Effect of Bi on graphite morphology and mechanical properties of heavy section ductile cast iron

To improve the mechanical properties of heavy section ductile cast iron, bismuth （Bi） was introduced into the iron. Five castings with different Bi content from 0 to 0.014 wt.% were prepared; and four positions in the casting from the edge to the center, with different solidification cooling rates, were chosen for microstructure observation and mechanical properties test. The effect of the Bi content on the graphite morphology and mechanical properties of heavy section ductile cast iron were investigated. Results show that the tensile strength, elongation and impact toughness at different positions in the five castings decrease with a decrease in cooling rate. With an increase in Bi content, the graphite morphology and the mechanical properties at the same position are improved, and the improvement of mechanical properties is obvious when the Bi content is no higher than 0.011wt.%. But when the Bi content is further increased to 0.014wt.%, the improvement of mechanical properties is not obvious due to the increase of chunky graphite number and the aggregation of chunky graphite. With an increase in Bi content, the tensile fracture mechanism is changed from brittle to mixture ductile-brittle fracture.     

基于多材质复合铸型的A356铝合金性能调控机制研究

本文建立变壁厚回字形结构多材质复合铸型,首先通过对A356铝合金在多材质复合铸型的充型、凝固过程模拟仿真,获得多材质复合铸型铸件充型时间和温度场结果,锆英砂与石英砂、铬铁矿砂与石英砂过度处凝固时间成阶梯状递减;且锆英砂与石英砂过度处与铬铁矿砂与石英砂过渡处铸件凝固时间更短,金属液凝固速度更快。其次通过对石英砂、铬铁矿砂、锆英砂复合铸型在重力铸造下A356铝合金铸件进行电子背散射衍射分析（EBSD）、电子显微探针分析（EPMA）、抗拉强度及扫描断口分析。结果表明：在相同壁厚时,铬铁矿砂、锆英砂型铸件的晶粒尺寸细小、Al、Mg、Si等元素集中度低、力学性能增大,断口呈现韧性断裂的特征;同时随着壁厚减小,同种材质砂型铸件晶粒尺寸细小、元素集中度低、力学性能增大,断口呈现韧性断裂的特征。     

Effect of Cooling Rate on Microstructure and Mechanical Properties of Thin-Walled Ductile Iron Castings

This article addresses the effect of cooling rate on microstructure and mechanical properties as determined by changing molding media and section size. The research was conducted for thin-walled iron castings with 2-5-mm wall thickness and for the reference casting with 13-mm wall thickness, using different molding materials (silica sand and insulating sand “LDASC”) to achieve various cooling rates. Thermal analysis was performed to determine the real cooling rate at the beginning of the graphite eutectic solidification. In general, it was found that the predictions based on theoretical analysis of the solidification process of ductile iron are in good agreement with the experimental outcomes. Finally, the present study provides insights into the effect of cooling rate on the graphite nodule count, the ferrite fraction and mechanical properties of thin-walled ductile iron castings. The study shows that the cooling rate of thin-walled castings varies in a wide range (80-15 °C/s) when changing the wall thickness from 2 to 5 mm, accompanied by significantly changing the mechanical properties of ductile iron. The cooling rate can be effectively reduced by applying an insulating sand to obtain the desired properties of thin-walled castings practically in the whole range of ductile iron grades in accordance with the ASTM Standard.     

厚大断面球墨铸铁四棱锥套的研制

采用缝隙式内浇口、铁液精炼、强制冷却等措施 ,成功地铸造出壁厚 75mm～ 170mm ,质量 3 .1t的厚大断面球墨铸铁铸件。     

厚大断面球墨铸铁件凝固装置的研制

自行研制了能够模拟厚大铸件冷却环境的小型凝固装置，通过控制不同的环境温度和冷却速度，来获取厚大断面球墨铸铁件凝固过程温度场的分布和变化规律。与空冷凝固时间相比，延长了300％的冷却凝固时间，验证了这一装置在实验中的有效性。     

Dynamic measurements of the load on castings and the contraction of castings during cooling in sand molds

The load on flange castings in sand molds was gradually increased beginning from the end of the solidification process until the final cooling stage. The maximum tensile load on the flange castings in furan sand molds was larger than that of the flange castings in green sand molds. With the furan sand mold, permanent deformation in the flange castings occurred beginning from the end of the solidification process until reaching a temperature of approximately 250 °C. The mechanical interaction between the casting and the sand mold should be considered for more accurate stress calculations, particularly in furan sand molds.     

