Centrifugal Casting of High Speed Steel/Nodular Cast Iron Compound Roll Collar

The centrifugal casting of compound HSS/nodular cast iron roll collar was studied,and the factors affecting transition zone quality were analyzed.The pouring temperature and interval in pouring are the main factors affecting transition zone quality.By controlling process parameter and flux adding during casting,high quality roll collar was obtained.The cause,why in the casting of HSS part,segregation appears easily,was analyzed and the countermeasure eliminating segregation was put forward,the measure eliminating heat treatment crackling was also put forward.

A study on centrifugal casting of high speed steel roll

High speed steel (HSS) rolls can replace traditional rolls such as alloyed cast iron rolls and powder metallurgical (PM) hard alloy rolls. The main reasons for the replacement are that the wear resistance of low-cost alloyed cast iron rolls is poor and the cost of high-quality PM hard alloy rolls is very high. By means of centrifugal casting, HSS rolls having excellent wear resistance have been manufactured. The hardness of the HSS roll is 6.5~67 HRC, the range of variation is smaller than 2 HRC and its impact toughness is 15 J/cm^2. The wear rate of HSS rolls used in the pre-finishing stands of high-speed hot wire-rod rolling mill reaches 2.5×10^(-4)mm per ton steel. Furthermore, the manufacturing cost of HSS rolls is significantly lower than that of PM hard alloy rolls; it is only 30 percent of that of PM hard alloy rolls.

Development of centrifugal casting high speed steel rolls

The present study aims at developing the high speed steel (HSS) as rollmaterials to replace the traditional roll materials such as the alloy cast iron and powdermetallurgical (PM) hard alloy. The HSS roll billet was formed by centrifugal casting, and the billetwas rough machined alter soften annealing heat treatment, then it was quenched and tempered to getsuitable hardness and toughness. After that the HSS roll was finish machined to the final dimensionof phi 285 mm in the outer diameter, phi 160 mm in the inner diameter and 120 mm in width and itssurface hardness was tested. Finally the HSS roll was used in high speed wire rod mill. The testresults show that a high and homogeneous hardness can obtain on the work surface of HSS rolls, thesurface hardness is 63-65HRC and its variation is smaller than 2HRC. The impact toughness of thiskind of HSS is about 16 J/cm^2. The results of on-line service investigation in high speed wire rodmill indicate that the HSS rolls have excellent wear resistance, the steel rolling quantity per mmof HSS rolls is 3120 t, the service life-span of HSS rolls is 4 times longer than that of highchromium cast iron rolls and it is close to that of the PM hard alloy rolls. The manufacturingburden of HSS rolls is obviously lower than that of the PM hard alloy rolls, it is only 25 percentof that of the PM hard alloy rolls.

Development of Centrifugal Cast High Speed Steel Roll with High Wear Resistance for Pre-Finishing Stands of a Hot Rod-Wire Mill

The present study aims at developing high speed steel (HSS) as roll materialsto replace traditional roll materials such as the alloy cast iron and powder metallurgical (PM)hard alloy, because low-cost alloy cast iron rolls have poor wear resistance and the cost ofhigh-quality PM hard alloy rolls is too high to be accepted by some users. By means of a centrifugalcasting method, HSS rolls with excellent wear resistance have been developed. Its hardness is 65-67 HRC, and its variation is smaller than 2HRC; its impact toughness excels 15J/cm^2. Usingpre-finishing stands of a high-speed hot wire-rod rolling mill, the wear rate of HSS rolls per onethousand ton of steel is 0. 25mm. However, the manufacturing burden of HSS rolls is obviously lowerthan that of PM hard alloy rolls; it is only 30% of that of PM hard alloy rolls.

Microstructural evolution and enhanced mechanical properties of Mg?Gd?Y?Zn?Zr alloy via centrifugal casting, ring-rolling and aging

