Professional Documents
Culture Documents
Next Paper
Abstract
Non-spherical graphite morphology is detrimental on the mechanical
properties of ductile iron castings. This includes the branched and
interconnected chunky graphite that occasionally occurs in the thermal
center of castings. In this work the graphite morphology in ferritic ductile
iron that contained chunky graphite was studied. Chunky graphite was
shown to be a progressively degenerated morphology of spherical
graphite. Attempts to investigate the presence and segregation patterns of
elements that might play a role in the still concealed formation and growth
mechanism of chunky graphite were made. No macro segregation was
detected. The possible role of micro segregation of trace elements was
discussed but could not be determined. The graphite nucleation potential
seemed to be low in the chunky graphite areas due to the lack of available
oxygen and/or sulphur.
Key words ductile iron,
segregation, nucleation
graphite
184/1
morphology,
chunky
graphite,
Introduction
Spherical graphite morphology is an important factor to attain high quality
ductile iron castings. Every other type of morphology is detrimental on the
mechanical properties. This includes the branched and interconnected
chunky graphite that occasionally occurs in the thermal center of ductile
iron castings. The presence of chunky graphite decreases the ultimate
tensile strength (Rm) and especially the fracture elongation (A5). The
possible decrease in a ferritic ductile iron has been shown to reach 25%
and 50% respectively depending on the amount of chunky graphite [1].
However, the hardness (HBW) and the yield strength (Rp02) are hardly
affected at all by chunky graphite. Regarding the dynamic properties of
almost 100% chunky graphite containing material the crack propagation
rate is not significantly affected but the fracture toughness of the material
will be lower [2].
The risk of chunky graphite formation is increasing with long solidification
time. Consequently, the amount of chunky graphite tends to increase with
increased wall thicknesses [1]. The call for further research work to
determine the cause and growth mechanism of chunky graphite is
escalating with increased used of heavy section ductile iron castings in
demanding applications within the heavy automotive and the windmill
industries among others.
According to Gagn and Argo chunky graphite shows a spiral crystal
growth pattern caused by carbon supersaturation and constitutional
supercooling as the driving forces [3]. Fast diffusion rate due to the lack of,
or partially disrupted, austenite shell around the graphite nodule has also
been discussed as one possible cause for chunky graphite formation [3].
According to Itofuji et al the chunky graphite forms as a result of the lack of
magnesium gas bubbles in the melt and, further on, the growing graphite
is in contact with residual liquid iron through thin liquid channels in the
austenite [4]. The liquid channels are formed when segregated elements
lower the solidus temperature. Liu et al regards the chunky graphite to be
a deteriorated form of nodular graphite [5]. It has in fact been observed
that the transition between the graphite structures type A flake, type B
flake, type D undercooled flake, coral, compacted, chunky and spherical
graphite is continuous and not intermittent [6]. The different morphologies
were stated, by Liu et al to occur as a result of change in solidification rate
and as a function of alloy addition or segregation [6].
In this work the graphite morphology in ferritic ductile iron that contains
chunky graphite has been studied and attempts have been made to
investigate the presence and segregation patterns of elements that might
play a role of the concealed formation mechanism of chunky graphite.
Experimental
High silicon alloyed ductile iron were prepared in a 250 kg induction
furnace. The charge material consisted of pig iron 41 %, returns 17 % and
184/2
184/3
The examined fracture surfaces of the tensile test bars are located within
the chunky graphite zone shown in Figure 1. SEM investigations of
graphite in the fracture surfaces indicate gradual degeneration from
spherical to chunky morphology. Figure 4 shows well-shaped nodules.
Approaching chunky graphite areas different graphite morphologies as in
Figure 5 and 6 can be observed. These observations, that chunky graphite
is a progressively degenerated morphology of nodules, are in line with the
theory of Liu et al [5]. The degenerated graphite shape in Figure 7 and the
pyramidal growth of chunky graphite branches in Figure 8 confirm the
observations of Liu et al [5].
All specimens from the front axle housing showed somewhat different
graphite morphology compared to the 200 mm thick block. In most
locations normal spherical graphite morphology emerged. Roughly 15%
degenerated chunky graphite appeared at the most in the hot spots.
Figure 9 shows a typical area, here the cell boarders appear in a brown to
white color. The blue etching parts in the microstructure contain
degenerated graphite and do appear before the brownish cell boarders.
Here two variants of degenerated graphite can be seen. One type of
graphite that appears as normal chunky graphite (see Figure 10 in deep
etched condition) and one more like a stringer of graphite (Figure 11).
These graphite stringers lie between the secondary dendrite arms. The
classical chunky graphite seems to be placed in the center of the dendrite
arms. In all cases the degenerated graphite can co-exist with spherical
graphite.
Segregation of elements
Bulk analyzes did not show any significant difference in chemical
composition between the different positions indicated in Figure 1. Some
variations could be seen in Si content, for example, between different
positions but no coupling to chunky graphite could be confirmed. Macro
segregation between the nodular areas outside the chunky graphite zone
as well as inside the zone was hence not detected, Table 1.
Attempts to investigate micro segregation tendencies of low content
elements such as Ce, Ca and S in the blocks by using EPMA turned out to
be unsuccessful since the concentrations were below the detection limit of
the instrument. This was a fact close to spherical graphite as well as
nearby chunky graphite. The average Si content was somewhat higher
near the chunky graphite compared to that near a nodule. Nevertheless,
the difference was not greater than the Si fluctuation between two
nodules.
Closer investigations of the graphite in the front axle housing show some
differences. The stringer like graphite had in most cases been nucleated
on oxides. Spot analysis of the oxide particles revealed normal oxides
containing Si and or Mg. The melts that produced the components had a
184/4
184/5
184/6
1
3.05
0.19
0.071
0.016
0.020
0.012
0.0013
0.024
0.0001
<0.001
0.005
2
3.38
0.16
0.059
0.013
0.018
0.012
0.0006
0.025
0.0002
<0.001
0.003
MELT 1
3
4
3.27
3.31
0.17
0.18
0.055
0.047
0.014
0.016
0.019
0.021
0.013
0.013
0.0009 0.0011
0.024
0.024
0.0001 0.0002
<0.001 <0.001
0.003
0.004
5
3.26
0.19
0.055
0.016
0.021
0.013
0.0011
0.020
0.0002
<0.001
0.003
184/7
6
3.29
0.18
0.067
0.015
0.021
0.013
0.0011
0.022
0.0002
<0.001
0.003
2
3.36
0.18
0.046
0.017
0.018
0.014
0.0010
0.025
0.0001
<0.001
0.003
MELT 2
4
6
3.30
3.55
0.21
0.19
0.072
0.062
0.018
0.014
0.019
0.019
0.014
0.015
0.0016 0.0013
0.020
0.020
0.0001 0.0001
<0.001 <0.001
0.006
0.006
Figures
1 2 3 4 5 6
184/8
184/9
Figure 13 Particles in the borderline and in the nodular areas (see Figure
12) were composed of these elements. The peak to the left is not valid for
the analyze.
Previous Paper
Next Paper
184/10
Back to Programme