Microstructural study and wear behavior of ductile iron surface alloyed by Inconel 617

In this research, microstructure and wear behavior of Ni-based alloy is discussed in detail. Using tungsten inert gas welding process, coating of nearly 1–2 mm thickness was deposited on ductile iron. Optical and scanning electron microscopy, as well as X-ray diffraction analysis and electron probe microanalysis were used to characterize the microstructure of the surface alloyed layer. Micro-hardness and wear resistance of the alloyed layer was also studied. Results showed that the microstructure of the alloyed layer consisted of M₂₃C₆ carbides embedded in Ni-rich solid solution dendrites. The partial melted zone (PMZ) had eutectic ledeburit plus martensite microstructure, while the heat affected zone (HAZ) had only a martensite structure. It was also noticed that hardness and wear resistance of the alloyed layer was considerably higher than that of the substrate. Improvement of wear resistance is attributed to the solution strengthening effect of alloying elements and also the presence of hard carbides such as M₂₃C₆. Based on worn surface analysis, the dominant wear mechanisms of alloyed layer were found to be oxidation and delamination.     

Effects of surface alloying on microstructure and wear behavior of ductile iron

In this research, the effect of austenitic stainless steel cladding on improving the wear behavior of ductile iron was studied. Samples made of ductile iron were coated with steel electrodes (E309L) by manual shielded metal arc welding. The effect of coated layer thickness on microstructure, hardness, and wear resistance of the surface were investigated. Wear resistance of the samples was measured using the pin-on-plate technique. Optical microscopy and scanning electron microscopy were used to investigate microstructure and wear mechanisms. The phases in the interface of both the coating and the substrate were studied by X-ray diffraction. The results showed that a film of white chromium-enriched iron formed at the interface between the substrate and coating which contained iron–chromium complex carbides. It was, therefore, concluded that enhanced properties would be obtained if the coating thickness and the carbides deposited on the surface were reduced. In samples with a thin coating, surface hardness rose to above 1150 HV (five times higher than that of the substrate) and wear resistance increased significantly.     

Effect of electric contact surface treatment on microstructure and wear behaviour of ductile iron

Abstract

A study of electric contact surface treatment to ductile iron has been carried out. This technology was based on the application of the contact resistance heating between the electrode and workpiece. For comparison, the experiments of induction hardening to ductile iron were studied. The microstructure, microhardness, surface residual stress and wear properties were investigated using optical microscope, scanning electron microscope, X-ray diffraction, Vickers microhardness and rolling contact wear tests. Electric contact surface treatment resulted in the formation of fine ledeburite (white bright layer) and martensite in the ductile iron surface, in which the hardness in these areas was higher than that of induction hardened surface. The wear test results showed that the ductile iron surface after electric contact surface treatment had better wear resistance owing to the fine microstructure, high hardness and residual compressive stress.     

Effect of matrix structure on the impact properties of an alloyed ductile iron

An investigation was performed to examine the influence of the matrix structure on the impact properties of a 1.03% Cu, 1.25% Ni and 0.18% Mo pearlitic ductile iron. Specimens were first homogenized at 925 °C for 7 h and a fully ferritic structure was obtained in all ductile iron samples. Then, various heat treatments were applied to the homogenized specimens in order to obtain pearlitic/ferritic, pearlitic, tempered martensitic, lower and upper ausferritic matrix structures. The unnotched charpy impact specimens were tested at temperatures between − 80 °C and + 100 °C; the tensile properties (ultimate tensile strength, 0.2% yield strength and elongation) and the hardnesses of the matrix structures were investigated at room temperature. The microstructures and the fracture surfaces of the impact specimens tested at room temperature were also investigated by optical and scanning electron microscope. The results showed that the best impact properties were obtained for the ferritic matrix structure that had the lowest hardness, yield and tensile strength. Ductile iron with a lower ausferritic matrix had the best combination of ultimate tensile strength, percent elongation and impact energies of all structures.     

