Oil quenched malleable iron,the strength of an old material in a “green cast” development and a new future

Malleable iron lost the interest and the development stopped in the turbulent seventies of tremendous developments of new technologies. The personal computer, emission spectrometer, thermal analysis, cold-box core system and automatic vertical moulding were introduced into the foundry industry. Experience shows that these new technologies do not always match up with malleable iron. Solidifciation and mould filling simulation programs are not always capable to handle a low carbon equivalent iron like malleable iron. Recent developments show however by using these new technologies and combined with practical experience, it is possible to increase the casting yield of malleable iron to the same level as ductile iron. The mechanical properties, especially the yield strength of malleable iron according to the standard are equivalent to those of ductile iron, however the yield strength of oil quenched malleable iron is signifciantly higher than that of ductile iron. An extensive investigation is made between ductile iron, air quenched and oil quenched malleable irons based on the properties of more than 350 test bars produced under the same conditions. The results are compared with the existing international standards and discussed. Other properties like fatigue strength and response to surface treatments as induction hardening are also discussed. The costs of malleable iron are reviewed and compared with other ferro alloys. These recent developments in increasing the casting yield, the understanding of the strength, makes malleable iron competitive with ductile iron and cheaper than the first grade of ausferritic ductile iron, or steel qualities. It is possible to design lighter and save weight which is essential in the automotive industry. An example of "green cast" development for typical applications, used in automotive transmissions and engines are shown.

A Mn-Series of Oil-Quenched Super-Strength Bainitic Steel With High Hardenability

A new Mn-series of oil-quenched super-strength bainitic steel was developed on the basis of the alloy system of the original Mn-series air cooled bainitic steel. The mechanical properties of the new steel are well combined while precious alloy elements and complicated technologies are not needed for its production. Experimental results show that bainite/martensite （B/M） dual phase microstructure can be obtained within a very wide cooling rate range and bainite microstructure exists even when the cooling rate reaches as fast as 60 ℃/s; the hardenability of the steel is better than that of 40CrNiMo and 42CrMo; the diameter of the round bar made of the steel is 250 mm, and the round bar tempered at 350 ℃ after oil quenching exhihits its central mechanical properties as follows： Rm = 1 550 MPa, Rp0.2 = 1 270 MPa, A=15%, aku=95 J/cm^2 （at room temperature）.