A ring-shaped Mg?8.5 Gd?4 Y?1 Zn?0.4 Zr(wt%) alloy was manufactured via centrifugal casting and ring-rolling process. The effects of accumulative ring-rolling reduction amount on the microstructure, texture, and tensile properties of the alloy were investigated. The results indicate that the microstructure of centrifugal cast alloy consists of equiaxed grains and network-like eutectic structure present at grain boundaries. The ring-rolled alloy exhibits a characteristic bimodal microstructure composed of fine dynamic recrystallized(DRXed) grains with weak basal texture and coarse un-DRXed grains with strong basal texture, along with the presence of LPSO phase. With increasing amount of accumulative ring-rolling reduction, the coarse un-DRXed grains are refined via the formation of increasing amount of fine DRXed grains. Meanwhile, the dynamic precipitation of Mg5 RE phase occurs, generating a dispersion strengthening effect. A superior combination of strength and ductility is achieved in the ring-rolled alloy after an accumulative rolling reduction of 80%. The tensile strength of this ring-rolled alloy after peak aging is further enhanced, reaching 511 MPa, while keeping a reasonable ductility. The salient strengthening mechanisms identified include the grain boundary strengthening of fine DRXed grains, dispersion strengthening of dynamic precipitated Mg;RE phase, short fiber strengthening of LPSO lamellae/rods, and precipitation strengthening of nano-sized prismatic β precipitates and basal γ precipitates.

Microstructure and Property of Hypereutectic High Chromium Cast Iron Prepared by Slope Cooling Body-Centrifugal Casting Method

In this paper, the ring-type ingot of hypereutectic high Cr cast iron was obtained by slope cooling bodycentrifugal casting method （SC-CCM）, and its microstructure and impact toughness were investigated, respectively. The results indicated that, first, the primary carbides in the microstructure are prominently finer than those in the hypereutectic high Cr cast iron prepared by conventional casting method. Second, in the ring-type ingot, the primary carbides near radial outer field are finer than those near radial inner field; furthermore, there is dividing field in the microstructure. Finally, the impact toughness values of the specimens impacted on the radial outer face and on the radial inner face are improved respectively about 36% and 138% more than that of the hypereutectic high Cr one prepared by conventional casting method.

Analysis of High-Cr Cast Iron/Low Carbon Steel Wear-resistant Laminated Composite Plate Prepared by Hot-rolled Symmetrical Billet

This study developed a new technology for preparing high-chromium cast iron(HCCI)/low-carbon steel(LCS)wear-resistant composite plates by hot rolling at a 1050°C and a rolling speed of 0.2 m/s.The effects of different rolling reductions(30%,45%,and 60%)on the microstructure(interface and HCCI layer)and mechanical properties(bonding strength,hardness,and wear resistance)of the composite plate were studied.SEM images showed that when the reduction was increased,no impurities and interlayers were found between the microscopic interfaces after hot rolling,and the bonding interface exhibited a wave-like shape.EDS analysis showed that the Cr element diffusion between two metals after hot rolling was promoted when the reduction was increased,thereby improving the bonding quality under the same rolling temperature and rolling speed.Experiments showed that due to the stress release effect of the LCS of the cladded layer,the macro-slab shape after hot rolling performed well,and the brittle HCCI layer underwent thermoplastic deformation without cracking.Moreover,the increase of rolling reduction improved the bonding quality.As the rolling reduction was increased,the volume fraction of Cr-carbides in the HCCI layer also increased,resulting in an increase of hardness and wear-resistance.

Effect of Rolling Process on Microstructure and Wear Properties of High Carbon Equivalent Gray Cast Iron

Rolling process based on the plastic deformation as a surface strengthening treatment was employed,aiming to improve the wear resistance ability and functional performance of the high carbon equivalent gray cast iron(HCEGCI).The microstructures and tribological performance of the untreated and rolled samples were characterized.In addition,the wear mechanism of HCEGCI samples was also studied via pin-on-disc tests.The experimental results show that the as-rolled samples possess the structure-refined layer of 15μm and work-hardened layer of 0.13 mm.In comparison with the surface hardness of untreated samples,the surface hardness of as-rolled samples increases by 84.6%(from 240HV0.1 to 443HV0.1)and the residual compressive stresses existed within the range of 0.2 mm.The wear rates of as-rolled samples were decreased by 38.4%,37.5%,and 44.4%under different loads of 5 N,10 N,and 15 N,respectively.The wear characteristics of the untreated samples mainly exhibit the peeling wear coupled with partial adhesive and abrasive wear.However,as for the as-rolled samples,the adhesive wear was limited by the structure-refined layer and the micro-crack propagation was controlled by the work-hardened layer.Therefore,the wear resistance of as-rolled samples can be improved significantly due to the low wearing degree of the friction contact zone.

Chemical Compositions,Microstructure and Mechanical Properties of Roll Core used Ductile Iron in Centrifugal Casting Composite Rolls

The industrial manufacture processes of three kinds of roll core used ductile irons have been investigated via systematical experiments. EfFects of the ratio of C/Si, pig iron, nodularizer and alloying method on the microstructure and mechanical properties of the heavy section ductile iron have been analyzed. It has been found that when treated with RE-Mg plus Sb, high quality nodular castings can be produced even if much anti spheroidizing alloy elements are included in the pig iron. The alloy element Sb played an important role in the control of graphite morphology.

