Malleable Iron Research Articles

Scientific analysis of iron objects excavated from the Guantian Iron Production Site at Sangzhi County, Hunan Province, China

The Guantian site located in Sangzhi County in northwest Hunan Province, China. It is a low-level settlement and possibly an iron casting and processing site that existed during the Han and Jin periods (202 BCE–AD 420) in the Wuling Mountains region. Analysis of the excavated iron objects from the site reveals that they were mainly made from pig iron, malleable cast iron, and low-carbon steel. The metallurgical ceramic fragments may reflect the existence of melting process. Both casting and forging, with evidence of quenching technique were used in the producing process. Decarburization of cast iron in solid state was the main method of obtaining steel. Since during the Eastern Han dynasty (AD 25–220), the aboriginal in the Wuling Mountains region gradually became stronger, the use of iron-casting and processing technology played an important role in promoting regional social development of the Wuling Man (minorities in the Wuling Mountains region).

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.

Regional characteristics of iron manufacturing techniques and the related issue of the supply system on Han’s southern Frontiers: A metallurgical study of iron implements from Chenzhou, Hunan

Southern Hunan is known to be one of the few iron manufacturing regions in the Han period. The study of iron implements from this region should yield important evidence concerning the regional iron-making techniques used and the local iron industry. We provide a detailed account of the technological aspects of iron implements yielded from Chenzhou, a major node on the traffic routes entering the broader southern frontiers. Our analysis focuses on the metallographic features and chemical compositions of inclusions in the examined objects. The results reveal that cast iron and related annealing or decarburization techniques were commonly used. Most implements were made using solid-state decarburization of cast iron, along with malleable cast iron and fined iron. This technological profile is similar to other case studies in the literature, but also highlights regional characteristics such as the relatively sparse presence of fined iron. Based on this observation, we discuss various factors that could have contributed to this situation. In a broader context, the analysis of this collection can contribute to the further investigation of the regional characteristics of the Han period iron industry.

Investigation of Mechanical Properties in Ductile Iron with Alloyed and Unalloyed at Time and Temperature on Austempering

Due to the combination of its numerous excellent mechanical qualities, the flexible iron has been used more and more since its invention in 1948. To develop significantly improved characteristics, the unnecessary investigation is being done. The most recent development in the field of flexible iron, or SG iron, is Austempererd malleable iron. At four different temperatures, two different types of spheroidal graphite (SG) cast iron samples with varying copper weight levels were austempered. The temperatures used for austempering were 200°C, 300°C, 350°C, and 400°C. As a component of the austempering time and temperature, the effect of the austempering process (i.e. time and temperature) on the mechanical characteristics of spheroidal graphite iron was investigated. The progress of spheroidal graphite iron's properties was significantly influenced by the pace of cooling and the extinguishing process. The organisation of different stages during isothermal change under varied austempering settings has also been the focus of XRD analysis. By using SEM, graphite morphology has been focused on. For this investigation, samples were obtained from the castings' focal point for XRD analysis. It was discovered that virtually always, it is possible to discriminate between the ferrite (110) and austenite (111) lines. The ferrite (110) line is growing with expanding austempering time and declining with increasing austempering temperature, whereas the highest power of the austenite (111) line is expanding with expanding temperature. Thus, very precise control of the interaction components (austempering duration and temperature) is required for austempering. The results showed that, when compared to other grades (N1) through the various austempering processes used in this evaluation, ADI containing the alloying component copper (grade N2) achieved crucial mechanical qualities.

MEEHANITE SF420.12

Abstract Meehanite SF420.12 is a ductile iron that has a minimum tensile strength of 420 MPa (61 ksi) and a minimum elongation of 12%, when measured on test pieces machined from separately cast samples. This Meehanite grade possesses a predominantly ferritic matrix giving the material a good level of ductility. It is used where a degree of shock resistance at ambient temperatures is important. Meehanite SF420.12 is of particular interest to design engineers wishing to replace fabrications or malleable iron castings. This datasheet provides information on composition, physical properties, hardness, elasticity, tensile properties, and compressive strength as well as fatigue. It also includes information on casting and heat treating. Filing Code: CI-106. Producer or source: Meehanite Metal Corporation.

