Thermal fatigue and wear of compacted graphite iron brake discs with various thermomechanical properties

The increase in payload capacity of trucks has heightened the demand for cost-effective yet high performance brake discs.In this work,the thermal fatigue and wear of compacted graphite iron brake discs were investigated,aiming to provide an experimental foundation for achieving a balance between their thermal and mechanical properties.Compacted graphite iron brake discs with different tensile strengths,macrohardnesses,specific heat capacities and thermal diffusion coefficients were produced by changing the proportion and strength of ferrite.The peak temperature,pressure load and friction coefficient of compacted graphite iron brake discs were analyzed through inertia friction tests.The morphology of thermal cracks and 3D profiles of the worn surfaces were also discussed.It is found that the thermal fatigue of compacted graphite iron discs is determined by their thermal properties.A compacted graphite iron with the highest specific heat capacity and thermal diffusion coefficient exhibits optimal thermal fatigue resistance.Oxidization of the matrix at low temperatures significantly weakens the function of alloy strengthening in hindering the propagation of thermal cracks.Despite the reduced hardness,increasing the ferrite proportion can mitigate wear loss resulting from low disc temperatures and the absence of abrasive wear.

Evaluation of red soil-bentonite mixtures for compacted clay liners

Compacted clay liners are an integral part of the waste landfills,which are provided to contain the leachate within the landfills and protect the surrounding environment.Generally,locally available natural soils are used for the construction of compacted clay liners if they satisfy the design criteria.However,not all soils in their natural state satisfy all the design criteria for the liner materials.Thus,there is a definite need to modify the locally available natural soils by blending with bentonite to meet the required design criteria for the liners.In view of this,the present study evaluates the suitability of an Indian red soil enhanced with bentonite as a liner material.To achieve this,a series of experiments were carried out using locally available red soil and bentonite.First,the suitability of the red soil was evaluated as a liner material.The experimental results showed that the red soil met all the selection criteria stipulated by the Environmental Protection Agencies(EPAs)for the liners except the hydraulic conductivity criterion.Therefore,the red soil was mixed with bentonite contents of 10%,20%and 30%,and the red soil-bentonite mixtures were evaluated for their suitability for liners in their compacted state.Further,as the liners in the arid and semi-arid regions are subjected to moisture variations due to seasonal moisture fluctuations and other factors,the red soil-bentonite mixtures were subjected to wetdry cycles,and their suitability was evaluated after wet-dry cycles.The experimental results revealed that all the red soil-bentonite mixtures met the stipulated EPA criteria for the liners in the as-compacted state.However,the red soil-bentonite mixtures with 20%and 30%bentonite contents only satisfied the hydraulic conductivity requirement even after wet-dry cycles.The experimental findings were supplemented with the microstructural insights captured through digital camera images,scanning electron microscopy(SEM),and mercury intrusion porosimetry(MIP)studies.

Effect of FeSi additive in dual-chamber sample cup on thermal analysis characteristic values and vermiculating rate of compacted graphite iron

Thermal analysis plays a key role in the online inspection of molten iron quality.Different solidification process of molten iron can be reflected by thermal analysis curves,and silicon is one of important elements affecting the solidification of molten iron.In this study,FeSi75 was added in one chamber of the dual-chamber sample cup,and the influences of FeSi75 additive on the characteristic values of thermal analysis curves and vermiculating rate were investigated.The results show that with the increase of FeSi75,the start temperature of austenite formation TALfirstly decreases and then increases,but the start temperature of eutectic growth TSEF,the lowest eutectic temperature TEU,temperature at maximum eutectic reaction rate TEM,and highest eutectic temperature TERkeep always an increase.The temperature at final solidification point TEShas little change.The FeSi75 additive has different influences on the vermiculating rate of molten iron with different vermiculation,and the vermiculating rate increases for lower vermiculation molten iron while decreases for higher one.According to the thermal analysis curves obtained by a dual-chamber sample cup with 0.30wt.%FeSi75 additive in one chamber,the vermiculating rate of molten iron can be evaluated by comparing the characteristic values of these curves.The time differenceΔtERcorresponding to the highest eutectic temperature TERhas a closer relationship with the vermiculating rate,and a parabolic regression curve between the time differenceΔtERand vermiculating rateηhas been obtained within the range of 65%to 95%,which is suitable for the qualified melt.

