不同蠕化率的蠕墨铸铁滚动磨损性能研究

采用M-2000型摩擦磨损试验机,对不同蠕化率的蠕墨铸铁、灰铸铁和球墨铸铁在相同条件下进行滚动磨损试验,对比分析了蠕墨铸铁表面磨损形貌及其滚动磨损机理。结果表明,随着蠕化率的提高,蠕墨铸铁中石墨尺寸减小、分布更加均匀化,其硬度和耐磨性能呈下降趋势。蠕墨铸铁滚动磨损机理以表面疲劳磨损和剥层损伤为主,磨损表面出现层状结构剥落后留下的凹坑。蠕铁中石墨虽然具有自润滑作用,但是因其本身硬度较低,在循环接触应力下破碎,成为表面疲劳的裂纹源,反而加剧了磨损。蠕墨铸铁滚动磨损性能接近球墨铸铁,而优于灰铸铁。     

蠕化率对蠕墨铸铁组织及热疲劳性能的影响

采用自约束热疲劳试验机,对不同蠕化率下的蠕墨铸铁进行热疲劳性能试验并观察其组织变化。结果表明,试样的抗热疲劳性能随着蠕化率的升高呈现先上升后下降的趋势。当蠕化率为70%~80%时,蠕墨铸铁的热疲劳性能最好。蠕虫状石墨占基体比重有一个最佳值,蠕化率过低时,由于球状石墨数量较多分布较密集,导致热疲劳性能较差;蠕化率过高时,由于蠕虫状石墨过于粗大使裂纹扩展速度加快,导致热疲劳性能较差。在裂纹扩展后期,主裂纹变粗大导致其向前扩展所需驱动力不足以及主裂纹上形成分叉裂纹及二次裂纹,进而导致裂纹扩展呈现先快后慢、阶段性扩展的特点。     

定向凝固条件下含磷蠕墨铸铁凝固特性研究

在定向凝固过程中向试样内加入纯稀土金属进行变质处理，获得了蠕墨铸铁的平界面生长试验结果；考察了磷含量和凝固速度对蠕墨铸铁液－固界面形态的影响；与同样条件下的灰铸铁试验结果相比较，阐明了蠕墨铸铁不同于灰铸铁的凝固特点，解释了含磷蠕墨铸铁易产生缩松倾向的原因。     

含有Cu、Mo、Sn的高强度蠕墨铸铁的蠕变行为

研究了一种含有Cu、Mo、Sn的高强度蠕墨铸铁在623~823 K、40~150 MPa的蠕变行为,观察了不同形态的蠕变损伤组织并分析了蠕变变形及断裂机理。当T/T_m＞0.5(T为使用温度,T_m为蠕墨铸铁熔点)、载荷大于150 MPa时这种蠕墨铸铁的蠕变变形显著,且变形主要来自基体变形、蠕变空洞的形核长大以及石墨/基体界面的开裂。随着温度的提高和载荷的增加,蠕变变形逐渐由晶界移动转变为晶内变形。在蠕变过程中有两种开裂机制：(I)微裂纹在石墨/基体开裂处形核长大并优先沿铁素体向基体扩展,与邻近石墨/基体开裂连接而逐渐形成主裂纹;(II)晶界处的蠕变空洞形核长大转变成蠕变裂纹。氧原子通过石墨的连通性向组织内部扩散,造成上述两种裂纹表面氧化。由于,石墨、铁素体、珠光体三者性能的差异,石墨/铁素体界面比石墨/珠光体界面更易发生开裂。另外,在773 K、823 K组织中的珠光体分解明显,层片状渗碳体逐渐转变为短棒状,在晶界附近则以颗粒状为主。     

基于聚类共晶团算法的蠕墨铸铁形核率预测模型

蠕墨铸铁是一种性能优良的结构材料,蠕化效果对力学性能有重要影响,形核率的准确预测是精准调控蠕化过程的重要前提,进而实现高效蠕化。为了更准确地通过金相照片计算金属材料的形核率,本文采用计算机图形学中的DBSCAN聚类算法来统计试样中的共晶团数,建立了直接描述形核率的模型及相对应的生长模型,并与通过统计金相照片中的石墨个数得到形核率的方法作为对照,对比分析发现,聚类算法计算后得到的冷却曲线和蠕化率与实验结果吻合良好,证明了该算法对应的形核率预测模型的合理性。此外,采用温度场模拟计算,通过对比石墨数统计共晶团数目、聚类数统计共晶团数目的温度场变化,进一步验证了聚类数统计共晶团方法的合理性。     

分布式流体脉动压力激励下泵喷推进器的结构辐射噪声分析

流体激励载荷的分布式特性对泵喷推进器的结构声辐射具有重要影响.采用计算流体动力学数值模拟结合自编径向基函数插值获得了推进器结构表面的分布式流体激励脉动压力,利用耦合有限元方法研究了泵喷推进器在其全部表面分布式激励、仅转子表面分布式激励、每个叶片0.7R处等效三向激励和桨毂处等效三向激励作用下的结构辐射噪声.结果表明:径...     

