, CT), and extreme-value statistics are used to estimate the most critical defect expected in the highly stressed region of notched specimens. This defect measure is then coupled to a strain energy density (SED) criterion to predict fatigue limits. Fatigue tests on plain and V-notched specimens with varying notch severity reveal a systematic transition from pore-dominated initiation (plain and mildly notched) to notch-dominated initiation (severe notches). The proposed CT–statistics–SED framework reproduces both the fatigue limits and the observed switch in the governing initiation site. Compared with GJS-600–3, the HSi grade shows lower intrinsic fatigue strength but greater tolerance to distributed microporosity, leading to improved reliability in geometries with large highly stressed volumes. The approach provides a practical route to defect-aware fatigue design of DCI components, suggesting material-and-geometry selection: pearlitic grades for smaller, sharper features where notch control prevails; high-silicon ferritic grades for large, blunt features where defect tolerance is paramount. Overall, the method supports lighter, more reliable cast designs without resorting to overly conservative safety factors.

Experimental and numerical characterization of Johnson–Cook plasticity and damage models for spheroidal graphite cast irons at high strain rates and elevated temperatures

Fatigue and leakage behaviour of corroded cast iron pipes.

The present study plays a crucial role in enhancing the safety and perceived quality of life for users of bone-anchored prostheses. It focuses on developing an innovative protective component using various metallic materials to identify and mitigate potential risks during use, thereby reducing the likelihood of sudden fracture and maintaining the system’s structural integrity. The protective element is manufactured from Ti6Al4V alloy, while the safety pin is made from ductile cast iron. This combination allows controlled fracture of the protective element without complete separation of the prosthesis, thereby reducing the risk of falls. To optimise the numerical analysis, a 3D model of the prosthesis and its protective component was created using SolidWorks software. Loading conditions were simulated to reflect two critical phases of the gait cycle: heel strike and toe-off. The analysis revealed that the highest stress occurred during the toe-off phase, reaching 248 MPa, with a safety factor of 1.6, demonstrating the design’s ability to prevent sudden failure. Tensile testing showed that ductile cast iron is a suitable material for the safety component. Although Ti6Al4V alloy surpasses it in tensile strength, ductile cast iron’s lower strength ensures a controlled and less catastrophic failure under excessive loading. Numerical results confirmed a high safety factor for the protective system, indicating improved reliability and mechanical load resistance. This study presents a novel approach aimed at improving the safety of bone-anchored prostheses by minimising injury risks due to mechanical overload, ultimately enhancing user comfort and confidence.

One method for assessing alloy properties is to analyze its microstructure image. Many factors influence the microstructure of alloys, particularly the content of alloying elements and the type of heat treatment. Depending on the alloy type, various alloying elements are used. In assessing the microstructure image, it is crucial to define the elements present. The quantity, shape, and arrangement of microstructural elements indicate the final parameters of the products. In the case of unalloyed cast iron, including vermicular cast iron, the basic matrix components are ferrite and pearlite. Currently, the analysis and assessment of microstructure phases is mostly performed manually. Microstructure assessment requires knowledge and experience in analysis, and its results have a significant impact on the production process control and decision-making, which will consequently allow for avoiding defects during the next process cycle. The lack of clearly defined rules makes the use of classical analysis methods ineffective. The aim of this work is to use machine learning methods to create an algorithm for predicting matrix phases such as pearlite, ferrite, and graphite in microstructure images of vermicular cast iron. This solution would accelerate and automate the process of metal melt inspection.

Abstract In power cable ducts, complex environmental conditions can accelerate the insulation aging of power cables, potentially triggering serious accidents. Thus, there is an urgent demand for real-time monitoring of the internal state of power cable ducts. To address the failure of traditional wireless communication caused by shielding from metal manhole covers and the ground in power cable duct monitoring, this paper systematically investigates a through-the-earth data transmission method using a rotating permanent magnet mechanical antenna. A finite element model incorporating the well shaft, manhole covers, and soil medium was established to analyze the propagation mechanisms of electromagnetic waves in through-the-earth communication and diffraction paths. This study reveals the ‘gain’ effect of the stratum and manhole covers on low-frequency magnetic fields, as well as their role in suppressing signal attenuation. Experimental results demonstrate that the proposed mechanical antenna system achieves 5 bps 2FSK-encoded data transmission at 15 m through cast iron manhole covers. This research verifies the feasibility of the rotating permanent magnet mechanical antenna for reliable cross-medium communication in complex underground environments, and is expected to provide an effective wireless transmission solution for intelligent monitoring and fault early warning of power pipe wells.

Microscopic Numerical Simulation and Experimental Investigation on the Machining Process of Compacted Graphite Cast Iron (CGI) Considering Microstructure and Different Tool Wear States

The study investigates the features of cast iron welding without preheating, which can be applied in the repair and restoration of automotive components. The relevance of the topic is determined by the inherent difficulties of welding cast iron due to its brittleness, susceptibility to cracking, and the formation of hard structures in the heat-affected zone. An analysis of existing cast iron welding methods was carried out, demonstrating that the use of specialized electrodes and optimized welding parameters can significantly improve the quality of welded joints. Experimental studies were performed on gray cast iron samples obtained from an engine exhaust manifold. Welding was carried out without preheating using three types of electrodes: TsCh-4, MNCh-2, and UTP-8. The quality of the welded joints was evaluated through tensile testing on an MR-100 testing machine, with each sample tested five times followed by the determination of the average fracture load. The obtained results made it possible to objectively assess the mechanical properties of the welded joints. A strength analysis of butt welded joints was conducted, showing that all investigated variants meet the strength requirements and possess a sufficient safety margin. It was established that the TsCh-4 electrode provides a strong but relatively brittle weld, making it suitable for components not subjected to dynamic loads. The MNCh-2 electrode is versatile and ensures a good balance between strength and ductility, while the UTP-8 electrode produces the most ductile and high-quality weld, although it is characterized by a higher cost. The results of the study confirm the effectiveness of welding of cast iron and allow for a well-founded selection of electrode type depending on operating conditions and economic feasibility.