Research on Preparation and Electrochemical Performance of the High Compacted Density Ni-Co-Mn Ternary Cathode Materials

The high compacted density LiNi0.5-xCo0.2Mn0.3MgxO2 cathode material for lithium-ion batteries was synthesized by high temperature solid-state method, taking the Mg element as a doping element and the spherical Ni0.5Co0.2Mn0.3 (OH)2, Li2CO3 as raw materials. The effects of calcination temperature on the structure and properties of the products were investigated. The structure and morphology of cathode materials powder were analyzed by X-ray diffraction spectroscopy (XRD) and scanning electronmicroscopy (SEM). The electrochemical properties of the cathode materials were studied by charge-discharge test and cyclic properties test. The results show that LiNi0.4985Co0.2Mn0.3 Mg0.0015O2 cathode material prepared at calcination temperature 930°C has a good layered structure, and the compacted density of the electrode sheet is above 3.68 g/cm3. The discharge capacity retention rate is more than 97.5% after 100 cycles at a charge-discharge rate of 1C, displaying a good cyclic performance.

Compacted graphite iron-A material solution for modern diesel engine cylinder blocks and heads

The demands for improved fuel economy,performance and emissions continue to pose challenges for engine designers and the materials they choose. This is particularly true for modern diesel engines,where the primary path to achieving improved engine performance and emissions is to increase the Peak Firing Pressure in the combustion chamber. The resulting increase in thermal and mechanical loading has required a change from conventional grey cast iron to Compacted Graphite Iron (CGI) in order to satisfy durability requirements without increasing the size or the weight of the engines. With at least 75% higher tensile strength,45% higher stiffness and approximately double the fatigue strength of conventional grey cast iron,CGI satisfies durability requirements and also provides the dimensional stability required to meet emissions legislation throughout the life of the engine. Currently,there are no CGI diesel engines running on the roads in North America. This is set to change considerably as new commercial vehicle and pick-up SUV diesel engines are launched with CGI cylinder blocks in 2008 and 2009. These initial programs will provide over 2 million CGI diesel engines when ramped to mature volume,potentially accounting for 10%-15% of the North American passenger vehicle fleet within the next four years.

Review of collapse triggering mechanism of collapsible soils due towetting

Loess soil deposits are widely distributed in arid and semi-arid regions and constitute about 10% of land area of the world.These soils typically have a loose honeycomb-type meta-stable structure that is susceptible to a large reduction in total volume or collapse upon wetting.Collapse characteristics contribute to various problems to infrastructures that are constructed on loess soils.For this reason,collapse triggering mechanism for loess soils has been of significant interest for researchers and practitioners all over the world.This paper aims at providing a state-of-the-art review on collapse mechanism with special reference to loess soil deposits.The collapse mechanism studies are summarized under three different categories,i.e.traditional approaches,microstructure approach,and soil mechanics-based approaches.The traditional and microstructure approaches for interpreting the collapse behavior are comprehensively summarized and critically reviewed based on the experimental results from the literature.The soil mechanics-based approaches proposed based on the experimental results of both compacted soils and natural loess soils are reviewed highlighting their strengths and limitations for estimating the collapse behavior.Simpler soil mechanics-based approaches with less parameters or parameters that are easy-to-determine from conventional tests are suggested for future research to better understand the collapse behavior of natural loess soils.Such studies would be more valuable for use in conventional geotechnical engineering practice applications.

Effects of alloy elements on ductility and thermal conductivity of compacted graphite iron

The infl uence of Si, Sn, Mo and Ni on the ductility and thermal conductivity of compacted graphite iron(CGI) was investigated. Metallographic observation and Differential Scanning Calorimetry(DSC) experiments were carried out to analyze the roles of various additions in the eutectoid reaction. The experimental results showed that the ductility of CGI is proportional to the ferrite fraction, so moderate Si content could dramatically improve the ductility by increasing the ferrite fraction. DSC measurements showed that Mo has moderate inhibition on eutectoid transformation during both the heating and cooling processes, while the sample without Sn obviously broadens the three-phase region. Vermicularity and ferrite are known to improve thermal conductivity, and the former plays a more important role. Besides, among the alloy elements investigated, Sn has the greatest negative effect on conductivity, followed by Ni and Mo having the smallest effects.