Effect of Cryogenic Treatment on Property of 14Cr2Mn2V High Chromium Cast Iron Subjected to Subcritical Treatment

Effect of cryogenic treatment on the microstructure, hardening behavior and abrasion resistance of 14Cr2Mn2V high chromium cast iron （HCCI） subjected to subcritical treatment was investigated. The results show that cryogenic treatment after subcritical treatment can obviously improve the hardness and abrasion resistance of HCCI because abundant retained austenite is transformed into martensite and fine secondary carbides E（Fe, Cr）23 C6 ] precipitate. The amount of martensite and precipitated secondary carbide in HCCI experiencing subcritical treatment followed by cryogenic treatment was more than that experiencing the subcritical treatment followed by air cooling. When the abrasion resistance of HCCI reaches the maximum, its microstructure contains about 15 % retained austenite. Cryogenic treatment can further reduce the austenite content but the retained austenite cannot be transformed in to martensite completely.

Effects of Rare Earths and Al on Structure and Performance of High Chromium Cast Iron Containing Wolfram

Effects of RE and Al on the structure, impact toughness, hardness, and wear resistance of high chromium cast iron containing wolfram were investigated. The results show that without modification the volume fraction of austenite is high and the carbide appears to be thick lath and the grain size is relatively large; proper modification using RE combined with Al can reduce volume fraction of residual austenite in the as-cast structure obviously, refine grain size of primary austenite notably, and make the morphology of carbide changing from thick lath to thin lath, rosette, and feather-like modification can also increase hardness, wear resistance and impact toughness of cast iron.

Effect of Ti-V-Nb-Mo addition on microstructure of high chromium cast iron

The effects of trace additions of multi-alloying elements （Ti, Nb, V, Mo） on carbides precipitation and ascast microstructure of eutectic high chromium cast iron containing 2.85wt.%C and 31.0wt.%Cr were investigated from thermodynamic and kinetic considerations. The thermodynamic calculations show that Ti and Nb exist in the multi-alloying system in the forms of TiC and NbC. The formation of VC during the solidification is not feasible from the thermodynamic consideration. XRD analysis shows that the V exists in alloy compounds （VCr2C2, VCrFes）. The first precipitated high melting point particles （TIC, NbC） can act as the heterogeneous substrate of M7C3 carbides, which results in significant refinement of the M7C3 carbides. After the addition of alloying elements, C atom diffusion is hindered due to the strong affinities of the strong carbide forming elements for carbon, which decreases the growth rate of carbides. The combined roles of the increase of nucleation rate and the decrease of carbides growth rate lead to the finer microstructure.

Microstructure and wear resistance of highchromium cast iron containing niobium

In the paper, the effect of niobium addition on the microstructure, mechanical properties and wear resistance of high chromium cast iron has been studied. The results show that the microstructure of the heattreated alloys is composed of M7C3 and M23C6 types primary carbide, eutectic carbide, secondary carbide and a matrix of martensite and retained austenite. NbC particles appear both inside and on the edge of the primary carbides. The hardness of the studied alloys maintains around 66 HRC, not significantly affected by the Nb content within the selected range of 0.48%-0.74%. The impact toughness of the alloys increases with increasing niobium content. The wear resistance of the specimens presents little variation in spite of the increase of Nb content under a light load of 40 N. However, when heavier loads of 70 and 100 N are applied, the wear resistance increases with increasing Nb content.

Effect of vibration frequency on microstructure and performance of high chromium cast iron prepared by lost foam casting

In the present research, high chromium cast irons(HCCIs) were prepared using the lost foam casting(LFC) process. To improve the wear resistance of the high chromium cast irons(HCCIs), mechanical vibration was employed during the solidification of the HCCIs. The effects of vibration frequency on the microstructure and performance of the HCCIs under as-cast, as-quenched and as-tempered conditions were investigated. The results indicated that the microstructures of the LFC-produced HCCIs were refined due to the introduction of mechanical vibration, and the hardness was improved compared to that of the alloy without vibration. However, only a slight improvement in hardness was found in spite of the increase of vibration frequency. In contrast, the impact toughness of the as-tempered HCCIs increased with an increase in the vibration frequency. In addition, the wear resistance of the HCCIs was improved as a result of the introduction of vibration and increased with an increase in the vibration frequency.

