Microstructure Of Cast Iron Research Articles

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.

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

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.

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.

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

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

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.

Influence of Cooling Rate After Destabilization on Microstructure and Hardness of a High-Cr Cast Iron

AbstractThis study investigates the impact of cooling rate after destabilization at 980 °C on the microstructure of 23 wt pct Cr–2.7wt pct C hypoeutectic high-Cr cast iron. Lowering cooling rate intensifies the secondary carbides formation, depleting carbon in austenite. This raises the martensite start temperature and lowers the bulk hardness. We thereby provide evidence explaining the origin of the sensitivity to cooling rate in high-Cr cast irons.

Effect of Austempering Holding Time Variations of 30, 60, and 90 Minutes at 300 °C on The Microstructure and Toughness of Nodular Cast Iron

The phases of the nodular cast iron matrix are similar to those of steel. Therefore, heat treatment of steel can be applied to nodular cast iron. A potential heat treatment for nodular cast iron is austempering. This study aimed to determine the effect of austempering holding time at 300 °C on the microstructure and toughness of nodular cast iron. The austempering process begins with austenitizing at a temperature of 850 °C for 60 minutes, then the quenching process is carried out in a salt bath until a temperature of 300 °C is held with variations of 30, 60, and 90 minutes, then cooled to room temperature. Metallographic testing was conducted to determine the phase change before and after the austempering process using a Scanning Electron Microscope (SEM). Meanwhile, impact testing was carried out to determine changes in toughness before and after the austempering process. At a holding time of 30 minutes, metallographic testing on the raw material produced a gray coarse pearlite phase, black nodular graphite surrounded by white ferrite. After the austempering process, gray fine pearlite and black nodular graphite appeared. At the holding time of 60 and 90 minutes, the graphite sizes were bigger. Austempering withholding times of 30, 60, and 90 minutes resulted in impact energy of 4.2, 10, and 11 Joule. From the results of the study, it was concluded that an increase in holding time would increase the size of the graphite and the toughness of nodular cast iron.

Effects of Ti addition and wall thickness on microstructure, hardness, and wear properties of spheroidal graphite cast irons

Spheroidal graphite cast irons (SGCIs) have been commonly used in automotive and energy sectors where superior mechanical strength and wear resistance are required. This paper investigated the performance of the SGCIs under severe wear conditions as a function of Ti content and cooling rate. SGCIs alloyed with various Ti content (0, 0.1, 0.2, 0.3, and 0.5 wt%) were produced by green sand-casting process in different section sizes (10, 30, and 50 mm). Ball-on-disk type wear equipment with an Al2O3 ball was used to determine the wear rates of the SGCI samples. With increasing Ti content, up to 45% of nodular graphite turned into vermicular graphite, depending on the Ti addition and section sizes. Carbide precipitation was observed in the matrix due to the carbide-forming effect of Ti. The hardness and wear resistance of the SGCIs were improved by adding Ti owing to the combined effects of increasing pearlite and TiC particles precipitated in the matrix. Thinner-wall castings provided a faster cooling rate, which improved hardness and wear resistance. Alloying with 0.5 wt% Ti decreased the wear rates up to 35%.

Evaluation of Microstructure and Abrasive Wear-Resistance of Medium Alloy SiMo Ductile Cast Iron.

Medium-alloy ductile iron with a SiMo ferritic matrix has very good heat resistance. The addition of chromium and aluminum also increases this resistance. This article presents the impact of chromium and aluminum on the structure of SiMo cast iron, especially their impact on the deformation of the spherical graphite precipitates and the formation of M6C and M3C2 carbide phases. These carbides are formed in a ferritic matrix or at the grain boundaries, resulting in increased hardness and a drastic reduction in impact strength. The article presents the influence of heat treatment on the material's microstructure and resistance to abrasive wear. Chromium and aluminum additions can also indirectly reduce the abrasive wear resistance of SiMo cast iron. The presented research shows the possibility of doubling the abrasive wear resistance of SiMo cast iron.

Study on the effect of ultrasonic treatment for fabricating nodular cast iron with improved mechanical properties

In this paper, a novel ultrasonic treatment technique was proposed in nodular cast iron melt with the aim of improving the microstructure and mechanical properties of nodular cast iron. The effects of ultrasound on the microstructures and properties were investigated by comparing experiments with and without ultrasound. The results showed that compared with the NO UT specimen, the mean equivalent diameter of graphite nodules was reduced by 46% in the UT 105 s specimen, while the mean roundness and nodule count per unit area were increased by 33.9% and 43.6%, respectively. In addition, the ultrasonic treatment of melt could increase the pearlite content, refine the matrix microstructure and reduce the pearlite interlamellar spacing from 392.7 nm to 231.3 nm. Compared with the NO UT specimen, the mechanical properties of the UT specimen were improved significantly, and could up to UTS of 739 MPa, YS of 579 MPa and El of 9.4% in the UT 105 s specimen. In this work, the mechanism of ultrasonic action on nodular cast iron also was discussed in detail.