Thermal conductivity of cast iron-A review

This paper gives a brief introduction to the four research methods for the study on thermal conductivity of cast irons,including experimental measurement,statistical analysis,effective medium theory and numerical simulation.Recent studies on the thermal conductivity of various cast irons are reviewed through the influence of alloying elements,structural constituents,and temperature.The addition of alloying elements is the main reason that restricts the thermal conductivity of cast irons,especially spheroidal graphite cast iron.The connectivity of graphite has a significant effect on the thermal conductivity of flake and compacted graphite cast irons,semiquantitative and quantitative analysis of this factor is a key and difficult point in the study of thermal conductivity of cast irons.The thermal conductivities of different types of cast irons show varying degrees of dependence on temperature.This phenomenon is the combination of graphite and matrix,rather than just depending on graphite morphology.The study of the relationship between individual phase and temperature is the focus of future research.These summaries and discussions may provide reference and guidance for the future research and development of high thermal conductivity cast irons.

Diffusion characteristics of HTO and 99TcO_4^- in compacted Gaomiaozi(GMZ) bentonite

The characteristics of diffusion are essential to the transport of radionuclides through buffer/backfill materials, such as bentonite, which are commonly found in waste repositories. This study used through-diffusion techniques to investigate the diffusion behavior of HTO and ^(99)TcO_4^- on GMZ bentonite of various densities. Diffusion rates were calculated by measuring the diffusion coefficients(De, Da), plotting breakthrough curves and interpreting experiment data. The apparent and effective diffusion coefficients of HTO ranged from(1.68 ± 0.40) 9 × 10^(-11) to(2.80 ± 0.62) 9 × 10^(-11) m^2/s and from(4.61 ±1.28) 9 × 10^(-12) to (16.2 ± 2.50) 9 × 10^(-12) m^2/s, respectively.The apparent and effective diffusion coefficients of^(99)TcO_4^-ranged from(5.26 ± 0.16) 9 × 10^-12to(7.78 ± 0.43) 9× 10^-12m^2/s and from(1.49 ± 0.002) 9 × 10^(-12) to(4.16 ±0.07) 9 × 10^(-12) m^2/s, respectively. The distribution coefficients of HTO and^(99)TcO_4^-ranged from(0.70 ± 0.12) 9× 10^(-2) to(1.36 ± 0.53) 9 × 10^(-2) mL/g and from(1.12 ±0.06) 9 × 10^(-2) to(5.79 ± 2.22) 9 × 10^(-2) mL/g, respectively.The Deand Kdvalues were shown to decrease with an increase in the bulk dry density of compacted bentonite. Our results show that HTO and ^(99)Tc could be considered nonsorbent radionuclides. The data obtained in this studyprovide a valuable reference for the safety assessment of waste repositories.

Modelling of compacted graphite cast iron solidification-Discussion of microstructure parameters

A melt maintained for hours in a press pour unit allowed the following changes over time from spheroidal graphite to compacted graphite iron by casting thermal cups at regular time intervals.This provided extensive experimental information for checking the possibility of simulating solidification of compacted graphite irons by means of a microstructure modelling approach.During solidification,compacted graphite develops very much as lamellar graphite but with much less branching.On this basis,a simulation of the thermal analysis records was developed which considers solidification proceeding in a pseudo binary Fe-C system.The simulated curves were compared with the experimental ones obtained from three representative alloys that cover the whole microstructure change during the holding of the melt.The most relevant result is that the parameter describing branching capability of graphite is the most important for reproducing the minimum eutectic temperature and the recalescence which are so characteristic of the solidification of compacted graphite cast irons.

A reliable and consistent production technology for high volume compacted graphite iron castings

The demands for improved engine performance,fuel economy,durability,and lower emissions provide a continual challenge for engine designers.The use of Compacted Graphite Iron(CGI)has been established for successful high volume series production in the passenger vehicle,commercial vehicle and industrial power sectors over the last decade.The increased demand for CGI engine components provides new opportunities for the cast iron foundry industry to establish efficient and robust CGI volume production processes,in China and globally.The production window range for stable CGI is narrow and constantly moving.Therefore,any one step single addition of magnesium alloy and the inoculant cannot ensure a reliable and consistent production process for complicated CGI engine castings.The present paper introduces the SinterCast thermal analysis process control system that provides for the consistent production of CGI with low nodularity and reduced porosity,without risking the formation of flake graphite.The technology is currently being used in high volume Chinese foundry production.The Chinese foundry industry can develop complicated high demand CGI engine castings with the proper process control technology.