Ductile iron with nodular and compact graphite as a rational alternative to malleable cast iron

There is a need for cast irons with a combined combination of properties in modern conditions. Such properties can be provided by ductile cast iron with nodular and vermicular graphite, which is essentially a hybrid cast iron in terms of microstructure. The article found that ductile iron with nodular and vermicular graphite in terms of its mechanical properties is a rational alternative to malleable cast iron, namely the grade KCh45-6 (GOST 1215-79). Also, the ratio of nodular/vermicular graphite (70…95/5…30%) was determined, which provides the data of mechanical characteristics. Differences in pearlite/ferrite ratio and hardness for ductile iron with nodular and vermicular graphite and ductile iron are shown, providing grade KCh45-6.

A New Machine Vision Method for Target Detection and Localization of Malleable Iron Pipes: An Experimental Case

Malleable iron pipes are widely used in construction, manufacturing, aerospace, and many other fields. Cast malleable iron pipes need to be treated flat to meet the needs of different shapes and sizes. This process is usually completed manually, which is low efficiency and is subject to potential safety risks. To solve this problem, a machine vision method is proposed to detect and localize malleable iron pipes. Point cloud images of malleable iron pipes are obtained by the Random Sample Consensus (RANSAC) algorithm, and precise matching is completed by the Iterative Closest Point (ICP) algorithm to obtain more accurate positions, so as to realize robot grasping. The grasping experiments of malleable iron pipes with the same and different specifications were carried out using a specially designed experimental platform. The results show that malleable iron pipes can be identified effectively and that the corresponding grasping success rate is more than 85 %. The target detection and localization method can obtain the three-dimensional (3D) position of malleable iron pipes to improve grasping efficiency, which provided a certain theoretical basis and guiding significance to improve production efficiency in practice.

Study on fracture cause of porcelain insulator of 220KV transmission line

Porcelain insulators are widely used in EHV and UHV lines because of their excellent mechanical properties. Recently, the porcelain insulator of a 220kV transmission line tension tower in Shandong Province broke, which directly affected the safe and stable operation of the power grid. In order to analyse the fracture cause of porcelain insulator, the insulation resistance test, electromechanical damage composite test, morphology analysis and metallographic structure analysis of faulty string insulator and adjacent string insulator are carried out in this paper. The results show that the insulation resistance and electromechanical failure load test of porcelain insulator meet the standard requirements, and the electrical performance is normal. The fracture of porcelain insulator is mainly caused by the damage of iron cap. The raw material of broken porcelain insulator iron cap is gray cast iron, and its mechanical properties are far lower than those of nodular cast iron or malleable cast iron required by the standard, which is easy to be damaged in the process of stress; At the same time, there are casting defects in the iron cap of the broken porcelain insulator, and there are micro cracks before hot galvanizing. With the stress of the insulator string during operation, the cracks gradually expand, which eventually leads to the fracture failure of the iron cap and the broken string. The relevant research process can provide reference for the quality control of porcelain insulator fittings.

ПОЛІПШЕННЯ ЕКСПЛУАТАЦІЙНИХ ВЛАСТИВОСТЕЙ ДЕТАЛЕЙ МАШИН ХОЛОДНИМИ ПЛАСТИЧНИМ ДЕФОРМУВАННЯМ

The article discusses the direction of improving the operational properties of machine parts by the cold plastic deformation. Purpose – to develop methods of experimental research of regular reliefs, including equipment, tools and material of prototypes; to create a classification of regular reliefs by purpose; to determine the mechanics of deepening of the linear indenter in the metal sample; to develop technological recommendations and research tools. The object of research – regular reliefs on the surface of machine parts. Methods and devices for conducting experiments were selected: hydrogenated presses, linear indentors, optical microscopes, microhardness testers, research materials, instruments and measuring instruments. The materials were alloy and stainless steel, gray and malleable cast iron, bronze and brass, aluminum and titanium alloys. The classification of reliefs by purpose, obtained by cold plastic deformation and cutting, has been developed. The mechanics of deepening of a linear indenter into a metal sample has been developed, which combines the values of the depth of indentation with the geometrical parameters of the indenter, friction coefficient, contact stress and groove depth. Experiments on 8 typical representatives of structural materials confirmed the theoretical principles of the mechanics of deepening. Scientific results allowed to develop and test a sample of the tool on a tubular part made of duralumin D16 (2117). The following process of improvement of operational properties of details of cars is offered: preparation of a surface under indentation; indenter deepening; removal of metal protrusions by cutting. KEYWORDS: REGULAR RELIEF, COLD PLASTIC DEFORMATION, LINEAR INDUCTOR, SURFACE OF PARTS, MECHANICS OF DEEPING

