Eutectic solidification mode of spheroidal graphite cast iron and graphitization

The shrinkage and chilling tendency of spheroidal graphite (abbreviated SG) cast iron is much greater than that of the flake graphite cast iron in spite of its higher amount of C and Si contents. Why? The main reason should be the difference in their graphitization during the eutectic solidification. In this paper, we discuss the difference in the solidification mechanism of both cast irons for solving these problems using unidirectional solidification and the cooling curves of the spheroidal graphite cast iron. The eutectic solidification rate of the SG cast iron is controlled by the diffusion of carbon through the austenite shell, and the final thickness is 1.4 times the radius of the SG, therefore, the reduction of the SG size, namely, the increase in the number, is the main solution of these problems.

Influence of boron on ferrite formation in copper-added spheroidal graphite cast iron

This paper reviews the original work of the authors published recently,describing the influence of B on the matrix of the Cuadded spheroidal graphite cast iron.The effect of Cu has been corrected as a ferrite formation promoter in the matrix of the grey cast iron by the usage of high-purity material.Also,this paper focuses on the ferrite formation and the observation of the Cu distribution in the B-added and B-free Cu-containing spheroidal graphite cast iron.The Cu film on the spheroidal graphite can be successfully observed in the B-free sample using a special etching method.However,in the B-added sample,no Cu film could be found,while the secondary graphite was formed on the surface of the spheroidal graphite.The interaction between B and Cu is stressed as a peculiar phenomenon by the employment of a contrast experiment of B and Mn.The heat treatment could make Cu precipitate more significantly in the eutectic cells and in the matrix in the form of large Cu particles because of the limited solubility of Cu.

Shrinkage Behaviour of Spheroidal Graphite Cast Iron in Green and Dry Sand Molds for the Benchmarking of Solidification Simulation

The effects of metallurgical and processing parameters on the formation of shrinkage cavities and porosities in spheroidal graphite cast iron have been studied, considering the parameters of carbon equivalent, inoculation, casting modulus, mold type (green or dry) and pouring temperature within specific ranges of these variables. Based on the orthogonal experiments, the metallurgical and processing parameters of the minimum casting shrinkage and the maximum casting shrinkage were obtained, and the effects of metallurgical and processing parameters on the formation of shrinkage cavities and porosities in spheroids graphite cast iron castings were discussed. Finally, two regression equations relating these variables to the formation of shrinkage porosity were derived based upon the orthogonal experiments conducted.

FORMATION OF AUSTENITE SHELL AROUND SPHEROIDAL GRAPHITE AND ITS EFFECT ON DETERIORATION OF GRAPHITE

To study the growth of austenitic shells around the spheroidal graphite,color metallography has been employed.It is found that the shell is not a continuous layer of austenite,but a clus- ter of wedge-shaped crystals.Three types of shells have been observed.That may strongly af- fect the deterioration of the spheroidal graphite.The mechanism of the formation of the austenitic shells has also been discussed.

Numerical simulation of microstructure evolution on near eutectic spheroidal graphite cast iron

A multiphase cellular automaton model was developed to simulate microstructure evolution of near eutectic spheroidal graphite cast iron(SGI) during its solidification process, and both dendritic austenite and spheroidal graphite growth models were adopted. To deduce the mesh anisotropy of cellular automaton method, the composition averaging and geometrical parameter were introduced to simulate the spheroidal graphite growth. Solute balance method and decentered square algorithms were employed to simulate austenite dendrites growth with different crystallographic orientations. The simulated results indicate that the graphite nodule grows in a spherical morphology when the surrounding environment of a single graphite nodule is same. However, for two adjacent graphite nodules, the environment is different. The higher the carbon concentration, the faster the growth of graphite. By comparison with experimental results, it is found that the microstructure evolution of near eutectic spheroidal graphite cast iron during solidification process can be reproduced quantitatively by numerical simulation with this model.

Cerium Distribution in Spheroidal Graphite of Cast Iron

Six thin sections of spheroidal graphites in cast iron have been investigated by TEM and SEM.The spheroidal graphites consist of two or three layers and have nuclei which are composed of Ce_2O_2S and Ce_2O_3. Cerium is existed ont only in nuclei,but also in central layer and middle layer of graphite.

Numerical Simulation of Shrinkage Cavity Formation in Spheroidal Graphite Iron Castings Based on Micro Modeling

A micro-modeling method (MM) for the quantitative prediction of the shrinkage cavity formation in SGiron castings is proposed. The mathematical models describing the volume changes during the solidification ofspheroidal graphite cast iron are established based on the models of solidification kinetics. The shrinkage cavityformation of T-shaped SG iron castings is calculated with MM method. The calculated results are compared with theexperimental results. It is shown that the predicted size, shape and distribution of shrinkage cavity by MM methodare in good agreement with the measured results.

Wear Behavior and Mechanism of Spheroidal Graphite Cast Iron

Wear behavior and mechanism of spheroidal graphite cast iron were studied on a pin on-disk elevated tem- perature wear tester. The phase and morphology of worn surfaces were examined by X ray diffraction and scanning electron microscopy. Results show that with an increase of load, wear rate of spheroidal graphite cast iron gradually increases under low loads, rapidly increases or potentially increases under high loads; wear rate increases with in- creasing ambient temperature. At 25 200 ℃, adhesive wear prevails; oxidative wear and adhesive wear coexist at 400 ℃. As load surpasses 150 N at 400 ℃, extrusive wear appears. The elevated-temperature wear of spheroidal graphite cast iron is a physical and chemical process including the following reactions： xFe＋y/2O2-FexOy , 2C＋ O2- 2CO and Fex Oy ＋yCO-xFe＋yCO2. Hence, at 400 ℃, the amount of graphite and tribo oxides are substan- tially reduced because of reductive function of graphite. It can be suggested that wear reduced effect of graphite and tribo-oxides is impaired.

