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.

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.

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.

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.

Pressure evolution in shock-compacted granular media

The pressure evolution associated with the transient shock-induced infiltration of gas flow through granular media consisting of mobile particles is numerically investigated using a coupled Eulerian–Lagrangian approach.The coupling between shock compaction and interstitial flow has been revealed.A distinctive two-stage diffusing pressure field with deflection occurring at the tail of the compaction front is found,with corresponding spikes in both gaseous velocity and temperature profiles emerging within the width of the compaction front.The compaction front,together with the deflection pressure,reaches a steady state during the later period.An analytical prediction of the steady deflection pressure that considers the contributions of porosity and the non-isothermal effect is proposed.The isothermal single-phase method we developed,combining the porosity jump condition across the compaction front,shows consistent pressure evolution with the non-isothermal CMP-PIC one under weak shock strength and low column permeability.Lastly,the microscale mechanism governing the formation of not only pressure deflection but also gaseous velocity and temperature spikes within the width of the compaction front has been described.These aforementioned evolutions of the flow field are shown to arise from the nozzling effects associated with the particle-scale variations in the volume fraction.

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.

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.

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.

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.

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.

Experimental study on the dynamic modulus of compacted loess under bidirectional dynamic load

The dynamic characteristics of compacted loess are of great significance to the seismic construction of the Loess Plateau area in Northwest China,where earthquakes frequently occur.To study the change in the dynamic modulus of the foundation soil under the combined action of vertical and horizontal earthquakes,a hollow cy-lindrical torsion shear instrument capable of vibrating in four directions was used to perform two-way coupling of compression and torsion of Xi'an compacted loess under different dry density and deviator stress ratios.The results show that increasing the dry density can improve the initial dynamic compression modulus and initial dynamic shear modulus of compacted loess.With an increase in the deviator stress ratio,the initial dynamic compression modulus increases,to a certain extent,but the initial dynamic shear modulus decreases slightly.The dynamic modulus gradually decreases with the development of dynamic strain and tends to be stable,and the dynamic modulus that reaches the same strain increases with an increasing dry density.At the initial stage of dynamic loading,the attenuation of the dynamic shear modulus with the strain development is faster than that of the dynamic compression modulus.Compared with previous research results,it is determined that the dynamic modulus of loess under bidirectional dynamic loading is lower and the attenuation rate is faster than that under single-direction dynamic loading.The deviator stress ratio has a more obvious effect on the dynamic compression modulus.The increase in the deviator stress ratio can increase the dynamic compression modulus,to a certain extent.However,the deviator stress ratio has almost no effect on the dynamic shear modulus,and can therefore be ignored.

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.

Structural,volumetric and water retention behaviors of a compacted clay upon saline intrusion and freeze-thaw cycles

This study investigates the evolution of the structural,volumetric and water retention behaviors of a compacted clay during soaking and desiccation considering the influences of freeze-thaw(FT)cycles and saline intrusion.Compacted specimens were subjected to different FT cycles and then submerged in NaCl solution with different concentrations to facilitate the saline intrusion and measure the swelling behaviors.Shrinkage curve and filter paper tests were thereafter performed to reveal the clay’s volumetric and water-retention characteristics during desiccation.Mercury intrusion porosimetry and field emission scanning electron microscopy tests were conducted to observe the evolution of the clay’s microstructure.Experimental results show that the clay’s micropores decrease and macropores increase after FT cycles,which is associated with the migration of water,growth of ice crystals,and development of FT-induced cracks during FT cycles.Similar observations were obtained from specimens after the saline intrusion,which is attributed to the osmotic and osmotically-induced consolidation.FT-induced cracks significantly reduce the clay’s swelling and shrinkage potentials.FT cycles result in the shrinkage of micropores which leads to a reduction in the water retention capacity in the low suction range(capillary regime).The salinization suppresses the swelling of the clay and prolongs its primary and secondary swelling stages.The shrinkage potential initially increases and then decreases with increasing saline concentration.Salinization has significant influences on the osmotic suction and thus alters the clay’s water-retention curves in terms of total suction.It demonstrates little impact on the clay’s water-retention curves in terms of matric suction.