Materials Selection for Malleable Cast-Iron Pipe Fittings with a Numerical Method

Materials Selection for Malleable Cast-Iron Pipe Fittings with a Numerical Method

Advances in Carbidic Austempered Ductile Iron (CADI) - A Wearresistant Material

Background: Ductile irons provide a more viable alternative for malleable cast iron in areas that do not demand extreme wear resistance. Austempering of ductile irons was a well researched area in the last two decades. Attempts to further improve the wear resistance led to the development of Carbidic austempered ductile iron (CADI), wherein the carbides contribute to wear resistance. Combination of ausferritic matrix, graphite nodules, and carbides (eutectic and alloy) symbolizes the microstructure of CADI. Methods: Two principal approaches adopted by the researchers to change the microstructure are (i) addition of carbide forming elements (ii) heat treatment (s). Results: Both the above methods result in the refinement of graphite nodules, carbide precipitations, along fine ausferrite. Conclusion: Improvement in hardness, toughness and wear resistance was observed largely as a consequence of fine carbide precipitations and formation of martensite.

Adaptation of Fracture Mechanics Methods for Quality Assessment of Tungsten Carbide Cutting Inserts.

Tungsten carbide (WC) is well known as one of the hardest materials widely used in machining, cutting and drilling, especially for cutting tools production. Knowing fracture toughness grants the opportunity to prevent catastrophic wear of a tool. Moreover, fracture toughness of WC-based materials may vary because of different material compositions, as well as a different way of production. Hence, each material should be treated individually. In this paper, SM25T (HW) tungsten carbide (HW—uncoated grade, TNMR 401060 SM25T, manufactured by Baildonit company, Katowice, Poland) was taken into consideration. Sintered carbides—designated as S—are designed to be applied for machining steel, cast steel and malleable cast iron. Fracture mechanics methods were adapted to make a quality assessment of WC cutting inserts. Both quasi-statical three-point bending tests, as well as Charpy dynamic impact tests, were performed to calculate static and dynamic fracture toughness (KIC and KID, respectively). In addition, a special emphasis was placed on the microscopic analysis of fracture surfaces after impact tests to discuss material irregularities, such as porosity, cracks and so-called “river patterns”. There is a lack of scientific works in this field of study. However, cutting engineers are interested in obtaining the experimental results of that kind. Although there are a few standardized methods that may be used to determine fracture toughness of hard metals, none of them is expected to be the most reliable. Moreover, there is a lack of scientific works in the field of determining static and dynamic fracture toughness of WC by the presented method. The proposed examination solution can be then successfully used to calculate toughness properties of WC-based materials, as the results obtained seem to be with a good agreement with other works.

High-Speed Machining of Malleable Cast Iron by Various Cutting Tools Coated by Physical Vapor Deposition

The coating material of a tool directly affects the efficiency and cost of machining malleable cast iron. However, the machining adaptability of various coating materials to malleable cast iron has been insufficiently researched. In this paper, turning tests were conducted on cemented carbide tools with different coatings (a thick TiN/TiAlN coating, a thin TiN/TiAlN coating, and a nanocomposite (nc) TiAlSiN coating). All coatings were applied by physical vapor deposition. In a comparative study of chip morphology, cutting force, cutting temperature, specific cutting energy, tool wear, and surface roughness, this study analyzed the cutting characteristics of the tools coated with various materials, and established the relationship between the cutting parameters and machining objectives. The results showed that in malleable cast iron machining, the coating material significantly affects the cutting performance of the tool. Among the three tools, the nc-TiAlSiN-coated carbide tool achieved the minimum cutting force, the lowest cutting temperature, least tool wear, longest tool life, and best surface quality. Moreover, in comparisons between cemented-carbide and compacted-graphite cast iron machined under the same conditions, the wear mechanism of the coated tools was found to depend on the cast iron being machined. Therefore, the performance requirements of a tool depend on multiple factors, and selecting an appropriately coated tool for a particular cast iron material is essential.