Austempering retards pitting failure in ductile iron spur gears

In this study, the effect of austempering process on pitting formation in spur gears made of ductile iron is analysed. A series of experiments are carried out to determine the pitting formation life. Gear test specimens were first austenitized in a salt bath at 900 °C for 90 min after which they were tempered in a salt bath at 250, 325, 375 and 425 °C for 60 and 90 min duration. All gear experiments were performed using FZG test machine. Pitting formation is investigated using scanning electron microscopy. It is concluded from the analysis that austempering contributes to the increase of pitting formation life.     

Ni合金化球墨铸铁组织和性能研究

为获得兼具较高强度和良好低温冲击韧性的球墨铸铁铸件,向球墨铸铁中加入质量分数约0.5%的Ni进行合金化,并对其进行中温奥氏体化(880℃+3 h)和低温退火(720℃+4 h)处理.采用光学显微镜(OM)、扫描电子显微镜(SEM)对铸态和热处理态试样的显微组织和冲击断口形貌进行分析;利用万能试验机、布氏硬度计和摆锤式冲击试验机等对铸态和热处理态试样进行了室温拉伸、硬度检测、低温冲击等力学性能测试.结果表明:铸态球墨铸铁的微观组织由珠光体、铁素体和球状石墨及少量的渗碳体组成,其强度、硬度偏高,塑性、韧性较差;热处理态试样中的珠光体向铁素体转变后为铁素体和球状石墨,试样强度、硬度有所降低,塑性、韧性得到明显的改善;铸态试样呈现典型的脆性断裂特征,热处理态试样冲击断口处存在少量韧窝,断裂模式以解理断裂为主,伴有少量塑性变形的韧脆混合断裂,且在-40℃冲击功达到12.4 J;比较铸态与热处理态的冲击断口形貌可知,试样断裂方式由脆性断裂转变为韧脆混合断裂.     

The wear of aluminium-based journal bearing materials under lubrication

The aluminium-based alloys, nowadays, are developed to be used in high performance engine bearings. In this study, new Al-based bearing alloys, which are produced by metal mould casting, were developed; and tribologic properties of these alloys under lubrication were analyzed experimentally. Four different aluminium alloys were carried out on pin on disc wear tester for that purpose. SAE 1040 steel was used as the disc material in the wear tester. Friction tests were carried out at 0.231–1.036 N/mm² pressures and at 0.6–2.4 m/s sliding speeds. Wear tests were carried out at 1.8 m/s sliding speed and at 70 N normal load. Friction coefficients and weight losses of the samples were determined under various working conditions as a result of the experiments. The morphographies of the worn surfaces were analyzed. Hardness, surface roughness, and surface temperature of the samples were measured. The results showed that the friction and wear behaviors of the alloys have changed according to the sliding conditions. The effects of the elements except aluminium composing alloys on the tribologic properties were analyzed. Al8.5Si3.5Cu alloy has a lower friction coefficient value than other alloys. Al8.5Si3.5Cu and Al15Sn5Cu3Si alloys, on the other hand, have the highest wear resistance. Al15Pb3.7Cu1.5Si1.1Fe alloy is the most worn material; and Al15Pb3.7Cu1.5Si1.1Fe alloy has the highest wear rate. As a result of the evaluations conducted, Al–Sn and Al–Si alloys, which include Si and Sn, can be preferred, among the aluminium alloys that will work under lubrication, as the bearing material.     

Nanoausferritic matrix of ductile iron

Abstract

Austempered ductile iron is known for its excellent mechanical properties resulting from special phase composition and austempering heat treatment. Typical microstructure consists of ferrite plates of micrometre size submerged in untransformed austenite matrix. It has been recently shown that by use of appropriate chemical composition of cast iron and well targeted heat treatment parameters, it is possible to reduce ferrite plates width to submicron or even nanometric size. This creates the potential to achieve even higher mechanical properties of austempered ductile iron. The paper describes the influence of applied heat treatment parameters on microstructure of selected austempered ductile iron grades. Conditions necessary to reduce size of phases to a nanometric scale by heat treatment in austempered ductile iron are discussed.     

