Microstructure Of Iron Research Articles

Effect of purity on the tensile mechanical behavior of pure iron

The current work systematically investigated the microstructures, mechanical properties, textures, dislocation density and dislocation substructures of 3N2, 4N2 and 5N2 pure irons (3N2, 4N2 and 5N2 pure irons represent that the content of Fe are 99.9264 wt%, 99.9925 wt% and 99.9992 wt%, respectively) using SEM, EBSD, XRD and TEM. The results indicated that the recrystallization temperature decreased with increasing purity, and higher purity accelerated grain growth. 4N2 and 5N2 pure irons both presented equiaxed ferrite grains, while the microstructure of 3N2 pure iron was consisted of irregular polygonal ferrites and equiaxed ferrite grains. Low-density LAGBs were observed in annealed pure irons. The fraction of LAGBs increased significantly after deformation, and the LAGBs density decreased as the purity increased. The dislocation substructures of 3N2 and 4N2 pure irons were dominated by sub-grain boundaries with high dislocation densities and dislocation tangles, whilst 5N2 pure iron primarily consisted of fewer sub-grain boundaries and random dislocations. Work hardening was the primary strengthening contribution of pure irons. As the purity decreased, the capacity of work hardening increased, which resulted from the effective obstacles to dislocations by higher fraction of LAGBs, sub-grain boundaries with high dislocation densities and dislocation tangles. Therefore, the improved mechanical properties may be attributed to the increase of work hardening ability with the decrease of purity. 3N2 pure iron presented discontinuous yielding behavior, while 4N2 and 5N2 pure irons exhibited continuous yielding behaviors. The continuous yielding was attributed to the minimal interstitial atoms rarely segregated on mobile dislocations to form Cottrell atmosphere.

A FEM-based model for failure initiation in the microstructure of gray cast iron under uniaxial compression

PurposeThe purpose of this study was to validate the feasibility of the proposed microstructure-based model by comparing the simulation results with experimental data. The study also aimed to investigate the relationship between the orientation of graphite flakes and the failure behavior of the material under compressive loads as well as the effect of image size on the accuracy of stress–strain behavior predictions.Design/methodology/approachThis paper presents a microstructure-based model that utilizes the finite element method (FEM) combined with representative volume elements (RVE) to simulate the hardening and failure behavior of ferrite-pearlite matrix gray cast iron under uniaxial loading conditions. The material was first analyzed using optical microscopy, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD) to identify the different phases and their characteristics. High-resolution SEM images of the undeformed material microstructure were then converted into finite element meshes using OOF2 software. The Johnson–Cook (J–C) model, along with a damage model, was employed in Abaqus FEA software to estimate the elastic and elastoplastic behavior under assumed plane stress conditions.FindingsThe findings indicate that crack initiation and propagation in gray cast iron begin at the interface between graphite particles and the pearlitic matrix, with microcrack networks extending into the metal matrix, eventually coalescing to cause material failure. The ferritic phase within the material contributes some ductility, thereby delaying crack initiation.Originality/valueThis study introduces a novel approach by integrating microstructural analysis with FEM and RVE techniques to accurately model the hardening and failure behavior of gray cast iron under uniaxial loading. The incorporation of high-resolution SEM images into finite element meshes, combined with the J–C model and damage assessment in Abaqus, provides a comprehensive method for predicting material performance. This approach enhances the understanding of the microstructural influences on crack initiation and propagation, offering valuable insights for improving the design and durability of gray cast iron components.

Extracting ductile cast iron microstructure parameters from fracture surfaces: A deep learning based instance segmentation approach

This study investigates the deep-learning based microstructural analysis from SEM images of ductile cast iron fracture surfaces. A Mask R-CNN model was trained, achieving 70% precision and 75% recall in graphite particle detection. Combined with a fracture surface reconstruction using the.4-quadrant backscattered electron signal, key parameters, including the particle size, shape and distance were extracted accurately. Compared to micrograph analysis, following probabilistic simulations showed the impact of the higher microstructural variance for the fracture surfaces on crack initiation, leading to higher scatter and elevated crack resistance curves. This highlights the potential of deep-learning based analysis for comprehensive microstructural characterization.

Normalizing temperature influence on the microstructure characteristics, mechanical and wear performance of a novel high chromium cast iron

The microstructure, mechanical and wear behavior of a high chromium cast iron were studied at different normalizing temperatures (950 °C, 1000 °C, 1050 °C, 1100 °C). The martensite content was proportional to the normalizing temperature except at 1100 °C because of the appearance of retained austenite. As the temperature increased, the primary carbide downsized whereas the secondary carbide content first increased but then decreased, contributing to the superior mechanical properties observed tempered at 1050 °C. The superior hardness and strength improved the surface deformation resistance, including enhanced work-hardening in the matrix and stacking fault locks in carbides, hindering dislocation slipping and material spalling, thus achieving excellent wear properties when normalized at 1050 °C. Moreover, the wear mechanism changed from oxidative/fatigue to abrasive/adhesive wear as the temperature increased.

