Strong exploration of a cast iron pipe failure model

A physical probabilistic failure model for buried cast iron pipes is described, which is based on the fracture mechanics of the pipe failure process. Such a model is useful in the asset management of buried pipelines. The model is then applied within a Monte-Carlo simulation framework after adding stochasticity to input variables. Historical failure rates are calculated based on a database of 81,595 pipes and their recorded failures, and model parameters are chosen to provide the best fit between historical and predicted failure rates. This provides an estimated corrosion rate distribution, which agrees well with experimental results. The first model design was chosen in a deliberate simplistic fashion in order to allow for further strong exploration of model assumptions. Therefore, first runs of the initial model resulted in a poor quantitative and qualitative fit in regards to failure rates. However, by exploring natural additional assumptions such as relating to stochastic loads, a number of assumptions were chosen which improved the model to a stage where an acceptable fit was achieved. The model bridges the gap between micro- and macro-level, and this is the novelty in the approach. In this model, data can be used both from the macro-level in terms of failure rates, as well as from the micro-level such as in terms of corrosion rates.     

Computation and application of local solidification times of grey cast iron cast in metallic moulds

Heat conduction equations applicable to the solidification of grey cast iron cast in moulds of the same material were solved for the cases of plate and cylindrical shaped castings made by pouring the metal at different temperatures into moulds of different wall thicknesses preheated to different temperatures, when the heat transfer coefficient at the casting-mould interface was assumed to have different values. An explicit finite difference method was used to solve the equations with the aid of a digital computer. Local solidification times at different nodal points were determined from the solutions and a relationship between the local solidification time and the location in a ‘casting’ was established. The application of local solidification times for predicting the microstructure and estimating the ultimate tensile strength of these “castings” cast in metallic moulds has been demonstrated.     

Stress/strain simulation model for grey cast iron

A simple model for estimating the stress/strain response of grey cast iron subjected to variable amplitude cyclic loading is presented. Material properties for the model are readily determined from the tensile and compressive stress/strain curve of the material.     

Cast joining of cast iron to aluminium casting matrix

Abstract

The present study focused on reinforcing Al–Si–Cu alloy with a cast iron insert and using Zn–xAl–3Si–0·5Mg (wt-%) intermediate alloys by the cast joining technique to take advantage of lightness and stiffness of the hybrid structure. The experimental set-up consisted of coating the insert using hot dipping method followed by immersing the coated insert into the Al melt and allowing the system to cool down to the room temperature. The quality of Al–Fe joints in terms of morphology, thickness, chemistry and microhardness was evaluated as a function of coating composition and immersion time in the Al melt. Characteristics of reaction layer at the coating/insert interface and its effects on the joint properties were determined using microstructural analysis and thermodynamic calculations. Combination of a suitable coating containing 27 wt-%Al and optimised process parameters, including 1 min immersion time, resulted in the formation of an Al–Fe joint with promising characteristics.     

Cavitation corrosion of nodular cast iron (NCI) in seawater: Microstructural effects

An investigation was carried out to determine the effect of the microstructure of nodular cast iron (NCI) on its cavitation corrosion behavior in natural seawater. The cavitation tests were conducted using a cavitation-induced facility at a frequency of 20 kHz on detached specimens. Morphological examinations on cavitated specimens indicated that the surface of NCI became very rough with large size cavity pits. Examination by optical microscopy of cross-sectioned specimens revealed the presence of microcracks in the bottom of cavity pits. Localized material removal on the NCI surface was due to ductile tearing and brittle modes of failure.     

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.     

Effect of heat treatment on ultrasonic velocity in ductile cast iron

Abstract

The measurement of the ultrasonic velocity is a common method in the foundry industry for the evaluation of the nodularity in ductile iron castings. Practical experience has shown that heat treatment can reduce the ultrasonic velocity compared to the as cast condition. Using ductile iron samples with different heat treatments in order to vary the ferrite and pearlite content respectively confirmed this decrease in the ultrasonic velocity compared to the as cast state. Further investigations showed that with all the heat treatments applied, irrespective of their effect on the microstructure, the density was decreased. The decrease in density correlated with the decrease in ultrasonic velocity for all heat treatments. The mechanisms involved in the reduction in the density are discussed.     

Vermicular graphite cast iron—current state of the art

Vermicular graphite cast iron is a new addition to the family of cast irons. Various methods for producing vermicular graphite cast iron are briefly discussed in this paper. The mechanical and physical properties of cast irons with vermicular graphite have been found to be intermediate between those of gray and ductile irons. Other properties such as casting characteristics, scaling resistance, damping capacity and machinability have been compared with those of gray and ductile irons. Probable applications of vermicular graphite cast irons are suggested.     

Microstructural evolution and thermal fatigue resistance of grey cast iron

In the present work, thermal fatigue in grey cast iron has been investigated by means of a numerical and an experimental approach. Temperature gradients were generated within the material by means of a testing rig specifically designed for the experiments. The temperature gradients were responsible for the formation of severe stress fields that led to the failure of the specimens after a fairly low number of cycles. Crack growth was monitored during the tests, and the microstructure and hardness of samples were analysed after failure and compared with those of untested alloy. The repeated thermal cycles at peak temperatures of 600, 700, and 800°C led to important microstructural alterations of cast iron and to a drop in material hardness. The pearlite lamellae lost their original shape and became more fragmented. Oxygen‐rich regions surrounding the graphite flakes were produced by microgalvanic corrosion mechanism.     

