Understanding compacted graphite iron solidification through interrupted solidification experiments

While the manufacture of compacted graphite (CG) iron castings has seen significant expansion over the recent years, the growth of CG during iron solidification is still not fully understood. In this work, effort was expanded to experimentally reveal the evolution of graphite shape during early solidification and its relationship to the solid fraction. To this purpose, interrupted solidification experiments were carried out on hypereutectic irons with three magnesium levels. The graphite shape factors were measured and analysed as a function of chemical composition and solid fraction. Scanning electron microscopy was carried out to establish the fraction of solid at which the transition from spheroidal graphite (SG) to CG occurs. It was confirmed that solidification started with the development of SG for all CG irons. The SG-to-CG transition was considered to occur when the SG developed a tail (tadpole graphite). The findings were integrated in previous knowledge to attempt an understanding of the solidification of CG iron.     

Controlling graphite content in plasma sprayed cast iron coatings via in-flight particle diagnostic

Graphite formation and degradation in thermally 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 and introduce new approaches to control the graphite content. In this study, it has been demonstrated that the graphite content can be controlled by means of in-flight particle diagnostic. For this purpose, cast iron coatings were plasma sprayed under a variety of spray conditions and characterized by using an optical microscope, X-ray diffractometer and electron probe micro-analyzer. As a result, a significant amount of graphite with respect to a wide range of in-flight particle temperature and velocity was preserved in cast iron coatings.     

Unambiguous classification of complex microstructures by their three-dimensional parameters applied to graphite in cast iron

Three-dimensional (3D) quantitative analysis is indispensable for the unambiguous characterization and objective classification of complex microstructures. Focused ion beam (FIB) nanotomography provides complete information of the spatial arrangement, chemistry and orientation of different phases of real microstructures on scales especially important in materials science (10 nm–100 μm). Complex graphite particles were analyzed in three-dimensions. Whereas nodular, vermicular and temper graphite particles can be characterized individually, the whole network of flake graphite has to be considered due to the high spatial interconnection of particles. The characterization method was verified in comparison to established two-dimensional stereological methods. The influence of anisotropy and image resolution was discussed. Basic stereological characteristics (volume, surface area, integrals of mean and total curvature) as well as 3D connectivity (Euler number) and shape parameters objectively differentiate these graphite morphologies and contribute to the understanding of their growth mechanisms and the properties of the cast iron.     

Identification and evaluation of modification level for compacted graphite cast iron

The shape of the freezing zone of a thermal analysis cooling curve not only contains the information about the modification level of compacted graphite cast iron (CGI) right after vermicularizing treatment, but also reflects the following fading process during holding. When the freezing zones of two cooling curves are approximately the same, graphite morphologies of the samples cast from the two corresponding melts right after vermicularizing treatment are similar, and those of the two corresponding samples cast after holding for the same period are similar too. Based on the pattern recognition method and database established from a large amount of experimental results, the shape of the freezing zone of a cooling curve can be used to identify the modification level of CGI melt and on-line prediction of a CGI melt quality has been realized.     

Eutectic solidification mode of spheroidal graphite cast iron and graphitization

The shrinkage and chilling tendency of spheroidal graphite (abbreviated SG) cast iron is much greater than that of the flake graphite cast iron in spite of its higher amount of C and Si contents. Why? The main reason should be the difference in their graphitization during the eutectic solidification. In this paper, we discuss the difference in the solidification mechanism of both cast irons for solving these problems using unidirectional solidification and the cooling curves of the spheroidal graphite cast iron. The eutectic solidification rate of the SG cast iron is controlled by the diffusion of carbon through the austenite shell, and the final thickness is 1.4 times the radius of the SG, therefore, the reduction of the SG size, namely, the increase in the number, is the main solution of these problems.     

Fluidity and solidification microstructures of flake graphite cast iron in thin sections

Fluidity determinations have been undertaken using a silica tube as the fluidity channel, metal being drawn in to the test tubes by means of a regulated vacuum system. Fe-Si and Ca-Si inoculants were added to a hypoeutectic cast iron melt which was then tested for fluidity. A linear relationship between fluidity length and tube diameter was obtained. Fluidity length increased with increasing suction pressure and with increasing temperature of the molten iron. Fluidity length is proportional to the square root of effective suction pressure. Structures within the fluidity specimens have been classified, from the tip backwards, into three zones, containing ledeburite, mottled and flake graphite structures. The length of each structural zone increases with increasing suction pressure. The total length of the ledeburite zone, plus the mottled zone, is constant for increasing tube diameter. Thus, the flake graphite zone increases linearly with tube diameter. The effects of inoculation on the structure and its fading were evaluated by the length of the flake-graphite zone.     