Saturated anisotropic hydraulic conductivity of a compacted lateritic soil

This study focuses on the saturated anisotropic hydraulic conductivity of a compacted lateritic clayey sandy soil. The effects of the molding water content and the confining stress on the anisotropic hydraulic conductivity are investigated. The hydraulic conductivity is measured with a flexible-wall permeameter. Samples are dynamically compacted into the three compaction states of a standard Proctor compaction curve： the dry branch, optimum water content and wet branch. Depending on the molding water content and confining stress, the hydraulic conductivity may increase or decrease. In addition, the results indicate that, when the samples are compacted to the optimum water content, lower hydraulic conductivity is obtained, except at a confining stress equal to 50 kPa. The increase of the confining stress decreases the hydraulic conductivity for each of the evaluated compaction states. In the wet branch, horizontal hy- draulic conductivity is about 8 times higher than the vertical value. The anisotropic hydraulic conduc- tivities of the dry and wet branches decrease when the confining stress increases, and the opposite is observed in the optimum water content state.

Some paradoxical observations about spheroidal graphite degeneracy

Differential thermal analysis experiments have been performed on samples machined from Y2-blocks cast with different high-silicon spheroidal graphite irons. Depending on magnesium, silicon, cerium and antimony content, the as-cast microstructure showed various levels of chunky graphite in the central part of the blocks. In contrast, the microstructure of the materials after remelting and resolidification during differential thermal analysis consisted of lamellar or compacted graphite. The formation of chunky graphite in the as-cast microstructure is rationalized using an index or silicon equivalent that has been recently suggested. The differences in the microstructures after differential thermal analysis are discussed in terms of available free magnesium. Emphasis is finally put on the striking differences in characteristic size of the microstructures made of compacted graphite as compared to lamellar graphite and chunky graphite. This leads to tentative conclusions about growth of compacted and chunky graphite which would be worthy of further experimental investigations.

Shear Strength Behavior of Two Landfill Clay Liners

Direct shear tests were conducted to obtain both the shear strength of compacted clay liners (CCLs) specimens and the interface shear strength between compacted clay liner and base soil. These experiments were conducted under the conditions of five different water contents. The experimental results show that shear strength of both CCLs and CCLs/base interface decreases with the increase in the water content of CCLs and base soil. In addition, the considerate concentration of NaCl in leachate has no deteriorating effect on the shear strength of liners. Triaxial shear tests were also conducted on clay liner specimens to obtain total and effective shear strength under a fast compression. The shear strength parameters with total stress are =18.5° and c =30 kPa for clay bentonite, and =48.5° and c =90 kPa for sand bentonite and those with effective stress are ’=27.2° and c’ =25 kPa for clay bentonite, and ’=35° and c ’=100 kPa for sand bentonite, respectively. These results indicate that the compacted clay bentonite shows normal consolidation, but that the compacted sand bentonite exhibits over consolidation.

Effects of mineralogy on thermo-hydro-mechanical parameters of MX80 bentonite

Thermal conductivity, water retention curve and swelling behavior of two MX80 bentonite samples were studied in the present work. The difference obtained from these two MX80 bentonite samples was then analyzed in terms of mineralogical effects （effects of the proportion of quartz and montmorillonite）. It was concluded that the mineralogical effect was significant on the thermal conductivity and the swelling capacity; on the contrary, it was negligible on the water retention property.

Mixed graphite cast iron for automotive exhaust component applications

Both spheroidal graphite iron and compacted graphite iron are used in the automotive industry. A recently proposed mixed graphite iron exhibits a microstructure between the conventional spheroidal graphite iron and compacted graphite iron. Evaluation results clearly indicate the suitability and benefits of mixed graphite iron for exhaust component applications with respect to casting, machining, mechanical, thermophysical, oxidation, and thermal fatigue properties. A new ASTM standard specification(A1095) has been created for compacted, mixed, and spheroidal graphite silicon-molybdenum iron castings. This paper attempts to outline the latest progress in mixed graphite iron published.