Effects of particulate reinforcement and heat treatment on the hardness and wear properties of AA 2024-MoSi2 nanocomposites

In this study, nanocomposites of AA 2024 aluminum alloy matrix reinforced with different volume fractions of nanometric MoSi₂ intermetallic particles ranging from 0 to 5%, were produced using mechanical alloying technique. For comparison, samples without reinforcing particles and mechanical alloying and a sample with micrometric MoSi₂ particles were also synthesized. The prepared composite powders were consolidated by cold and hot pressing and then heat treated to solution and aged condition (T6). The effects of MoSi₂ particle size, volume fraction and also heat treatment on the hardness and wear properties of the composites were investigated using Brinell hardness and pin-on-disc wear tests. The results indicated that although T6 heat treatment increases the hardness of all samples compared to as hot-pressed (HP) condition, the age-hardenability (aging induced hardness improvement) decreases after mechanical alloying and with increasing MoSi₂ volume fraction due to the high dislocation density produced during mechanical alloying. With increasing the volume fraction of nano-sized MoSi₂ particles up to 3–4%, the hardness of the composites continuously increases and then declines most probably due to the particle agglomeration. The wear sliding test disclosed that the wear resistance of all specimens in T6 condition is higher than that of HP condition and increases with increasing MoSi₂ content. Scanning electron microscopic observation of the worn surfaces was conducted and the dominant wear mechanism was recognized as abrasive wear accompanied by some adhesive wear mechanism.     

Surface reactivity of thin wall ferritic ductile iron. The effect of nodule count and grinding variables

Thin wall ductile iron (TWDI) castings constitute an attractive alternative to several applications in which the strength to weight ratio becomes a key design variable. In TWDI, the nodule count for a given chemical composition is highly dependent on cooling rate during solidification, and hence on thickness.For mechanical parts, where accurate dimensional tolerance is mandatory, the most common machining process applied is grinding. This process induces significant temperature gradients and surface plastic deformations which could affect service performance, particularly in corrosion environments.In TWDI, surface properties become more relevant due to the high surface area to volume ratio. Therefore, the aim of this paper is to determine the effect of nodular count and grinding conditions on surface reactivity of ferritic TWDI. Electrochemical assays were carried out in a three-electrode cell in a 3.5 wt.% NaCl solution on both polished and ground samples. The results obtained indicate that surface reactivity increases with higher nodular counts and residual plastic strain.     

Production of surface chilled ductile iron

Surface chilled ductile iron has become a promising material for machine parts exposed the wearing and impact because of good combination of high wear resistance and toughness. In this study, the effect of the chemical composition, mold wall thickness and sample diameter on the chill formation, chill depth, and carbide precipitation in the ductile iron were studied. The casting having four different chemical compositions were carried out to copper molds having various samples diameter (? 10–50 mm) and mold wall thickness (5, 15, 20, 30 and 50 mm). Microstructural and hardness profile evaluation were carried out from surface to center of part in order to define the effects of cooling rate on the chill formation. Experimental results showed that the production of surface chilled ductile iron having various chill depths can be achieved with controlling of the cooling rate. Hardness profile increases with increasing of mold wall thickness (cooling rate). High chromium content increases chill depth and decrease graphite formation. High silicon content promotes graphite formation while it decreases carbide precipitation. Chill formation on the ductile iron can be optimized with controlling mold wall thickness and sample diameter (cooling rate).     