Processing and the Effect of Nb–Mo on the Microstructure, Mechanical and Tribological Behavior of High-Cr Cast Iron

Processing and the Effect of Nb–Mo on the Microstructure, Mechanical and Tribological Behavior of High-Cr Cast Iron

Microstructure, hardness, and wear resistance of high-carbon hypereutectic high chromium irons containing W for use as roller sleeves

High chromium irons (HCI) have rarely been investigated the impact of varying W content on the microstructure and performance of high-carbon irons by scholars. In this study, after calculating by Java-based Materials Properties software (JMatPro), the casting alloying method was applied to explore the effect of adding W (0-15 wt%), Mo 3 wt%, and C 6 wt% on HCI to prepare highly wear-resistant and hard materials. The results showed that the maximum volume fraction of carbide was 38% at C 6 wt%. The addition of W promoted the formation of M6C with a maximum volume fraction of 21%, which increased the hardness to 64.5 HRC and reduced the weight loss to 0.062 g. Since W10 (the iron with W 10 wt%) and W15 (the iron with W 15 wt%) exhibited similar wear resistance but lower impact resistance, the W10 samples were heat-treated. W10 after QT550 (quench and temper heat treatment at 550 °C) sample developed a large number of M6C-type carbides and martensite in the matrix, which improved the properties of the matrix by diffusion strengthening, leading to a hardness of 70.0 HRC and a reduction in weight loss to 0.035 g. Compared to the Cr20 reference iron, W10 after QT550 was 22.8% higher in hardness and 76.8% lower in abrasion. Concurrently, an experiment was conducted on the production of roller sleeves. With the use of W10 after QT550, the lifetime of the roller sleeve was increased by 1.6 times.

Microstructure Characteristics and Mechanical Properties of Grey Cast Iron at Varied Ferrosilicon Addition

Inoculation is an essential metallurgical route for controlling solidification conditions of cast iron, consequently, in this study, the influence of varied percent ferrosilicon (FeSi) addition on microstructure and mechanical properties of grey cast iron (GCI) was investigated. A 50Kg capacity rotary furnace was used to melt the charge (Auto engine block scrap, graphite, ferrosilicon (FeSi) and limestone). The casting was produced in a greensand mold with wooden rectangular pattern of length 50 mm and breadth 30 mm. Chemical compositions and carbon equivalent values (CEVs) of the samples were determined, using Optical emission spectrometry (AR 4 metal analyzer) and the expression respectively. Microstructures of the samples were obtained, using metallurgical microscope (model number NJF-120A). The tensile and hardness properties were measured, using Universal tensile tester and Rockwell hardness tester respectively. From the results, C and Si were the major elements. Other trace elements were Mn, P, S and Al. CEVs of both the control and inoculated samples were less than 4.3%. Microstructure of the control sample was comprised of primary dendrites and graphite flakes, while those of the inoculated samples were characterized by varied amount of more developed primary dendrites, longer graphite flakes and austenite dendrites. Also, a number of small MnS particles were observed in relative amount within the microstructures. Tensile and hardness properties of the FeSi inoculated samples were superior to the control sample. Highest tensile strength and hardness values of 76.62 MPa and 99.89 HRB respectively were obtained at the optimum inoculation of 1.5 wt. % FeSi.

Effect of Cerium Addition on Microstructure and Mechanical Properties of the Ductile Iron

The effect of the cerium addition on the microstructure and properties of the ductile iron is investigated. The ferrocerium is added to obtain ductile iron samples with cerium contents of 10–750 ppm. In the ductile iron with a cerium content of 60 ppm, the amount and the spheroidization rate of graphites are the highest. The tensile strength of the ductile iron is 488 MPa and the elongation rate reaches 20.17%. For the ductile iron with a high toughness demand, it is necessary to add 60 ppm Ce in the ductile iron to increase the number density and spheroidization rate of graphites. The formation of CeS inclusions effectively promotes the heterogeneous nucleation of graphites, increasing the amount of graphites. The stronger carbon diffusion during the eutectic process increases the ferrite formation in the ductile iron, leading to a lower tensile strength and a higher elongation rate. When the cerium content exceeds 460 ppm, the precipitated Ce2C3 significantly reduces the performance of the ductile iron.

