An unalloyed thin-wall ductile cast iron with the chemical composition of C = 3%, Si = 4.15%, Mn = 0.36%, Mg = 0.04%, and carbon equivalent of 4.39% was cast by both conventional and ablation casting in sections of nominal thickness 1, 2, 4, 8 mm. The effect of various commercial inoculants (based on Zr, Sr, and Ba) on microstructure and mechanical properties of the samples was investigated. In the ablation casting, the mold is eroded away by water, and the water becomes responsible for the heat transfer from the casting. In our work, ablative cooling could not be applied quickly enough to have any influence on the microstructure of the 1 mm thick cast section. In the 2-mm-thick specimen, ablation increased the nodule count from 497 to 1484 and graphite nodularity from 76 to 93%. In the 8 mm section, the tensile yield strength increased from 539 to 624 MPa and elongation was increased from 4.9 to 10.2%.

Ablation Casting of Thin-Wall Ductile Iron

Two different grades of nodular Cast iron one with Copper and another without Copper were austempered at 300°C for different lengths of time (30 minutes, 60 minutes, 90 minutes & 120 minutes). The mechanical properties like Yield strength (0.2 % offset) U.T.S. and ductility (in terms of % of elongation) were determined and at the same time the fractured surfaces of all the specimens were analyzed with the help of the Scanning Electron Microscope (S.E.M.).

http://dspace.nitrkl.ac.in:8080/dspace/bitstream/2080/1302/1/Characterization.pdf

Characterization of adi through fractographic analysis

The selection of material for the engineering components plays major role in the manufacturing process. Grey cast iron is the suitable material for the centrifugal pump casing used to lift water to overhead storage tanks. The complication in the involute profile made the casing produced by the casting process to overcome the difficulty in machining the whole, except few machining areas. The outer face and bore are machinable to assemble shaft and impeller. Since the involute profile perfectly build kinetic energy in the water, the inner walls of the casing are so perfect to withstand unequal forces due to pressure. The structural dimension of the casing is affected by the machining operation and component must be thermally stable while machining the critical areas. In modern manufacturing, high speed machining using CNC machines, is inevitable, which in turn produces enormous amount of heat energy during machining. It leads to non-uniform thermal distribution throughout the component. This results in thermo-mechanical affected zone in the component which leads to early failure of the component. Functional dimensions are deviated, microstructural changes and surface finish also affected during the machining process. This research work studies the thermal disruption and microstructure during machining of the casing. The experiment is conducted on 6-inch centrifugal F210 Cast Iron pump casing, machined in Vertical machining centre. Recommended machining parameters widely followed in industries are used for experimentation purpose. Temperature measurements are done at various selected points using non-contact pyrometer. The surface roughness measured at various locations of the machined areas of the casing to fix the machining parameters. The results observed from the experiment reveals the recommended parameters for machining at critical areas of the casing. 

Prediction of thermal disruption and microstructure study on cast iron pump casing in metal removal process

Microstructure, hardness and wear characteristics were studied for: (1) Austempered SG-iron (ADI); and (2) low alloyed SG-iron. Comparison has been made between the properties of these two types and that of conventional SG-iron. The present ADI samples were produced by austenitising at 1203K, for 3.6 ks and austempered at 773K for 1.8 ks. The second type was prepared by adding low percentages of Ni, Cr, Mn and Mo to SG-iron. The microstructure of ADI consists of upper bainite and retained austenite, while the low alloyed SG-iron showed the graphite nodules to be surrounded by ferrite, pearlite, and iron carbides. Macrohardness study showed a maximum value for low alloyed SG-iron, and a minimum for conventional SG-iron, and hardness of ADI is intermediate between the two irons. The wear properties were determined using pin on ring machine, under dry sliding conditions at room temperature. The variation of wear rate with sliding distance, at variable loads and speeds were studied. The wear mechanisms were investigated by means of subsurface observations with an optical microscope. Microhardness test was used to study the change in the matrix strength with distance from the worn surface due to plastic deformation. Mild wear was observed for a wide range of sliding distances in the ADI. On the other hand, its range in low alloyed SG-iron was very narrow and most of the curves of mass loss revealed severe wear.

Structure and enginieering properties of some ductile irons

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Structure and enginieering properties of some ductile irons