Numerical simulation of microstructure evolution on near eutectic spheroidal graphite cast iron

A multiphase cellular automaton model was developed to simulate microstructure evolution of near eutectic spheroidal graphite cast iron (SGI) during its solidification process, and both dendritic austenite and spheroidal graphite growth models were adopted. To deduce the mesh anisotropy of cellular automaton method, the composition averaging and geometrical parameter were introduced to simulate the spheroidal graphite growth. Solute balance method and decentered square algorithms were employed to simulate austenite dendrites growth with different crystallographic orientations. The simulated results indicate that the graphite nodule grows in a spherical morphology when the surrounding environment of a single graphite nodule is same. However, for two adjacent graphite nodules, the environment is different. The higher the carbon concentration, the faster the growth of graphite. By comparison with experimental results, it is found that the microstructure evolution of near eutectic spheroidal graphite cast iron during solidification process can be reproduced quantitatively by numerical simulation with this model.     

Crystallography of graphite spheroids in cast iron

To further understand graphite growth mechanisms in cast irons, this study focuses on the crystal structure of a graphite spheroid in the vicinity of its nucleus. A sample of a graphite spheroid from a commercial cast iron was characterised using transmission electron microscopy. The chemical composition of the nucleating particle was studied at the local scale. Crystal orientation maps of the graphite spheroid revealed misorientations and twist boundaries. High-resolution lattice fringe images showed that the basal planes of graphite were wavy and distorted close to the nucleus and very straight further away from it. These techniques were complementary and provided new insights on spheroidal graphite nucleation and growth.     

Hydrogen evolution reaction on spheroidal graphite cast iron with different pearlite areas in sulphuric acid solutions

The rate equation of hydrogen evolution reaction of spheroidal graphite cast iron with different pearlite area has been studied in sulphuric acid solutions at 298 K. The cathodic Tafel slope of ?0·130 V/decade and the reaction order with respect to the activity of hydrogen ion of 1 are obtained by linear potential sweep technique. The rate equation of hydrogen evolution reaction does not depend on the area of pearlite. There is no difference in hydrogen evolution reaction mechanisms between pure iron and spheroidal graphite cast iron.     

Experimental assessment of interfacial contact thermal conductance between graphite and matrix in cast iron

Cast iron with good mechanical and thermal combination property is preferred material for the cylinder head of high power density diesel engine. Interface between graphite and matrix should play a key role in thermal conductivity of cast iron. However, it is difficult to measure the interfacial contact thermal conductance (ICTC) between graphite inclusion and matrix in cast iron. In this paper, a modeling experimental sample containing a macroscopic interface is designed and ICTC can be estimated with the aid of finite element (FE) calculation. At last the effect of ICTC on the thermal conductivity of cast iron is assessed according to the change of metallographic FE simulation results before and after considering ICTC. Results show that the magnitude of ICTC is between 1.0 × 10⁵ and 2.0 × 10⁵ W m^?2·K on the whole. The interface makes the theoretical thermal conductivity of cast iron drop down 34.6%.     

Pitting corrosion of older underground cast iron pipes

Major water supply distribution networks in many cities consist of buried cast iron pipes. Often the pipes are internally cement-lined. For these the most severe external pitting corrosion is important because this may cause leakage and eventual structural failure. Herein representative data is reported for 10 pipes, ranging in age from 34 to 129 years and from 200 to 600?mm diameter that are part of a larger data set. The pipes examined were selected by the water utilities from several critical locations. Pit depths over 1–2?m lengths of pipes were measured and examined and soil properties measured. The morphologies of pitting around the pipes were found to be very different, with often much greater pit depths and larger pit areas at the base of the pipes. There were also considerable differences along the length of individual parts of pipes. When plotted on a Gumbel plot for the maximum pit depths, the deepest pits showed a different Gumbel trend compared with the majority of pit depth maxima. Theoretically, this indicates that different pitting mechanisms are involved. This possibility is explored by reference to earlier work on the long-term pitting corrosion of steels in sea water. Comments are made also about empirical fitting with other extreme value distributions, as sometimes suggested.     

