solution strengthened ferritic spheroidal graphite cast ... stets.pdf · -3-ifg - institut für...

- 1 -IfG - Institut für Gießereitechnik

- 1 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Dr.-Ing. Wolfram Stets; Dr.-Ing. Herbert Löblich;

Prof. Dr.-Ing. Peter Schumacher; Dr. Gert Gassner

Solution strengthened ferritic spheroidal graphite cast iron according DIN EN 1563:

2012-03- Production, properties and application

- 2 -IfG - Institut für Gießereitechnik

- 2 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Economic efficiency

Product quality

Process stability

Materials properties

Qualified employees

Environmental protection and health & safety

…..Single – source consultancy and research

IfG – Institut für GießereitechnikThe branch institute of the German foundry industry

- 3 -IfG - Institut für Gießereitechnik

- 3 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

The revised standard DIN EN 1563 includes three new cast iron grades:

EN-GJS-450-18

EN-GJS-500-14

EN-GJS-600-10

EN-GJS- 450-18 500-14 600-10

Rm [N/mm2]

min.450 500 600

Rp0,2 [N/mm2]

min.350 (310) 400 (320) 470 (370)

A [%] min. 18 (10) 14 (7) 10 (3)

Material

Values in brackets: comparable grades of the conventional GJS

Initial situation

- 4 -IfG - Institut für Gießereitechnik

- 4 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Si contents between 3 and 4,3 % cause a solution strengthened 100 % ferrite microstructure with high

mechanical properties

The pearlite generating elements

Mn, Cu, Sn

in the conventional alloys determine the pearlite / ferrite ratio and the mechanical properties.

EN GJS-600-3

EN GJS-600-10

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- 5 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Contents of the project

• Static Mechanical properties in dependence on the Silicon content

• Influence of carbide and pearlite generating elements (Mn, Cr, V) on the static mechanical properties

• Cast technological properties of high Silicon ductile iron

• Influence of inoculation on microstructure in dependence on the wall thickness

• Investigation of the machinability of high Silicon ductile iron

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- 6 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Production of several cast samples for the materials investigation

Radial sample

Y2 sample

Y4 sample

Wedge samples

Samples for shrinkage testing

1) Static mechanical properties

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- 7 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Rm and Rp0,2 pass through a maximum in dependence on the Si content

Massenprozent Silicium

Rm

[Mpa

]

Y-2Y-4

2 3 4 5 60

100200

300400500600700

4,3%

Si

Separate cast Y-samples

[MP

a]

Mass% Silicon

- 8 -IfG - Institut für Gießereitechnik

- 8 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Massenprozent Silicium

Bru

chde

hnun

g [%

]Y-2Y-4

2 3 4 5 60

5

10

15

20

25

30

In the neighbourhood of 4,3 % Si the elongation is decrasing

4,3%

Si

Separate cast Y-samples

Mass% Silicon

Elo

ngat

ion

[%]

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- 9 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Mass% Silicon

HB

Har

dnes

s

Continous course of the hardness in dependence on Si content

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- 10 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

[MP

a]

No influence of the added elements on the tensile strength

2) Influence of carbide and pearlite generating elements on the static mechanical properties.

Added elementsNon

- 11 -IfG - Institut für Gießereitechnik

- 11 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

4,3%

Si

[MP

a]

No influence of the added elements on the yield strength

Added elementsNon

- 12 -IfG - Institut für Gießereitechnik

- 12 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

The elongation is reduced with 0,6 % Cr

[%]

Non Added elements

Elo

ngat

ion

[%]

- 13 -IfG - Institut für Gießereitechnik

- 13 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Y2-Probe: 4,03% Si; 3,01 %C; 1,0 % Mn

Rm: 581 MPa; Rp0,2: 486 MPa; A: 19,8 %

Y2-Probe: 3,99 % Si; 3,01 %C; 0,63 % Cr

Rm: 649 MPa; Rp0,2: 506 MPa; A: 14,3 %

ca. 25% pearlite

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- 14 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

3) Cast technological properties of high Silicon ductile iron

Downsprue with

turbulences

Filter

Collecting bassin with scale

• Dross generating behaviour

Filling of the bassin in dependence on the time

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- 15 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

• Mold filling behaviour

Cast harp sample

Degree of filling in dependence on the Si content and pouring temperature

No strong influence of Si

- 16 -IfG - Institut für Gießereitechnik

- 16 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

4) Influence of inoculation on microstructure in dependence on the wall thickness

Wall thickness (radial sample)

inoculantC

onte

nt o

f gra

phite

sh

ape

V +

VI [

%]

Different inoculants generate a wide range of microstructure

- 17 -IfG - Institut für Gießereitechnik

- 17 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Con

tent

of g

raph

ite

shap

e V

+ V

I [%

]

Wall thickness (radial sample)

Inoculant 2

Not only the inoculant determines the microstructure but also the Si content.

- 18 -IfG - Institut für Gießereitechnik

- 18 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Schematic correlation between inoculation technique, wall thickness and microstructure

Rising Si content

Inoculation good

Inoculation poor

Different inoculants

Wall thickness [mm]

Con

tent

of g

raph

ite

shap

e V

+ V

I [%

]

- 19 -IfG - Institut für Gießereitechnik

- 19 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Graphite shape deviation comparable to Chunky graphite

- 20 -IfG - Institut für Gießereitechnik

- 20 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

5) Investigation of the machinability of high Silicon ductile iron

Longitudinal turning of cylindrical castings (diameter 120 mm)- tool life at cutting speed 240 m/min

Tool life 50 – 60 % longer

- 21 -IfG - Institut für Gießereitechnik

- 21 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

GJS-600-3GJS-600-10

min

Mittelwert

max

476

271288

210

135 165

0

50

100

150

200

250

300

350

400

450

500

Frei

fläch

enve

rsch

leis

s in

µm

minMittelwertmax

Flank wear at the machining of planet carriers (300 kg), materials GJS-600-3 and GJS-600-10.

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- 22 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Comparison of hardness and microstructure of GJS-600-3 with GJS-600-10

Hardness course

- 23 -IfG - Institut für Gießereitechnik

- 23 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Microstructure of GJS-600-3

etched

- 24 -IfG - Institut für Gießereitechnik

- 24 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Microstructure of GJS-600-10

etched

- 25 -IfG - Institut für Gießereitechnik

- 25 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

6) Summarization

• The new grades of GJS give a optimized combination of strength and thoughness (static loading).

• The worse influence of carbide generating elements is suppressed by the high Si content.

• The castability of the Si alloyed GJS is not worse than the conventional alloys

• The inoculation technology must be adapted to the new grades

• The high Si contents enhance the probability of graphite deviations

• The cyclic mechanical properties of the Si alloyed GJS grades are higher

- 26 -IfG - Institut für Gießereitechnik

- 26 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Das vorgestellte IGF-Vorhaben der Forschungsvereinigung Gießereitechnik e.V. FVG, Sohnstraße 70, 40237 Düsseldorf wurde

über die AiF Allianz Industrieforschung im Rahmen des Programms zur Förderung der industriellen Gemeinschaftsforschung und –entwicklung

(IGF) vom BMWi Bundesministerium für Wirtschaft und Technologie aufgrund eines Beschlusses des Deutschen Bundestages gefördert.

- 27 -IfG - Institut für Gießereitechnik

- 27 -CastTech, Krefeld, 09.11.2012 – High Silicon Ductile Iron

Thank you !