MULTIFRACTAL ANALYSIS OF THE INFLUENCE OF CHROMIUM-NICKEL CAST IRON STRUCTURE ON ITS QUALITY CRITERIA

The influence of the structure of cast irons on their hardness was studied using multifractal analysis. The spectrum of statistical dimensions of the cast iron microstructure was calculated using the Renyi formula. The hardness of chromium-nickel cast iron was determined at three points of the sample. It was found that the pairwise correlation coefficients for predicting hardness by traditional structure characteristics (length, diameter, area) were R2= 0.73...0.87. When assessing hardness indicators by multifractal characteristics, the correlation coefficients are 0.78...0.88 for the pearlite structure with flake graphite and 0.81...0.93 for the pearlite structure with spherical graphite. The sensitivity coefficients of the hardness indicators of СПХН-43 rolls to the information and correlation dimensions of carbides, as well as to the fractal and statistical D-100 dimensions of flake graphite were determined. The sensitivity of hardness indicators to the fractal and statistical D100 dimensions of carbides and to the fractal and correlation dimensions of flake graphite was determined for СПХНФ-47 rolls. Based on the results obtained, an approach to assessing the hardness of СПХН-43 and СПХНФ-47 rolls was developed, which includes: 1). Determination of the statistical dimension spectrum of the cast iron structure elements. 2). Determination of the sensitivity coefficients of hardness indicators to the spectrum of dimensions of structural elements. 3). Creation of a mathematical model for predicting the hardness of rolls. The considered approach can be interpreted as an alternative method for assessing the quality criteria of cast irons based on the analysis of their structure.

Microstructure and Properties Variation of High-Performance Grey Cast Iron via Small Boron Additions

A study was undertaken to investigate the effects of small boron additions on the solidification and microstructure of hypo-eutectic alloyed grey cast iron. The characteristic temperatures upon crystallisation of the treated metal melt were recorded, specifically those concerning small boron addition by using thermal analysis with the ATAS system. Additionally, a standardised wedge test was set to observe any changes in chill performance. The microstructures of thermal analysis samples were analysed using a light optical microscope (LOM) and field emission scanning electron microscopy (FE-SEM) equipped with energy dispersive spectroscopy (EDS), which reveal variations in graphite count number with the addition of boron within observed random and undercooled flake graphite. The effect of boron was estimated by the classical analytical and statistical approach. The solidification behaviour under equilibrium conditions was predicted by a thermodynamic approach using Thermo-Calc. Based on all gathered data, a response model was set with boron for given melt quality and melt treatment using the experimentally determined data. The study reveals that boron as a ferrite and carbide-promoting element under the experimental set shows weak nucleation potential in synergy with other heterogenic nuclei at increased solidification rates, but no considerable changes were observed by the TA samples solidified at slower cooling rates, indicating the loss of the overall inoculation effect. The potential presence of boron nitride as an inoculator for graphite precipitation for a given melt composition and melt treatment was not confirmed in this study. It seems that boron at increased solidification rates can contribute to overall inoculation, but at slower cooling rates these effects are gradually lost. In the last solidification range, an increased boron content could have a carbide forming nature, as is usually expected. The study suggests that boron in traces could affect the microstructure and properties of hypo-eutectic alloyed grey cast iron.

Mechanism Analysis for the Enhancement of Low-Temperature Impact Toughness of Nodular Cast Iron by Heat Treatment.

The low-temperature impact toughness of nodular cast iron can be significantly enhanced by heat treatment, and thus meet the severe service requirements in the fields of high-speed rail and power generation, etc. In order to explore the enhancement mechanism, microstructure, hardness, composition and other characteristics of as-cast and heat-treated nodular cast iron is systematically tested and compared by optical microscopy, microhardness tester, EBSD, SEM, electron probe, and impact toughness testing machine in this study. The results show that heat treatment has little effect on the morphology and size of graphite in nodular cast iron, ignores the effect on the grain size, morphology, and distribution of ferritic matrix, and has little effect on the hardness and exchange of elements, while it is meaningful to find that heat treatment brings about significant decrease in high-angle grain boundaries (HAGB) between 59° and 60°, decreasing from 10% to 3%. Therefore, the significant enhancement of low-temperature impact toughness of nodular cast iron by heat treatment may result from the obvious decrease in HAGB between 59° and 60°, instead of other reasons. From this perspective, the study can provide novel ideas for optimizing the heat treatment process of nodular cast iron.

Characterization on vermicular graphite rate and tensile strength in vermicular graphite cast iron based on nonlinear ultrasonic technique

Ultrasonic techniques have been widely used to detect the percentage of vermicular graphite, defects, etc. in vermicular graphite cast iron. The linear ultrasonic velocity method is the main ultrasonic method for characterizing vermicular graphite rate and tensile strength in the current study, however, it is often easy to misjudge the vermicular graphite rate due to its insignificant variation. This study explores the feasibility of using the nonlinear ultrasonic technique (NUT) to characterize the vermicular graphite rate and tensile strength. Based on the longitudinal critically refracted (LCR) wave detection model, an experimental study to detect the vermicular graphite rate and tensile strength of vermicular graphite cast iron is carried out using the nonlinear ultrasonic harmonic method, and compared with the ultrasonic velocity method. The experiment results show that the relative nonlinear parameter of the LCR wave decreases along with the increase of vermicular graphite rate and increases along with the increase of tensile strength, and it has higher detection sensitivity and resolution than ultrasonic velocity by analyzing the obtained data. The increase in the acoustic nonlinearity parameter (ANP) is related to the increase in the number of grain boundaries in the microstructure. Therefore, the relationship among microstructure, ANP, and mechanical properties of vermicular graphite cast iron can be established, and it’s promising that a new approach might be developed for quickly detecting the vermicular graphite rate and corresponding tensile strength with the NUT.