Variable amplitude fatigue of high-strength cast iron alloys for automotive applications

In the automotive sector, the cumulative damage calculation method generally applied is the Palmgren–Miner-Hypothesis with its modification according to Haibach (steeper slope of the SN-line after the knee-point) as a means of also including the damage by stress amplitudes below the knee-point. This approach results in the total damage sum of the spectrum D_spec. However, the resulting question is the value of the allowable damage sum D_al for the evaluation of D_spec ⩽ D_al. The only design code that considers the assessment of cast iron components under spectrum loading is the FKM-Guideline of the Cooperative Research Association for Mechanical Engineering (FKM, Frankfurt/Germany) for designing machine components. Here, the theoretical Palmgren–Miner-damage sum D_th = 1.0 is still suggested as the allowable damage sum D_al despite the fact that this damage sum renders unsafe calculated fatigue lives in about 90% of all published results.The results obtained with component-like notched specimens of modern high-strength cast iron alloys (R_m = 650–800 MPa) such as EN-GJS-500-7, SiboDur 700-10 and MADI (Machinable Austempered Ductile Iron), which were investigated under a standard Gaussian spectrum for chassis applications and also for a fuller injection pump spectrum, suggest the allowable damage sum D_al = 0.3 for fatigue life estimations of components manufactured with these materials can be proposed; i.e. the allowable fatigue life is about one third compared to calculations with the theoretical damage sum D_th = 1.0 that is still used.     

Cell model simulation of void growth in nodular cast iron under cyclic loading

The failure of cast iron under high plastic cyclic strains is controlled by the mechanisms of formation, growth and coalescence of voids. A cell model approach is used to simulate nodular cast iron as a periodic array of loosely bonded spherical inclusions in the matrix material. The models are analyzed by the finite element method under cyclic loading while keeping the stress triaxiality constant. Different types of matrix hardening are used: isotropic, kinematic and combined hardening. The graphite inclusions are simulated by a rigid body. Deformation and void growth are studied in dependence on stress triaxiality and strain range. In most cases after a few cycles a non-symmetric stationary mesoscopic cyclic stress–strain curve is established. The deformation response and the development of the void volume fraction are strongly affected by the value of triaxiality. The void volume is incrementally increasing with each load cycle in a ratcheting manner. The void growth rate depends on the chosen hardening type and is smallest for kinematic hardening. The comparison with simulations in absence of graphite inclusions revealed that void evolution is favored by the inclusions.     

On the weldability of grey cast iron using nickel based filler metal

Shielded metal arc welding process using nickel based filler metal was used to join grey cast iron. The effect of post weld heat treatment (PWHT) on the microstructure and hardness was studied. PWHT included heating up to 870 °C, holding for 1 h at 870 °C and then furnace cooling. By using nickel based filler metal, formation of hard brittle phase (e.g. carbides and martensite) in the fusion zone is prevented. Before PWHT, heat affected zone exhibited martensitic structure and partially melted zone exhibited white cast iron structure plus martensite. Applied PWHT resulted in the dissolution of martensite in heat affected zone and graphitization and in turn the reduction of partially melted zone hardness. Results showed that welding of grey cast iron with nickel based filler metal and applying PWHT can serve as a solution for cast iron welding problems.     

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.     

The rise and fall of cast iron in Victorian structures – A case study review

The Victorian era in English history is often referred to as a ‘golden age’, marked by unique and historic achievements in the field of engineering and technology. It was in Victorian Britain that new production methods first allowed cast iron to be produced in large enough quantities to be used in substantial building projects. However, a series of high profile structural failures sent shock waves through the engineering profession and general public, prompting one of the first ever systematic investigations into the failure of structures. To track these developments, this paper takes a retrospective view of a number of major cast iron structural disasters that occurred during this period of history. Reassessment of historic incidents will allow use of modern analytical techniques not available at the time of initial investigation. A specific case study analysis into the demise of the Tay Bridge is used to demonstrate the value of engineering lessons to be learnt from taking a retrospective view. Reconsideration of historic failure is shown to demonstrate incremental advances made in the understanding of the limits of materials available at that time.     

Influence of methane and carbon dioxide on in-flight particle behavior of cast iron powder by atmospheric plasma spraying

Graphite degradation in plasma sprayed cast iron coatings is a technological barrier for achieving superior wear resistant coatings. Therefore, there is a need to understand the in-flight particle behavior of cast iron powder. In this study, methane (CH₄) and methane/carbon dioxide (CO₂) mixture has been introduced into the plasma flame to decrease the in-flight particle temperature of cast iron powder in order to prevent the oxidation and dissolution of graphite as well as provide additional free carbon. It has been observed that, CH₄ and CH₄/CO₂ addition remarkably decreases the in-flight particle temperature as a result of the in-situ endothermic reactions. Also, results demonstrate that while CH₄ and CH₄/CO₂ addition does not alter the microstructure, it slightly increases the graphite content in cast iron coatings.     