Use of electron microscopy on microstructure characterization of high chromium cast irons

The physical metallurgy underlying the development of cast microstructures in abrasion resistant high chromium cast irons, and their structural modification by thermal treatments is relatively complex. Structural characterisation via electron microscopy therefore has a key role to play in furthering our understanding of the phase transformations that control the microstructures and hence the service performances of these irons as wear parts. This paper shows how both scanning and especially transmission electron microscopy can provide valuable information on the nature of eutectic and secondary carbides and on the matrix structures in these irons. Particular attention is given to current characterisation research on conventionally cast 30%Cr irons that are used for applications involving corrosive wear e.g. slurry pumps and on a semi-solid cast 27%Cr iron that has a potential for applications in industry.

SPHERICAL MICROSTRUCTURE FORMATION OF THE SEMI-SOLID HIGH CHROMIUM CAST IRON Cr20Mo2

The nondendritic semi-solid slurry preparation of high chromium cast iron Cr20Mo2 has been studied in this paper. The experiments show that the proeutectic austenitic particles are more spherical under a larger stirring power condition, even if the stirring time is shorter, while the proeutectic austenitic particles are not very much spherical under a smaller stirring power condition and some proeutectic austenitic dendrites also exist, even if the stirring time is very long. The experiments also show that when stirred for 5-6 minutes under the test condition, the semi-solid slurry with 40vol.%-50vol.% solid fraction and spherical proeutectic austenite in the size of 50-80μm can be obtained.

Effect of surface Cr/C infiltration on microstructure,mechanical properties and wear resistance of high chromium cast iron

A new type of high chromium cast iron(HCCI)was prepared,and its microstructure,mechanical properties,and abrasion resistance were investigated systematically.Results showed that after surface carburizing and chromizing,the microstructure of HCCI mainly consists of martensite,boride(M_(2)B),and carbide(M_(7)C_(3)),accompanied with a large amount of secondary precipitations M_(23)C_(6).Moreover,the morphology and hardness of the carbide and boride in HCCI change little,while the volume fraction of carbide and boride increases from 16.23%to 23.16%.This effectively increases the surface hardness of HCCI from 64.53±0.50 HRC to 66.58±0.50 HRC,with the result that the surface of HCCI possesses a better abrasion resistance compared to the center position.Furthermore,the wear mechanism of HCCI changes from micro-plowing to micro-cutting with the increase of surface hardness.

STUDY ON THE STRUCTURE AND PROPERTIES OF HIGH CHROMIUM WHITE CAST IRON AND ITS TEMPERING STANDARD

The structure and properties of high chromium white cast iron in different treatment states were studied. Using X ray diffraction method, observing their metallograph and measuring their microhardness, the phases involved in the iron were determined. The notch toughness, macrohardness and the fractograph of the samples are compared and their performance was determined, which mainly depends on the matrix structure. Relatively good comprehensive properties can be obtained in the tempering state. Improvements have been made on the commonly used tempering standard. Tempering for a short period at low temperature can improve the materials′ service performance obviously.

Effects of RE,V,Ti and B composite modification on the microstructure and properties of high chromium cast iron containing 3% molybdenum

The effects of RE, V, Ti and B on the microstructure and properties of high chromium cast iron containing 3% molybdenum under as-cast and heat treatment conditions were investigated with the method of comparing experiments. The results show that with the increase of RE content, the primary austenite of high chromium cast iron is obviously refined. The morphology of carbide is changed from netlike and lath to small multiangular isolated blocks or massive blocks, the isolated degree of carbide is improved obviously, and the size is significantly refined. The addition of V and B into high chromium cast iron can refine the microstmcture, reduce coarse columnar crystals and make the carbide smaller and uniform. Through composite modification with RE, V, Ti and B, the hardness, wear resistance and impact toughness of high chromium cast iron are increased conspicuously. After heat treatment, the hardness of high chromium iron is increased significantly, but the toughness and wear resistance do not show great improvement.

Effect of Manganese on As-Cast Microstructure and Hardening Behavior of High Chromium White Cast Iron

The effect of manganese on the as-cast structure and hardening behavior of high chromium white cast iron subjected to sub-critical treatment was studied.The results indicate that the fraction of retained austenite and the manganese distribution in as-cast alloys are controlled by manganese content.The manganese distribution in as-cast alloys is not homogeneous.The manganese content in carbide is higher than that in matrix.Whether the secondary hardening occurs or not and the peak hardness of secondary hardening is controlled by manganese content in retained austenite in as-cast structure.Higher manganese content can cause more retained austenite.The secondary hardening occurs in sub-critical treating process if the fraction of retained austenite is high.