Influence of cooling rate and antimony addition content on graphite morphology and mechanical properties of a ductile iron

Cooling rate and inoculation practice can greatly affect the graphite morphology of ductile irons.In the present research,the effects of the cooling rate and antimony addition on the graphite morpholog...     

消失模铸造球墨铸铁件收缩缺陷计算机模拟的处理方法

本文主要讨论了初始温度场和铸型硬度对消失模铸造球墨铸铁件收缩缺陷的影响,用计算机数据采集系统测试了消失模和空腔铸造的初始温度场分布。结果表明,两者初始温度场分布仅有微小差别,不同真空度下消失模铸型硬度的测试结果表明,消失模铸型的硬度高于普通湿型砂铸型,并且硬度分布更均匀 ,这一特点可以减少球铁石墨化膨胀引起的型壁移动,根据上述测试,确立了球铁件消失模铸造收缩缺陷的计算机模拟及预测方法,模拟结果与实际生产铸件的解剖结果吻合较好。     

Optimization of Mold Yield in MultiCavity Sand Castings

The productivity of ductile iron foundries engaging in mass production of castings for the automobile and other engineering sectors depends on the number of cavities per mold. A denser packing of cavities, however, results in slower heat transfer from adjacent cavities, leading to delayed solidification, possible shrinkage defects, and lower mechanical properties. In this article, we propose a methodology to optimize mold yield by selecting the correct combination of the mold box size and the number of cavities based on solidification time and mold temperature. Simulation studies were carried out by modeling solid and hollow cube castings with different values of cavity-wall gap and finding the minimum value of the gap beyond which there is no change in casting solidification time. Then double-cavity molds were modeled with different values of cavity-cavity gap, and simulated to find the minimum value of gap. The simulation results were verified by melting and pouring ductile iron in green sand molds instrumented with thermocouples, and recording the temperature in mold at predetermined locations. The proposed approach can be employed to generate a technological database of minimum gaps for various combinations of part geometry, metal and process, which will be very useful to optimize the mold cavity layouts.     

物理模拟大断面球墨铸铁中异常石墨形态的观测

使用自行研制的大断面铸件冷却模拟装置,研究了不同共晶时间球墨铸铁样品的石墨形态及相关的力学性能。验证了这一装置对于厚大断面球铁铸件研究的有效性。随着共晶时间的延长,铸件的石墨形态逐渐偏离球形,向异常化趋势发展,石墨颗粒的圆整度随之降低。异常石墨的形态表现出相互联结的立体网络状。     

微观组织对A201铝合金铸件机械性能之研究

系统改变A201铝合金平板铸件的长度、厚度及冒口大小,探讨微观组织中微孔隙量及树枝状晶胞尺寸(DCS)对A201铸件抗拉强度及伸长率的影响程度,进而于铸造实务工作时,可为冒口设计及金属凝固之参考,为研究的目的。砂型的种类有三种,分别是100%石英砂的A类石英砂、50%石英砂及50%铬砂的B类、及100%铬砂的C类。实验结果显示,A201铝合金平板铸件的机械性质同时受空孔量及DCS之影响,当微孔隙量增加及DCS变大时,均会降低铸件的抗拉强度及伸长率,其中微孔隙量影响为主要的因素。     

Linear contraction of ductile iron castings

The effect of casting design on the linear contraction of ductile iron castings produced in clay- and silicate-bonded sand moulds has been studied. The designs included free and restrained square bar castings.

Free contraction of very thin sections of ductile iron in sand moulds was found to approach 1.35%. As sections increased to 25 mm thick, the contraction decreased linearly to 1.08% in silicate-bonded sand moulds, but to 0.90% in clay-bonded sand moulds.

For test pieces with end flanges which stimulated various degrees of constraint as would be experienced in a shaped casting, the contraction was found to be sensitive to the third power of the relative cooling time of the flange and the cast section. In conditions of high constraint, contraction could fall as low as 0.55%.

The data from this study represent a first attempt to provide a designer and toolmaker with realistic contraction allowances for shaped castings.     