Ultraflexible and Malleable Fe/BaTiO3 Multiferroic Heterostructures for Functional Devices

AbstractThe high demand for flexible spintronics based on multiferroic heterostructures makes growing high‐quality flexible, functional oxides urgently, in which needs to be deposited on lattice‐matched substrates. In this paper, ultraflexible and malleable iron (Fe)/BaTiO3 (BTO) multiferroic heterostructures are demonstrated, showing a perfect crystallinity and hetero‐epitaxial growth. In terms of performance, they indicate good multiferroic properties and excellent bending tunability, as well as obvious magnetoelectric (ME) coupling effect. During the phase transformation from the rhombohedral phase to the orthorhombic phase of BTO layers in the heating process, a large ME coupling coefficient of 120 Oe °C−1 along the out‐of‐plane direction is obtained. This value keeps consistent in the phase‐field simulation of magnetic domain evolution, in which the biaxial compressive strain induced‐magnetoelastic anisotropy facilitates the magnetic easy axis of Fe layers to the [110] or [–1–10] direction. Besides, ultraflexible Fe/BTO heterostructures are found to have a 690 Oe ferromagnetic resonance (FMR) field shift along the out‐of‐plane direction under the flexible tuning (R = 5 mm). This work should pave a way toward flexible spintronic and functional devices with fast speed, portability, and low energy consumption.

A computational study on camshaft used in IC engine under various materials and load conditions

The camshaft is driven by utilizing the driving rod by means of timing gears cams are made as indispensable added substances of the camshaft and are planned in the sort of way to open and close the valves at the best possible planning and to keep up them open for the fundamental length. A typical case of the camshaft in a car, which takes the rotational movement of the motor, deciphers it to the responding development basic to complete the utilization and fumes valves of the chambers. In this article, a camshaft is designed for 6-cylinder IC engine and the modeling has done in CATIA V5R20 design software. Which is modeled in CATIA V5 R20 STP format file is imported into ANSYS 2019R2 software and analysis done with different materials by varying loads with respect to time The materials are, Stainless steel 316 and 35Ni1Cr60, malleable cast iron, EN24T and C55Mn15. In this project, the dynamic analysis, fatigue analysis and Modal analysis is done to conclude the deformation, stresses, strains and the deformation with respect to frequencies at different mode shapes and fatigue analysis is to estimate the life of the component. Finally compared simulations results with theoretically calculated values.

ПІДВИЩЕННЯ ЕКСПЛУАТАЦІЙНИХ ВЛАСТИВОСТЕЙ ДЕТАЛЕЙ МАШИН РЕЛЬЄФАМИ ПОВЕРХНІ

The article discusses the direction of improving the operational properties of machine parts by applying regular reliefs to the surface/ Purpose - to develop a model, plan and methodology for experimental studies of regular reliefs and create their classification by purpose and methods of obtaining. The object of research - regular reliefs on the surface of machine parts. The hierarchy of the main factors that affect the profile of reliefs formed by triangular grooves is determined. This is the normal penetration force of a linear indenter, hardness and elongation of the experimental material. The optimization parameter is the groove depth. A mathematical model and research plan have been developed 23. The methodology and devices for conducting experiments are determined. These are hydraulic presses, linear indenters, optical microscopes, microhardness testers, test materials, instruments, and measuring instruments. Materials for research: alloyed and stainless steel, gray and malleable cast irons, bronze and brass, aluminum and titanium alloys. Classifications of reliefs according to the methods of obtaining and destination are developed. Production methods are based on cold plastic deformation and cutting. The basic methods for the study are static methods: the introduction of a dividing element with discrete drawing and a single protrusion of the shaped mandrel during reduction. The dependence of the depth and double angle of the relief groove on the normal force is shown. A new method for obtaining the surface of a part, including the alternation of supporting platforms and grooves is proposed. The method is carried out using machining and subsequent deformation pulling. A distinctive feature of the method is the use of an intermediate elastic sleeve. KEYWORDS: REGULAR RELIEF, COLD PLASTIC DEFORMATION, LINEAR INDUCTOR, SURFACE OF PARTS, COATING, MODEL OF FORMATION OF RELIEF.