Influence of Silicon on Solidification Behavior, Microstructure and Oxidation Resistance of Gray Iron for Cookware Applications

Gray iron, a widely used engineering material, is favored for its desirable properties such as good damping capacity, thermal conductivity, and corrosion resistance. However, when exposed to elevated temperatures over time, issues like oxidation and graphite depletion can impact its durability. High-silicon gray iron, with elevated silicon content exceeding 3.0%, is known for its ability to withstand heat and oxidation, making it suitable for many applications, including cookware. This study investigates the impact of varying silicon levels (2.00-4.56%Si) on the solidification behavior, microstructure, and oxidation resistance of gray iron. Three heats with different silicon concentrations were produced and analyzed. Results indicated that higher silicon content increases the eutectoid temperature, stabilizes the ferritic structure, and introduces Type-D graphite in the microstructure. Graphite depletion was observed only in samples with 2.00%Si. The oxidation resistance improved with higher silicon content, as evidenced by a decrease in weight gain after exposure to 800 °C for 4 hours. This suggests the potential of using lower silicon levels in gray iron for cookware applications, balancing material cost with good impact resistance.

Effect of Bismuth on Microstructure and Properties of Ductile Iron

Effect of Bismuth on Microstructure and Properties of Ductile Iron

Influence of Casting Materials on the Microstructure and Mechanical Properties of Gray Cast Iron for Cylinder Liners

Influence of Casting Materials on the Microstructure and Mechanical Properties of Gray Cast Iron for Cylinder Liners

Effect of tempering temperature on microstructure and properties of low silicon hypereutectic high chromium cast iron

Effect of tempering temperature on microstructure and properties of low silicon hypereutectic high chromium cast iron

Investigation of microstructure, corrosion and mechanical properties of iron and holmium modified Sn-3.0Ag0.5Cu solder alloy with ultrasonic treatment

This research investigated the microstructure, corrosion behavior and mechanical properties of iron and holmium modified Sn-3.0Ag-0.5Cu solder alloy with ultrasonic treatment. The results demonstrated that the distribution of the phases in the ultrasonically treated solder alloys became homogeneous and the microstructure of ultrasonically treated solder alloys were more refined. The average grain size of ultrasonically treated solder alloys was reduced from 206.7 μm to 184.1 μm. A significant increase in the tensile strength from 38.75 MPa to 47.38 MPa was found in the ultrasonically treated solder alloys. The polarization curves results indicated that the solder alloys treated with ultrasound possessed lower corrosion current density and the results of atomic force microscopy suggested that roughness of corrosion products morphology was reduced. Furthermore, the electrochemical impedance spectroscopy (EIS) results indicated that the ultrasonically treated solder alloys had larger diameter of the semicircular loops and higher total impedance values.

The influence of trace vanadium on the solidification process, microstructure, and mechanical properties of gray cast iron

This study employed optical microscopy (OM), scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS) to investigate the impact of vanadium (V) on the microstructure and mechanical properties of gray cast iron (GCI) HT250. Additionally, Thermo-Calc software was employed to explore the influence of V on the solidification process. The results indicate that adding trace amounts of V in GCI forms a face-centered cubic VC phase, with the precipitation temperature of the VC phase gradually increasing. When the V content reaches 0.28 wt%, the VC phase begins to precipitate during the eutectic reaction. The incorporation of V consumes carbon, reducing the graphite content and promoting the formation of type D graphite. As the V content increases, there is an enlargement in the pearlite area ratio, a decrease in the pearlite layer spacing, and a reduction in the size of eutectic cells. These microstructural alterations lead to enhanced mechanical properties. The tensile strength peaks at 336 MPa with a V content of 0.77 wt%, representing a 29% increase compared to samples without added V. Similarly, the Vickers hardness increases with increasing V content, reaching a peak of 373 HV at 0.92 wt% V, a 27% increase compared to samples without V addition. However, at this point, the tensile strength decreases to 322 MPa.

Experimental Simulation of Directional Crystallization of SiMo Cast Iron Alloyed with Al and Cr.