小型球铁件的收缩特点及其补缩工艺

根据国内外有关研究结果，阐述了球墨铸铁件冷却凝固过程中的体积变化规律，建立了球墨铸铁的收缩和膨胀模型，用以分析球墨铸铁小件的缩孔缩松形成机理。以轮毂铸件为例提出了防止缩孔缩松缺陷的工艺措施。     

铸铁件针孔缺陷产生的原因与防止方法

介绍了灰铸铁和球墨铸铁件针孔缺陷的形成机理以及铁液化学成分、铸型材料、铸件壁厚、浇注温度、充型速度和熔炼工艺等因素对针孔形成的影响情况。根据球铁件形成针孔的特点,提出了防止措施,并列举了消除铸铁件针孔缺陷的成功实例。     

厚大断面球墨铸件模拟凝固装置的研制

自行研制了模拟厚大铸件的冷却环境的小型凝固装置。通过控制环境温度和冷却速度,模拟厚大断面球墨铸件凝固过程温度场的分布和变化规律。试验结果表明,铸件在模拟环境下的冷却凝固时间比空冷凝固时间延长了300%。     

冷却速度对铝合金铸件气孔形成的影响

为研究冷却速度对铝合金铸件气孔形成的影响,分别采用潮模砂型、树脂砂型和金属型浇注壁厚10mm、25mm、40mm的铸件,观察截取试样的气孔分布。试验结果表明,冷却速度较慢的铸件气孔数量较多,形状不规则、大小不一,且气孔分散程度大;冷却速度较快的铸件气孔数量少,形状为小圆形且集中分布。潮模砂型铸件因砂型中的水分增加了铝液中的含氢量,铸件中的气孔数量较多;树脂砂型铸件因其凝固时间长,形成的氢气在铝液中溢出一部分,减少了铸件中的气孔量;金属型厚壁铸件由于成分过冷严重,铸件中心部位的气孔数量比边缘部位多。     

厚大断面大型球铁花盘无冒口铸造

为实现厚大断面大型球铁实体花盘无冒口铸造,采取挂砂冷铁与石墨冷铁组成的型芯强制冷却;运用大流量快速浇注,创造均衡快速凝固条件及运用合金化等手段;有效地防止铸件缩孔缩松等缺陷。经多年生产验证,铸件合格率１００％,工艺出品率９３３％,属国内、外先进水平     

Effects of Cooling Rate on High-temperature Mechanical Properties of A356 Alloys

High temperature mechanical properties of A356 alloy castings under different solidification cooling rates have been studied and the influence of cooling rates on secondary dendrite arm spacing (SDAS) and mechanical properties has been discussed. To get different cooling rates, three different types of mold—green sand, green sand with chill and permanent mold, were used to pour castings which would subsequently be machined into tensile test and metallographic specimens. The temperature curves of castings’ solidification in three different mold were recorded using thermal couples, which would be used to calculate their corresponding cooling rates. Tensile tests were carried out at 20, 200, 300, 400 and 500 ℃ and then mechanical properties, such as tensile strength, yield strength, elongation, of specimens from different mold types at different test temperatures were obtained. And SDAS of different specimens were measured using optical metallographic photos. From integrated analysis of all those results, following conclusions could be reached. The relationship between SDAS and cooling rates is negative, and the quantitative relationship has been obtained through data fitting analyzing. Generally speaking, tensile strength and yield strength decease as the temperature elevates while elongation behaves in the contrary trend. Through the regression analysis of SDAS, mechanical properties and temperature, the relationship among them is obtained, which makes quantitative prediction of A356 alloy’s mechanical properties at different temperatures with different solidification cooling rates be possible.     

湿型球墨铸铁件收缩特性的试验研究

采用正交试验的方法，浇注一系列铸件，测量铸件的冷却曲线；解剖铸件，测定铸件质量、铸件及缩孔体积。研究了碳当量、孕育、铸件模数以及铸型条件对湿型球铁件收缩特性及缩孔缩松的影响。为开展数值模拟预测球铁件缩孔、缩松的工作打下了基础。     

高强高韧合成球墨铸铁的组织及力学性能

以废钢为主要原材料(20%生铁+20%回炉料+60%废钢),使用中频感应电炉熔炼,采用中间加入和镜面加入联合增碳方式,制备了合成球墨铸铁QT450-23铸件。合成铸铁球化级别1级,球化率95%,石墨圆整,球径10～20μm,基体为100%铁素体。合成铸铁抗拉强度为450MPa,伸长率为23.3%。在高温组织中,奥氏体枝晶发达,显著提高材料的冲击韧性,V型缺口冲击试样常温冲击韧性为18.4 J/cm2,是相同成分和工艺条件下,传统生铁为主配方球铁的2倍。