Using Computer Microscopy Methods to Control the Microstructure of Malleable Cast Iron Product with Spherical Graphite

The method of identification of objects on images of the microstructure of cast iron with spherical graphite of the correct shape with uniform distribution is presented. Morphological analysis techniques were used to identify shrinkage pores and graphite inclusions in microstructure images. Geometric features of the shape of graphite inclusions were used as methods for identifying graphite, in particular, particle size analysis, which is widely used to identify various objects in computer microscopy. The computer analysis of the image was performed with the program ImageJ. To determine the pores against the background of graphite inclusions, two characteristics were used - the shape and size of the objects themselves. The pores, presented on the image, differ from graphite inclusions by a complex, fractal border and comparatively large areas. For the visualization of the research results, the combination of the graphite part with the calculation and analytical part was used. Such presentation of the results is the most significant and allows to perform the most correct evaluation of the graphitized cast iron microstructure in accordance with GOST 3443-87.

Metal and iron construction in sacral space shaping

The article considers the use of innovative materials in the European sacred space of the late 18th - early 20th centuries in particular metal structures as well as the structural basis of reinforced concrete. The chronological framework of stages of this process which consistently master properties of the new building materials offered by an epoch of industrial revolution is established: cast iron, malleable iron, steel, reinforced concrete. The desire to be “modern” in the formation of sacred space, which follows from the artistic decisions of the first consumers of steel and concrete in sacred buildings, is analyzed. The constructive advantages and disadvantages of new materials are revealed. Metal constructions and decorative elements that form a sacred space are presented. A comparative analysis of public spaces, both sacred and secular in terms of the use of metal structures. Possibilities of new materials which demanded aesthetic comprehension are presented. It was found that during the XIX century such comprehension in the architecture of sacred spaces took place in line with two approaches: traditional-aesthetic, when constructive elements made of new material were designed in traditional historical forms in line with the eclectic understanding of styles; and structural and technological, by inventing new design principles for new construction. It was found that in both cases the use of metal and reinforced concrete was a significant factor that influenced the formation of modern sacred space.

Experimental Investigation of Twist Fatigue Characteristics on Piston Rings

Piston ring is one of the most important parts of the internal combustion engines. This paper investigates the mechanical and twist fatigue characteristics on different piston ring materials. The piston ring materials were chosen in this study such as grey cast irons (3740 and 6140), malleable cast iron (3929), spheroidal graphite cast iron (6139) and martensitic carbidic grey cast iron (6454). Twist fatigue test was conducted on different materials of piston rings in order to identify the suitable piston ring for the effective operation. Geometrical features and the mechanical properties were also assessed in different materials for the effectiveness of piston rings.

Hopper-skeletal and hemispherical crystallization of graphite in iron–carbon–silicon alloys

The growth of graphite during solidification and solid-state transformation of Fe–C–Si alloys continues to be the subject of extensive research. This is particularly valid for spheroidal graphite, as control of graphite shape is vital to achieving the level of performance required in contemporary applications of these casting alloys. For irons solidifying in the stable system, growth of spheroidal graphite typically starts in the liquid before the eutectic reaction, and then continues through carbon diffusion from the liquid to the austenite through an austenite shell, to finally being completed through growth in solid state because of decreased carbon solubility during cooling or iron carbide decomposition if metastable solidification also occurs. The process may be complicated by partial or even complete metastable solidification. This last scenario is typical for industrial malleable iron. To further understand graphite growth mechanisms, irons of similar composition but with four level of Mg (<0.01–0.047%) were rapidly solidified in copper molds to produce samples with metastable eutectic. The samples were annealed at 950 °C for 4–40 min to promote graphite growth, and then quenched in water. Optical and scanning electron microscopy on polished and deep etched specimens was used to study the growth kinetics of nucleation and growth of graphite. Sequential nucleation of graphite on complex Mg sulfides that have nucleated on Mg oxides was documented. Unique features such as honeycomb structure typical for hopper skeletal-type crystals analogous to ice crystals, and hemispherical growth of graphite aggregates in Fe–C–Si alloys were observed and documented. The experimental findings are additional support of the multi-mechanism theory of graphite growth in iron alloys.