Investigation of mechanical properties of boro-tempered ductile iron

In this study, the effects of boro-tempering heat treatment on mechanical properties of ductile iron were investigated. Standard tensile test samples and unnotched Charpy specimens were boronized at 900 °C for 1, 3 and 5 h and then tempered at four different temperatures (250, 300, 350 and 450 °C) for 1 h. Micro-hardness measurements were performed on cross-section of the metallographically prepared samples, where cut from fractured impact test samples. The hardness of boride layers was measured in the range of 1654–1867 HV_0.05. It was observed that tempering temperature was more effective on the mechanical properties of the material than boronizing time. Optimum mechanical properties were obtained for the samples boronized for 1–3 h and then tempered between 250 and 350 °C for 1 h.     

A study on microstructure and toughness of copper alloyed and austempered ductile irons

In this study, ductile irons with and without 1 wt% copper alloy were austempered to become austempered ductile irons (ADIs). Microstructure, impact toughness, and fracture toughness were evaluated to determine how both the copper alloying and austempering treatments influenced the toughness properties of ductile irons. The results show that, because copper increases the retained austenite content in ADI, the Cu-alloyed ADI has better impact toughness and fracture toughness (K_IC value) than does the unalloyed one. In particular, the impact toughness and the fracture toughness of ADI could be efficiently improved by treating the Cu-alloyed ductile iron at a higher austempering temperature (360 °C) to obtain more retained austenite in its microstructure.     

Enhancement of the wear resistance of epoxy: short carbon fibre, graphite, PTFE and nano-TiO2

Enhancements of the wear resistance of epoxy using various fillers, e.g. short carbon fibre (CF), graphite, polytetrafluoroethylene (PTFE) and nano-TiO₂, have been systematically investigated in the present study. Wear properties were carried out on a block-on-ring apparatus. The best wear resistant composition was achieved by a combination of nano-TiO₂ with conventional fillers; as an example, epoxy+15 vol% graphite+5 vol% nano-TiO₂+15 vol% short-CF exhibits a specific wear rate of 3.2×10⁻⁷ mm³/Nm, which is about 100 times lower when compared to the neat epoxy. Worn surfaces were investigated using a scanning electron microscope and an atomic force microscope, from which it is assumed that a mechanism of nanoscale rolling governs this positive effect of the nanoparticles. The main concept of this paper is to strength the importance of integrating various functional fillers in the design of wear resistant polymer composites.     

Improvement of wear and corrosion resistances of 17-4PH stainless steel by plasma nitrocarburizing

17-4PH stainless steel was plasma nitrocarburized at 460 °C for improving its mechanical properties without compromising its desirable corrosion resistance. The plasma nitrocarburized layers were studied by optical microscope, X-ray diffractometer, microhardness tester, pin-on-disc tribometer and the anodic polarization method in a 3.5% NaCl solution. The experimental results show that the nitrocarburized layer depths increase with increasing duration time and the layers growth conform approximately to the parabolic law. The phases in the nitrocarburized layer are mainly of γ′-Fe₄N and α′-Fe with traces of CrN phase. The surface hardness of the modified specimen is more than 1200 HV, which is three times higher than that of untreated one. The friction coefficient and corrosion resistance of the specimen can be apparently improved by plasma nitrocarburizing. With the increase of duration time, the surface hardness slightly decreases whereas the friction coefficient and corrosion resistance of the modified specimen are first increase and then decrease. The 8 h treated specimen has the lowest friction coefficient and the best corrosion resistance in the present test conditions.     

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.     