Different thermal fatigue behaviors between gray cast iron and vermicular graphite cast iron

The initiation and propagation of thermal fatigue cracks in gray cast iron and vemicular graphite cast iron were investigated by Uddeholm method to reveal the complex thermal fatigue behaviors of cast iron. Differences of thermal fatigue behaviors of gray cast iron and vemicular graphite cast iron were observed and analyzed. It is found that the observed differences are related to the combination of graphite morphology and the oxidization of matrix. More oxidized matrix is observed in gray cast iron due to its large specific surface area. The brittle oxidized matrix facilitates the propagation of microcracks along the oxidization layer. By contrast, the radial microcracks are formed in vermicular graphite at the edge of graphite due to fewer oxidization layers. It indicates that the thermal fatigue resistance of gray cast iron is dominated by graphite content and morphology while that of vermicular graphite cast iron strongly relates to the strength of the matrix.

     

Grey cast iron cast in shell and sand moulds: relationship between tensile and wedge strengths

The tensile strength S_t of grey cast iron can be calculated from measurement of wedge strength S_c by using a linear relation between both variables: S_t = AS_c-B. The coefficients A and B depend on the casting process, the geometry of wedge penetration tool and specimen, and also on the device used to perform the wedge penetration test. Low alloyed grey cast irons of FL15, FL20, FL25 and FL30 basic materials have been cast in shell and sand moulds, at two different pouring temperatures and with and without inoculation. These changes in the process produce large variations in the structure and mechanical strength of the materials. Although these variations are important, the relationship between tensile and wedge strengths can be well described by an equation of the above mentioned type with a unique pair of values for coefficients A and B. IJCMR/453     

Control of graphite formation in solidification of white cast iron

Abstract

Graphite formation should be strictly suppressed for the most abrasion resistant white cast irons, since austenite (γ)+graphite eutectic structure shows lower hardness and selectively wears thus deteriorates the abrasion resistance even though the austenite transform to hard phase such as martensite. On the other hand, a small amount of fine graphite is desired to distribute in rolls for hot steel mills to suppress the scoring. However, strong carbide formers such as Cr, V, Nb have been increasingly added to rolls, in order to crystallise more harder carbides. As γ+carbide eutectic grows, the residual liquid among eutectic cells becomes poor in carbide formers and rich in elements which promote graphite formation. Therefore an appropriate alloy design is essential for the hot steel milling rolls. In this study, the graphite formation mechanisms are discussed for chromium cast iron, high speed steel type cast iron and Ni hard type cast iron.     

Post-perforation external corrosion of cast iron pressurised water mains

The corroded external surfaces of older cast iron water mains buried in soils for many decades usually show a rough undulating topography. Sometimes, there also are areas of relatively smooth topography similar to uniform corrosion but over undulating surfaces. Investigations show this pattern is associated with localised pipe-wall perforation and sometimes pipe fracture. It is proposed that corrosion pitting from the outside surface of the pipe perforates the pipe-wall, allowing fresh oxygenated drinking water from inside the pipe to effuse through the orifice. This then causes a high rate of localised general corrosion under the graphitised layer. The resulting thinning of the pipe-wall may then lead to pipe fracture under high water pressure.     

Carburiser properties transfer into the structure of melted cast iron

Heredity in the microstructure of cast iron produced solely from scrap (synthetic cast iron) was considered experimentally. The carbon deficiencies were adjusted using anthracite, synthetic graphite and petroleum coke as carburisers. The small flakes of anthracite resulted in smaller graphite flakes in the final microstructure, proving that heredity is affected by the carburiser as much as by the particular “pig iron-steel scrap-cast iron” combination.     

Study of shrinkage porosity in spheroidal graphite cast iron

This study aims at identifying the relationship between the shrinkage cavities and the solidification structure in spheroidal graphite cast iron. Cast samples specially designed to contain shrinkage cavities were used. The solidification macrostructure was revealed using the Direct Austempering After Solidification method, while the solidification microstructure was revealed by using colour etching. At the midsection of the pieces, the shrinkage cavities and the solidification structure were observed jointly. The study showed that the classification of shrinkage porosity found in literature does not correspond to the ductile iron solidification model recognized by most of the scientific community. Early solidification models, and therefore shrinkage formation mechanisms, were proposed in instances when there was not a thorough knowledge of the morphology of the solid phases during solidification. Nowadays, defects formation mechanisms can be described with higher accuracy. Therefore, an updated classification of shrinkage porosity for spheroidal graphite iron is proposed.