Iron casting skin management in no-bake mould – Effects of magnesium residual level and mould coating

The relative performance of coatings for furan resin sand moulds [P-toluol sulphonic acid(PTSA) as hardener] [FRS-PTSA moulds], was compared by analyzing the surface layer for degenerated graphite in Mg treated iron with 0.020 wt.% to 0.054 wt.% Mgres. It was found that the iron nodularising potential(Mg, Ce, La content) and whether the mould coatings contained S, or were capable of desulphurizing were important factors. These moulds have S in the PTSA binder, which aggravates graphite degeneration in the surface layer, depending strongly on the Mgres with lower Mgres increasing the layer thickness. The application of a mould coating strongly influenced graphite deterioration in the surface layer of castings. It either promoted graphite degeneration to less compact morphologies when using S-bearing coatings, or conversely, limited the surface layer thickness using desulphurization type coatings. Independently of the S-source at the metal – mould interface, the presence of sulphur had an adverse effect on graphite quality at the surface of Mg-treated irons, but its negative effect could also reach the graphite phase within the casting section. If the coatings employed desulphurization materials, such as Mg O, or a mixture(Ca O + Mg O + Talc) or Mgbearing Fe Si, they protected the graphite shape, improving graphite nodularity, at the metal – mould interface, and so decreased the average layer thickness in FRS-PTSA moulds. Fe Si Mg was highly efficient in minimizing the casting skin by improving graphite nodularity. It is presumed that the Mg O or(Mg O + Ca O + Talc) based coatings acted to remove any S released by the mould media. The Mg-Fe Si coatings also reacted with S from the mould but additionally supplemented the Mg nodularising potential prior to solidification. This dual activity is achievable with coatings containing active magnesium derived from fine Mg-Fe Si materials.

Properties of a Lateritic Red Soil for Pollutant Containment

In many regions of Brazil, lateritic clays are the natural candidates for the construction of compacted clay liners of waste disposal sites because of their availability and appropriate geotechnical characteristics. Lateritic soils have been extensively used in recent decades in dam and road construction, but little is known about the migration of pollutants through compacted layers of such soils. This paper describes the characteristics of a lateritic clay, representing a group of soils of significant occurrence in the State of S?o Paulo, to be employed in a clay liner of a waste disposal site. Laboratory tests to assess permeability, adsorption and diffusion of six metals through the compacted soil showed that permeability criterion may be met in the field, that the soil presents a modest capacity to retain cadmium and that constituent metal oxides may be dissolved from the soil grains by acidic solutions.

Effects of Wood Ash on Properties of Concrete and Flowable Fill

This research investigated the use of wood ash to partially replace cement or sand in conventional concrete, roller compacted concrete (RCC), and flowable fill. The main focus was to determine how the wood ash addition affected the main fresh and hardened properties of these materials. It was found that the wood ash could be successfully incorporated into the conventional concrete. In particular, the wood ash addition not only accelerated the setting, but also improved the early and the 28-day compressive strength of concrete that contained the blast furnace slag. It was also observed that the wood ash could be positively added into RCC to facilitate the compaction and reduce the risk of segregation. In addition, the wood ash can be beneficially introduced into the flowable fill mixtures to facilitate flow, to alleviate bleeding and subsidence, as well as to achieve controlled strength especially when combined with the class C or the class F fly ash.

Aluminium in compacted graphite iron

Compacted graphite was obtained using inmold technology.The effect of aluminium on the crystallization process,microstructure,ferrite microhardness,and hardness of compacted graphite iron was studied.The microscopic and diffraction tests were also performed,and the process of cast iron crystallization was also investigated.Results show that aluminium increases the temperature of the eutectic transformation as well as the transformation temperature in the solid state.It is found that aluminium is a graphite forming element in compacted graphite iron(CGI)at a concentration up to 2.4wt.%.When its concentration is higher than 3.1wt.%,aluminium causes the spheroidization of the carbides in eutectoid mixture.It is also demonstrated that in cast iron with an aluminium content higher than^8wt.%,AlFe3C(0.5)phase crystallizes from the liquid.