Elevated temperature low cycle fatigue of grey cast iron used for automotive brake discs

This paper evaluates the fatigue life properties of low carbon grey cast iron (EN-GJL-250), which is widely used for automotive brake discs. Although several authors have examined mechanical and fatigue properties at room temperatures, there has been a lack of such data regarding brake discs operating temperatures. The tension, compression and low cycle fatigue properties were examined at room temperature (RT) and at brake discs’ working temperatures: 500 °C, 600 °C and 700 °C. The microstructure of the material was documented and analysed. Tensile stress–strain curves, cyclic hardening/softening curves, stress–strain hysteresis loops, and fatigue life curves were obtained for all the above-mentioned temperatures. It was concluded, that Young’s modulus is comparable with both tension and compression, but yield its strength and ultimate strength are approximately twice as great in compression than in tension. All the mechanical properties remained quite stable until 500 °C, where at 700 °C all deteriorated drastically. During fatigue testing, the samples endured at 500 °C on average at around 50% of cycles at room temperature. Similar to other materials’ properties, the cycles to failure have dropped significantly at 700 °C.     

Probabilistic risk analysis of corrosion associated failures in cast iron water mains

This paper proposes a method using probabilistic risk analysis for application to corrosion associated failures in grey cast iron water mains. External corrosion reduces the capacity of the pipeline to resist stresses. When external stresses exceed the residual ultimate strength, pipe breakage becomes imminent, and the overall reliability of a water distribution network is reduced. Modelling stresses and external corrosion acting on a pipe involves uncertainties inherent in the mechanistic/statistical models and their input parameters. Monte Carlo (MC) simulations were used to perform the probabilistic analysis. The reduction in the factor of safety (FOS) of water mains over time was computed, with a failure defined as a situation in which FOS becomes smaller than 1. The MC simulations yielded an empirical probability density function of time to failure, to which a lognormal distribution was fitted leading to the derivation of a failure hazard function. A sensitivity analysis revealed that the contribution of corrosion parameters to the variability of time to failure was more significant than the combined contributions of all other parameters. Areas where more research is needed are identified.     

Predicting breakage behavior and particle size of bronze and cast iron machining chips pulverized by jet milling

It has been proposed that the breakage behavior of particulate materials can be described by two material parameters f_mat and W_min. f_mat describes the resistance of the material to fracture in impact pulverization and W_min characterizes the specific energy which a particle can absorb without fracture. It is shown in this study that this concept can be used to quantify breakage behavior of bronze and cast iron chips in jet milling process and also to predict particle size of the jet milled product. Different tin bronze and cast iron chips with varying initial size were pulverized in a target plate jet mill with different velocity. f_mat was found to be in the range of 0.06–0.09 and 0.18–0.25 for bronze and cast iron alloys, respectively. For the cast iron alloys f_mat increased with increasing content of carbon and silicon. Similarly, for the bronze alloys, f_mat increased with increasing tin content. An equation was developed to predict mean particle size of the jet milled chips as a function of the kinetic energy, initial chip size and material parameters. The experimental results of various alloys confirmed that the mean particle size after single and multiple impacts were accurately predicted.     

Application of grey relational analysis based on Taguchi method for optimizing machining parameters in hard turning of high chrome cast iron

High chrome white cast iron is particularly preferred in the production of machine parts requiring high wear resistance. Although the amount of chrome in these materials provides high wear and corrosion resistances, it makes their machinability difficult. This study presents an application of the grey relational analysis based on the Taguchi method in order to optimize chrome ratio, cutting speed, feed rate, and cutting depth for the resultant cutting force (F_R) and surface roughness (R_a) when hard turning high chrome cast iron with a cubic boron nitride (CBN) insert. The effect levels of machining parameters on F_R and R_a were examined by an analysis of variance (ANOVA). A grey relational grade (GRG) was calculated to simultaneously minimize F_R and R_a. The ANOVA results based on GRG indicated that the feed rate, followed by the cutting depth, was the main parameter and contributed to responses. Optimal levels of parameters were found when the chrome ratio, cutting speed, feed rate, and cutting depth were 12%, 100 m/min, 0.05 mm/r, and 0.1 mm, respectively, based on the multiresponse optimization results obtained by considering the maximum signal to noise (S/N) ratio of GRG. Confirmation results were verified by calculating the confidence level within the interval width.The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-018-0231-z     

Determination of presence of undesirable carbides at surface of cast iron parts using differential eddy current technique

Abstract

Machinability of grey cast iron parts can greatly suffer from the formation of carbide at the surface, resulting in a decrease in cutting tool life and higher production costs. Therefore, detection of the hardened layer and its hardness are the key factors in quality control and inspection processes. In the present paper, a number of metallurgical parameters (surface carbide, surface hardness and hardened depth) have been investigated using the non-destructive differential eddy current technique. The results show the high potential of the proposed method as a fast and accurate technique in inspecting and in consequent separation of undesirable parts.