Study on the Themal Conductivity of Compacted Buffer/Backfill Materials

The thermal property is one of the key properties for the design of the high-level radioactive waste (HLW) repository. In this study, the thermal properties transient automatic tester (HPP-F) is uesd to study the thermal conductivity of multiphase composite buffer/backfill material including the type B-Z and B-Z-P (Here B、Z、P represents bentonite、zeolite and pyrite respectively,the same as in the following.) in different dry density and moisture conditions. The results show that for the same moisture content (dry density), thermal conductivity of specimens increases as the dry density (moisture content) increases. As a result, the type B-Z-P which is highly compacted of 1.8 g/cm3 in dry density and 17.65% in moisture content performs well, it meets the requirements of the IAEA and is easy to be compacted ,so it can be recommend as a alternative material of high level radioactive waste disposal repository buffer/backfilling materials.

STUDY ON NODULE RATIO AND COMPACTED GRAPHITE RATIO OF IRON FLUID TREATED BY RARE EARTH MAGNESIUM ALLOY QUICKLY EXAMINED BY CONCENTRATED DIFFERENCE FIXING OXYGEN

The article uses the method of regression statistics to obtain the regression formula of iron fluid nodule ratio Q and compacted graphite ratio R, through rare earth magnesium treatment. At the same time it has given thejudging figure of Q and R, considering oxygen activity and temperature. When using oxygen activity to judgenodule ratio and compacted graphite ratio of the ironfluid treated by rare earth magnesium alloy, its limit value changes with the change of temperature.

The coupled hydro-mechanical behaviours of compacted crushed Callovo-Oxfordian argillite

Callovo-Oxfordian （COx） argillite obtained from the excavation of high-level radioactive waste geological disposal has been evaluated as an alternative sealing/backfill material in France. This paper presents an experimental investigation into the hydro-mechanical behaviour of compacted crushed COx argillite. A series of oedorneter compressive tests including various loading-unloading cycles were conducted on COx argillite powders at different initial water contents. After reaching the desired dry density （2.0 Mg/m^3）, the vertical stress was reduced to different levels （7.0 and 0.5 MPa） and the compacted sample was then flooded under constant volume conditions while measuring the changes in the vertical stress. It was found that the initial water content significantly affects the compressive behaviour. The measured saturated hydraulic conductivity is less than 1×10^-10m/s.

Study on Improvement of Dumping Site Stability in Weak Geological Condition by Using Compacted Layer

Berau Basin, a sub-basin of Tarakan Basin, had been developed during Eocene to Miocene period. Rocks in Berau Basin consist of sedimentary, volcanic and igneous rocks aged from Pre-tertiary until Quaternary epoch. The youngest identified rock formation was alluvial deposit consists of mud, silt, sand, gravel and swamp with brown to dark color. This youngest rock formation is relatively weak geological condition and can cause problems in the coal mining operation. PT Berau Coal as one of the coal mining companies in Berau Basin area had experienced some problems related to the occurrence of alluvial deposit. A large failure has occurred at one of its out pit dumping?area which lies over the swamp material. The failure caused a higher operating cost since it made that the distance for waste rock dumping became to be farther than the designated area. Therefore, in order to prevent similar failure occurring at dumping area which lies above swamp material, an improvement of dumping site stability on weak geological condition has to be needed. The proposed method for improving the stability of out pit dumping area in weak geological condition is to construct the compacted layer of waste rock before the out pit dumping area construction. Based on experimental results, a minimum of 40 kPa pressure is needed to give a proper compaction to the waste rock. The result of numerical analysis by Finite Element Method (FEM) shows that construction of compacted layer on the base of out pit dumping area can improve its stability.

Comparison of in situ Shear Test and In-Lab Triaxial Shear Test of Compacted Rockfill

The in situ shear test and in-lab triaxial shear test on compacted rockfill of Fuling safety embankment were carried out and their advantages and disadvantages were compared. The discreteness of cohesive force C and internal frictional angle by in situ shear test is much severer than that by in-lab triaxial shear test. The consolidation of in-lab triaxial shear test is bigger than actual consolidation in rockfill engineerings, so the confining pressure should be reduced to a low level in-lab triaxial shear test.

Suitability of Irbid Clay as Compacted Liners for Landfill, Jordan

The goal of this study is to investigate the possibility of using the Irbid city clayey soil as compacted clay liner. The geotechnical properties and the permeability characteristics of compacted clayey soil sample obtained from the eastern part of Irbid city were determined to evaluate their suitability as compacted clay liner. Falling head permeability test, unconfined compressive strength and volumetric shrinkage test were conducted on soil samples that were compacted at about 0% and 3% wet of its optimum water content. The leakage rates expected through clay-only and composite geomembrane-clay liners were determined. It could be concluded based on the results of the geotechnical tests and leachate rate calculations that Irbid clay is appropriate to be used as compacted landfill liner material.