Microstructure feature of friction stir butt-welded ferritic ductile iron

This study conducted friction stir welding (FSW) by using the butt welding process to join ferritic ductile iron plates and investigated the variations of microsturcture in the joined region formed after welding. No defects appeared in the resulting experimental weld, which was formed using a 3-mm thick ductile iron plate and tungsten carbide alloy stir rod to conduct FSW at a rotational speed of 982 rpm and traveling speed of 72 mm/min. The welding region was composed of deformed graphite, martensite phase, and dynamically recrystallized ferrite structures. In the surface region and on the advancing side (AS), the graphite displayed a striped configuration and the ferritic matrix transformed into martensite. On the retreating side (RS), the graphite surrounded by martensite remained as individual granules and the matrix primarily comprised dynamically recrystallized ferrite. After welding, diffusion increased the carbon content of the austenite around the deformed graphite nodules, which transformed into martensite during the subsequent cooling process. A micro Vickers hardness test showed that the maximum hardness value of the martensite structures in the weld was approximately 800 HV. An analysis using an electron probe X-ray microanalyzer (EPMA) indicated that its carbon content was approximately 0.7–1.4%. The peak temperature on the RS, 8 mm from the center of the weld, measured 630 °C by the thermocouple. Overall, increased severity of plastic deformation and process temperature near the upper stir zone (SZ) resulted in distinct phase transformation. Furthermore, the degree of plastic deformation on the AS was significantly greater than that on the RS, and relatively complete graphite granules and the fine ferrite grains resulting from dynamic recrystallization were observed on the RS.     

Enhancement of oxidation and wear resistance of Fe-based amorphous coatings by surface modification of feedstock powders

Surface oxidation of the in-flight powders during the preparation of amorphous coatings in high velocity oxygen fuel process causes the formation of oxygen-rich intersplat regions. These regions are brittle in nature and can dramatically deteriorate the mechanical performance of the coatings. To solve this problem, the starting FeCrMoCBY amorphous feedstock powders were modified by electroless plating a thin layer of Ni–W–P amorphous phase. It was found that the covering of the Ni–W–P layer can significantly reduce the oxygen content in the resultant Fe-based amorphous coatings. The wear resistance of the coatings with and without the modification of Ni–W–P thin layer was comparatively studied by ball-on-disk wear tests against Si₃N₄ counterpart in air. It revealed that the wear of two types of coatings follows the same oxidation wear mechanism but the modified coating exhibits much better wear resistance due to the improved oxidation resistance.     

Microstructure and abrasive wear resistance of an alloyed ductile iron subjected to deep cryogenic and austempering treatments

To further improve the mechanical performance of a new alloyed austempered ductile iron(ADI), deep cryogenic treatment(DCT) has been adopted to investigate the effect of DCT time on the microstructure and mechanical behaviors of the alloyed ADI Fe-3.55 C-1.97 Si-3.79 Ni-0.71 Cu-0.92 Mo-0.64 Cr-0.36 Mn-0.30 V(in wt.%). With increasing the DCT time, more austenite transformed to martensite and very fine carbides precipitated in martensite in the extended period of DCT. The amount of austenite decreased in alloyed ductile irons, while that of martensite and carbide precipitation increased. The alloyed ADI after DCT for 6 h had the highest hardness and compressive strength, which can be attributed to the formation of more plate-like martensite and the finely precipitated carbides. There was a gradual decrease in hardness and compressive strength with increasing the DCT time to 12 h because of the dissolution of M3 C carbide. After tempering, there was a decrease in mechanical properties compared to the direct DCT sample, which was caused by the occurrence of Ostwald ripening of precipitated carbides. The optimum wear resistance was achieved for the alloyed ADI after DCT for 6 h. The wear mechanism of the alloyed ADI in associating with DCT is mainly consisted of micro-cutting wear and some plastic deformation wear.     

Properties and microstructure of copper-alloyed solid solution-strengthened ductile iron

Solid solution-strengthened ductile iron (DI) exhibits outstanding mechanical properties due to the high silicon content. The strengthening by silicon addition is limited since additions above 4.3?wt-% lead to embrittlement. For a further improvement of mechanical properties, other alloying elements need to be considered. In the present work, the effect of various copper additions on the microstructure and the mechanical properties of solid solution-strengthened DI were investigated. The results show that no appreciable strengthening can be achieved by copper addition without the formation of pearlite in the matrix. The pearlite content increases considerably for Cu-additions above 0.23?wt-% and is independent of the cooling rate for the cooling conditions analysed.