玻璃模具用球墨/蠕墨复合铸铁的研究

介绍了用稀土和Ｋ－Ｎａ复合变质处理而形成的球墨／蠕墨复合铸铁玻璃模具材质的组织,力学性能及热特性,探讨了影响这些性能的因素,试用表明,这种材和于玻璃具有着良好的使用性能和较高的经济价值。     

The thermal fatigue resistance of vermicular cast iron coupling with H13 steel units by cast-in process

This paper focuses on improving the thermal fatigue resistance on the surface of vermicular cast iron coupling with inserted H13 steel blocks that had different cross sections, by cast-in processing. The microstructure of bionic units was examined by scanning electron microscope. Micro-hardness and thermal fatigue resistance of bionic samples with varied cross sections and spacings were investigated, respectively. Results show that a marked metallurgical bonding zone was produced at interface between the inserted H13 steel block and the parent material – a unique feature of the bionic structure in the vermicular cast iron samples. The micro-hardness of the bionic samples has been significantly improved. Thermal resistance of the samples with the circular cross section was the highest and the bionics sample with spacing of 2 mm spacing had a much longer thermal fatigue life, thus resulting in the improvement for the thermal fatigue life of the bionic samples, due to the efficient preclusion for the generation and propagation of crack at the interface of H13 block and the matrix.     

Fracture analysis of a camshaft made from nodular cast iron

The camshaft is a shaft having some semi-oval protrusions which are designed to control the open and close intervals of the inlet and exhaust poppet valves in the gasoline and diesel engines. Rotation of the cam which takes its movement from the crankshaft via a chain or a trigger belt causes its profile to slide against the smooth flat closed end of a cylindrical member known as a follower. In this study, fracture analysis of a camshaft of an automobile engine is carried out. The analyzed camshaft is fractured after a very short period of usage of the car. For the determination of the failure reason, the microstructure and chemical compositions of the camshaft material are determined. Some fractographic studies are carried out to asses the fracture conditions. A stress analysis is also carried out by the finite element technique for the determination of highly stressed regions on the camshaft.     

Failure analysis of a crankshaft made from ductile cast iron

This paper describes the failure analysis of a diesel engine crankshaft used in a truck, which is made from ductile cast iron. The crankshaft was found to break into two pieces at the crankpin portion before completion of warranty period. The crankshaft was induction hardened. An evaluation of the failed crankshaft was undertaken to assess its integrity that included a visual examination, photo documentation, chemical analysis, micro-hardness measurement, tensile testing, and metallographic examination. The failure zones were examined with the help of a scanning electron microscope equipped with EDX facility. Results indicate that fatigue is the dominant mechanism of failure of the crankshaft. It was observed that the fatigue cracks initiated from the fillet region of the crankpin-web. The absence of the hardened case in the fillet region and the presence of free graphite and nonspheroidal graphite in the microstructure of the crankshaft made fatigue strength decrease to lead to fatigue initiation and propagation in the weaker region and premature fracture.     

Weibull analysis, extrapolations and implications for condition assessment of cast iron water mains

The applicability of Weibull statistics to the condition assessment of cast iron water distribution pipes has been considered. The effect of Weibull modulus, characteristic strength, sample size and mode of loading (tension or flexure) on the strength of cast iron water distribution pipes is investigated. The strength distribution of cast iron samples cut from sections of five different water distribution pipes recovered from the ground have been characterized. Strengths have been measured in flexure, at two different temperatures (ambient and 0 °C), and in tension at ambient temperature using two different sample sizes. It is shown that characteristic strength values in flexure decrease with increasing size of graphite flake and that there is no significant difference between the results at the two temperatures investigated. For samples of the same volume tested in tension and flexure, the reduced strength measured in tension is consistent with Weibull predictions. However, the strength of large samples tested in tension was not significantly different from the small samples, perhaps because the samples were of the same thickness and conventional Weibull scaling is not applicable. Finally, using a method which treats a large pipe as an assembly of small samples, the strength distributions from the small samples tested in tension are used to make a prediction of the strengths of 1 m span sections of pipe loaded in three‐point bending, which were reported in previous work. The predicted pipe strengths are close to the lower end of the measured pipe strength distribution. Overall, this work suggests that Weibull analysis is a useful tool to examine the strength distribution of removed from cast iron water pipes and so has the potential to contribute in the assessment of asset condition.     