SiMo ductile cast iron combines ease of part fabrication with good mechanical properties, including a usable plasticity range. Its poor corrosion resistance inherited from grey cast iron could be alleviated through alloying with Al or Cr additions capable of forming a dense oxide scale protecting the substrate. However, the presence of Al and Cr in cast iron tends to make the material brittle, and their optimum alloying additions need to be studied further. The present work was aimed at investigating the effect of crystallization rates on microstructure changes during directional crystallization of SiMo-type alloys with up to 3.5% Al and 2.4% Cr. The experiment was performed using the Bridgman-Stockbarger method. The tubular crucible was transferred from the hot section to cold section at rates ranging from 5 mm/h to 30 mm/h with a 4/5 crucible length and then quenched. The introduced Al promoted graphitization up to a point, wherein, at the highest applied addition, the graphite precipitation preceded crystallization of the rest of the melt. A rising level of Cr in these alloys from 1% to 2.4% resulted in the formation of low and high contents of pearlite, respectively. The higher crystallization rates proved effective in increasing the ferrite content at the expense of pearlite. In the investigated cast iron samples with smaller applied alloying additions, Widmanstätten ferrite or ausferrite, i.e., fine acircular phase, were often found. The switch from directional crystallization to quenching caused a transition from a liquid to solid state, which started with nucleation of islands of fine austenite dendrites with chunky graphite eutectic separating them. As these islands expanded, they pushed alloying additions to their sides, promoting carbide or pearlite formation in these places and forming a super-cell-like structure. The performed experiments helped gather information concerning the sensitivity of the microstructure of SiMo cast iron modified with Al and Cr to crystallization rates prevailing in heavy cast structures.

Effect of Copper Addition on Microstructure and Mechanical Properties of Ductile Cast Iron

Effect of Copper Addition on Microstructure and Mechanical Properties of Ductile Cast Iron

The evolution of intergranular networks during grain growth and its effect on percolation behavior

Triple junctions (TJs) are line defects in three-dimensional (3D) polycrystalline materials where three grains meet. Transport along the TJs depends on the connectivity between them. Here, we investigate the connectivity of more than 6000 TJs in a 3D microstructure of pure iron (Fe) through the lens of bond percolation. Our efforts are made possible by synchrotron-based x-ray diffraction tomography, which allows us to resolve the TJ network both temporally and spatially, during grain growth. In the framework of standard percolation theory, we determine a percolation threshold of the TJs, above which there exists a continuous pathway of TJs that travels infinitely far. Our experimental results indicate a surprisingly different percolation threshold (by 16%) compared to models and theories. The reason for the discrepancy is that the real TJ network has a topological disorder that is not present in the idealized microstructures considered in prevailing models and theories. Leveraging the wealth of time-resolved data we trace the origin of this disorder by following the topological transitions that accompany grain growth. Overall, the insights obtained in this study can help guide the design of polycrystalline materials via defect engineering.

Effect of mo content on the microstructure and properties of powder metallurgy iron based friction materials

This article uses powder pressing and sintering methods to prepare iron-based friction materials. The influence of molybdenum on the microstructure and comprehensive properties of powder metallurgy friction materials was studied from the aspects of density, hardness, and wear resistance. The results show that with the increase of Mo mass fraction, the sintering density of iron-based friction materials gradually increases, and the hardness of sintered materials first shows an increasing trend. As the Mo content increases by more than 12%, the hardness of sintered friction materials decreases. With the addition of Mo, the wear amount of the friction material first decreases and then increases. When the mass fraction of Mo added to the sintered friction material is 12%, the wear rate of the material is lower than that of other samples, and it has good wear resistance. Adding Mo element to iron copper based friction materials improves the wear resistance of sintered friction materials due to the strengthening effect of Mo.

Microstructure and mechanical properties of SiMo ductile cast irons alloys with varied Mo and Nb contents

Four silicon and molybdenum (SiMo) ductile cast irons (DCI) alloys were produced with the intention of evaluating the possibility of substituting molybdenum (Mo) by niobium (Nb) for cost reduction purposes. These alloys were evaluated in terms of their chemical composition, microstructure, hardness and tensile properties at room and high temperatures (800 °C). Results show that substitution of Mo by Nb does not change the mechanical properties of the DCI alloys significantly either at room or high temperatures.

The Effect of Tempering Temperature on Microstructure and Wear Behavior of Tungsten and Boron Alloyed Ni-Hard 4 White Cast Irons

AbstractThis study investigates the effect of tempering temperature on the microstructure and wear resistance of high-alloy white cast iron (Ni-Hard 4) with 1.15% W and 0.5% B additions. Specimens were austenitized at 850 °C for 5 h, quenched in air, and tempered at temperatures between 250 and 650 °C for 4 h. Equilibrium and non-equilibrium thermodynamic calculations were performed using Thermo-Calc software. After the microstructural investigations, hardness testing was carried out. A pin-on-disk tribometer was used to conduct wear tests under dry sliding conditions. Microstructure and worn surfaces were examined using light and scanning electron microscopes. The results showed that increasing tempering temperature resulted in a higher volume fraction of carbides. It was found that tempering at 550 °C for four hours increases resistance to wear giving the lowest measured values of weight loss and wear rate. Accordingly, tempering allows the precipitation of fine carbides in the martensitic matrix which may increase wear resistance.