High temperature oxidation of inoculated high Si/SiMo ductile cast irons in air and combustion atmospheres

The present work aims to investigate the effect of heating temperature(400,600 and 800°C)and inoculating elements(Ca,Ca-Ba,Ca-RE)on oxidation behavior of ductile irons containing 5.25%Si and 4.8%Si-2.3%Mo in dry air and combustion gas containing water vapour(natural gas burning).The oxidation is influenced by the gas atmosphere type,the iron alloying system,and the inoculating elements depending on the heating temperature.The weight gain increases from 0.001%-0.1%(400°C)to 0.05%-0.70%(600°C)and up to 0.10%-2.15%(800°C).No particular effects of the considered influencing factors are found when heating at 400°C,while at 600°C,mainly the oxidation gas atmosphere type shows a visible influence.At the highest heating temperature of 800°C,a limited increase of the weight gain is found for dry air atmosphere(up to 0.25%),but it drastically increases for combustion atmospheres(0.65%-2.15%).The water vapour presence in the combustion atmosphere is an important oxidising factor at 600-800°C.The alloying system appears to influence the oxidation behavior mainly at a heating temperature of 800°C in the combustion atmosphere,as evidenced by the lower weight gain in 5.25%silicon cast iron.Positive effects of inoculating elements increase with the heating temperature,with Ca and Ba-FeSi inoculation generally showing better performance.Irons inoculated with CaRE-FeSi exhibit a higher degree of oxidation.These results are in good relationship with the previous reported data:Ca-Ba-inoculation system appears to be better than simple Ca for improving the graphite parameters,while RE-bearing inoculant negatively affects the compactness degree of graphite particles in high-Si ductile irons.As the lower compactness degree is typical for graphite nodules in high-Si ductile irons,which negatively affects the oxidation resistance,it is necessary to employ specific metallurgical treatments to improve nodule quality.Inoculation,in particular,is a potential method to achieve this improvement.

Formation Mechanism of Chunky Graphite and Its Preventive Measures

The formation mechanism of chunky graphite has been reviewed and studied. The study consisted of a unidirectional solidification method, a small droplet method and a furnace cooling method. Four kinds of iron samples were prepared, namely, the pure Fe-C, Fe-C-S, Fe-C-Ce and Fe-C-Si-Ce alloys, and three kinds of nickel samples, namely the Ni-C, Ni-C-S and Ni-C-Mg alloys. The results of the unidirectional solidification of the Ni-C alloys showed that spheroidal graphite is not observed in the continuous solidified region, in which only flake-like graphite is observed, while spheroidal graphite is usually observed in the quenched liquid region. The existence of spheroidal graphite in the solidified phase is recognized only in the discontinuous growth mode of the Ni-C-Mg alloy solidified at 150 mm/h. This means that the spheroidal graphite is directly crystallized from the melt and entrapped by the flake-like chunky graphite that is formed by the continuous growth mode. In the small droplet method, a small piece of the Fe-C or Fe-C-Ce sample was melted on a pure graphite plate then cooled at a different cooling rate in a He-3%H2 atmosphere. The graphite in the Fe-C-Ce alloy is usually spherical. Nevertheless, the graphite morphology of the final solidified area changed from spherical to chunky and chunky to ledeburite with an increase in the cooling rate. This means that the chunky graphite is formed in the residual liquid region by the solidification into Fe-graphite system. The sample was cooled in a furnace, and the graphite morphology changes from spherical to chunky and chunky to ledeburite with the decrease in the Si content. These phenomena can be confirmed by the cooling curves of these samples.

Influence of Si,Ce,Sb and Sn on chunky graphite formation

The thirteen mother alloys,C%+1/3Si%=4.45%,differing in their Si,Ce,Sb and Sn contents,were prepared.Seventy grams of these alloys was remelted in a high purity alumina crucible at 1,450oC under an Ar atmosphere,and then cooled at 30 K/min for obtaining their cooling curves.Their graphite morphologies were observed using an optical microscope and an SEM.Their three-dimensional graphite shapes were observed by the SEM using the samples whose matrices were etched off with an acid-aqua solution,to confirm the chunky graphite.For discussing the influence of the Si and Ce contents on the chunky graphite formation,two experiments were carried out.In the first one,the Si contents were changed from 0 to 4% in the 0.15%Ce alloys,and for the second one,the 3.5%Si and 4%Si samples that differed in the Ce contents of 0.1 and 0.2% were used.In the third experiment,the influence of Sb and Sn on the chunky graphite formation was investigated by using the 4%Si and 0.1%Ce samples.The results showed that with the increase of the Si content,the volume fraction of the chunky graphite increases,while the volume fraction of the ledeburite decreases,and the chunky graphite volume fraction in the 0.2%Ce samples is higher than that of the 0.1%Ce samples.The effect of the Sb and Sn additions on the prevention of chunky graphite formation cannot be confirmed due to their high Si contents.Therefore,further studies will be needed in this field.

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.