Nondestructive evaluation of cementite content in steel and white cast iron using inductive Barkhausen noise

A nondestructive testing method for the determination of the cementite content in iron-carbon steel and white cast iron is presented. The method is based on micromagnetic measuring parameters derived from inductive Barkhausen noise measurements taken under room temperature and with temperatures above the Curie temperature. The influence of different cementite contents and cementite modifications on the micromagnetic measuring quantities for steels with ferritic, pearlitic, martensitic annealed and martensitic soft annealed microstructure states and for white cast iron was determined. Cementite actively produces its own inductive Barkhausen noise and also influences the Barkhausen noise of the iron matrix both as a foreign body and by its stress fields of the second kind. Each influence has a different effect on steel and on white cast iron. It was shown that parameters derived from the Barkhausen noise can be used for determining the cementite content if the microstructure state is known. Moreover, when the steel grade is known, the microstructure state can be detected from the pattern of the Barkhausen noise curve by means of simple pattern recognition.This paper is dedicated to Prof. Dr. phil. Paul Hoeller ( Feb. 21, 1996), former director of the IZFP. Prof. Hoeller supported especially the scientific research work described in this article.     

Microstructure and mechanical properties of high boron white cast iron

In this paper, high boron white cast iron, a new kind of wear-resistant white cast iron was developed, and its microstructure and mechanical properties were studied. The results indicate that the high boron white cast iron comprises a dendritic matrix and an interdendritic eutectic boride in as-cast condition. The distribution of eutectic boride with a chemical formula of M₂B (M represents Cr, Fe or Mn) and with a microhardness of HV2010 is much like that of carbide in high chromium white cast iron. The matrix includes martensite and a small amount of pearlite. After quenching in air, the matrix changes to martensite, but the morphology of boride remains almost unchanged. In the course of austenitizing, a secondary precipitation with the size of about 1 μm appears, but when tempered at different temperature, another secondary precipitation with the size of several tens of nanometers is found. Both secondary precipitations, which all forms by means of equilibrium segregation of boron, have a chemical formula of M₂₃(C,B)₆. Compared with high chromium white cast iron, the hardness of high boron white cast iron is almost similar, but the toughness is increased a lot, which attributes to the change of matrix from high carbon martensite in the high chromium white cast iron to low carbon martensite in the high boron white cast iron. Moreover, the high boron white cast iron has a good hardenability.     

Large scale testing and statistical analysis of dynamic fracture toughness of ductile cast iron

The present paper deals with the experimental determination and statistical analysis of dynamic fracture toughness values of ductile cast iron. K_Id data from 140 mm thick single edge bend specimens of two dynamic fracture toughness test series on ductile cast iron from heavy-walled castings were analysed.At first, the statistical analysis of data at −40 °C was done based on ASME Code Case N-670 using a two-parameter Weibull distribution function. Weibull analyses of three samples covering different pearlite contents (?4%, ?9%, ?20%) were performed and characteristics of the distribution functions as well as two-sided confidence intervals were calculated. The calculated characteristics show that K_Id of ductile cast iron decreases with increasing pearlite content.In a second step, the applicability of the Master curve procedure according to ASTM E 1921 to ductile cast iron materials was investigated and it was formally used for statistical analysis of ductile cast iron dynamic fracture toughness data. Although the Master curve method was originally introduced for static fracture toughness data of ferritic steels, the successful individual analyses performed here support the engineering way taken to apply the method to ductile cast iron materials too. The results of both methods, the Master curve procedure and the ASME Code Case N-670, show acceptable congruity. At the same time, it is concluded from the present study that further investigations and experiments are required to improve precision and for verification before the results could be applied within component safety analyses.     

The role of graphite morphology and matrix structure on low frequency thermal cycling of cast irons

Low frequency thermal cycling tests were carried out on four types of cast iron (viz., austempered ductile iron, pearlitic ductile iron, compacted/vermicular graphite iron and grey cast iron) at predetermined ranges of thermal cycling temperatures. The specimens were unconstrained. Results show that austempered ductile iron has the highest thermal cycling resistance, followed by pearlitic ductile iron and compacted graphite iron, while grey cast iron exhibits the lowest resistance. Microstructural analysis of test specimens subjected to thermal cycling indicates that matrix decomposition and grain growth are responsible for the reduction in hardness while graphite oxidation, de-cohesion and grain boundary separation are responsible for the reduction in the modulus of elasticity upon thermal cycling.