The present work describes studies about the influence of processing variables on the microstructure and properties of dual phase austempered ductile iron (ADI). The upper and lower critical temperatures of conventional ductile iron melt were determined. Heat treatments involving austenitising within the intercritical interval, followed by austempering, allowed microstructures to be obtained composed of different combinations of free ferrite and ausferrite. Mechanical and fracture toughness tests performed on samples with mixed structures showed interesting combinations of strength and toughness, in comparison with fully ferritic and fully ausferritic matrices, particularly when austempering was carried out at 350uC. The results of the critical crack size, expressed by the relationship (K IC /s YS ) 2 , which indicates the relative toughness of the material, showed the best values for ferritic matrices with y20% ausferrite. This effect is attributed to the location of the ausferrite in the last to freeze regions (the weakest areas in the matrix) where it acted as a reinforcing phase.

The present work aims to evaluate and compare the influence that section size has on the microstructure and properties of fully ferritic, fully ausferritic and dual phase ADI matrices. Samples taken from ‘Y’ blocks of 25, 50 and 75 mm thickness were used to perform metallographic studies and mechanical tests. Cooling rate differences arising from changes in section size promote different microsegregation characteristics affecting solid state transformations and, consequently, the final microstructure and properties. When the section size increases, some properties decrease. The strongest deleterious effect was ascribed to the elongation and impact of ADI samples, where drops of nearly 40% were reached when specimens taken from the thinnest ‘Y’ blocks were compared to those taken from the thickest ones. Regarding fracture toughness, ferritic matrices exhibited the most noticeable detrimental effect. Dual phase ADI samples, on the other hand, presented the least deleterious section size effect on all the studied properties.

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A B S T R A C TThe effects of the microstructure topology on the fracture toughness of dual-phase austempered ductile iron are studied in this paper by means of finite element modelling and experimental testing. To this end, specimens with matrix microstructures ranging from fully ferrite to fully ausferrite were studied and the preferential zones and phases for crack propagation were identified in every case. The effectiveness of the ausferrite phase as a reinforcement of the ferritic matrix via the encapsulation of the brittle and weak last-to-freeze (LTF) zones was confirmed. The toughening mechanism is consequence of the increment in the crack path longitude as it avoids the encapsulated LTF zones. Besides, the presence of small pools of allotriomorphic ferrite increase the crack propagation resistance of the ausferrite-ferrite matrices. 0 n = mode-I fracture energy G 0 s = mode-II fracture energy K IC = Fracture toughness t 0 n = maximum normal traction t 0 s = maximum shear traction ε ut = ultimate strain σ 0.2 = yield stress σ ut = ultimate tensile stress ν = Poisson ratio I N T R O D U C T I O NThe engineering community is strongly pressed to produce lighter, stronger and stiffer metallic parts. Ductile iron (DI) can be a material of choice to fabricate numerous parts, because it is suitable to produce high resistance cast parts of complex shape and relatively inexpensive. For this reason DI is used to successfully replace cast and forged steels parts in a large number of applications. 1 The mechanical properties of sound DI cast parts depends mainly on the matrix microstructure (type, amount and distribution of microconstituents), the graphite phase and the cast defects present mainly in the last-to-freeze (LTF) regions. A wide range of microstructures, and consequentlyCorrespondence: Adrián P. Cisilino. mechanical properties, can be obtained by using different heat treatments. 2 Currently, DI producers work in the continuous improvement of DI properties while seeking for new applications. In particular, the market of safety critical parts in the automotive industry is a main target where high strength and toughness are customary requirements. In this regard special thermal cycles have been developed in order to obtain mixed microstructures. Wade et al., 3 He et al. 4 and Rashidi et al. 5 have obtained mixed microstructures starting from rapid uncompleted austenitizations into the austenitic field. The austenite nucleated mainly surrounding graphite nodules is transformed into pearlite, bainite or martensite depending on the cooling rate. The final phases obtained consisted of ferrite and pearlite, bainite or martensite. The relationship between

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This work aims at evaluating the fracture surfaces of tensile samples taken from a new kind of ductile iron referred to as ‘dual‐phase Austempered Ductile Iron (ADI)’, a material composed of ausferrite (regular ADI microstructure) and free (or allotriomorphic) ferrite. The tensile fracture surface characteristics and tensile properties of eight dual‐phase ADI microstructures, containing different relative quantities of ferrite and ausferrite, were studied in an alloyed ductile cast iron. Additionally, samples with fully ferritic and fully ausferritic (ADI) matrices were produced to be used as reference. Ferritic–pearlitic ductile irons (DI) were evaluated as well. For dual‐phase ADI microstructures, when the amount of ausferrite increases, tensile strength, yield stress and hardness do so too. Interesting combinations of strength and elongation until failure were found. The mechanisms of fracture that characterise DI under static uniaxial loading at room temperature are nucleation, growth and coalescence of microvoids. The fracture surface of fully ferritic DI exhibited an irregular topography with dimples and large deformation of the nodular cavities, characteristic of ductile fracture. Microstructures with small percentages of ausferrite (less than 20%) yielded better mechanical properties in relation to fully ferritic matrices. These microstructures presented regions of quasi‐cleavage fracture around last‐to‐freeze zones, related to the presence of ausferrite in those areas. As the amount of ausferrite increased, a decrease in nodular cavities deformation and a flatter fracture surface topography were noticed, which were ascribed to a higher amount of quasi‐cleavage zones. By means of a special thermal cycle, microstructures with pearlitic matrices containing a continuous and well‐defined net of allotriomorphic ferrite, located at the grain boundaries of recrystallised austenite, were obtained. The results of the mechanical tests leading to these microstructures revealed a significant enhancement of mechanical properties with respect to completely pearlitic matrices. The topographies of the fracture surfaces revealed a flat aspect and slightly or undeformed nodular cavities, as a result of high amount of pearlite. Still isolated dimple patterns associated to ferritic regions were observed.

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Bainitic microstructures obtained in high-carbon (HC) and high-silicon (HSi) steels are currently of great interest. Microstructural evolution and the bainitic transformation kinetics of a high-carbon and high-silicon cast steel held at 280, 330, and 380 °C was analyzed using dilatometry, X-ray diffraction, optical and scanning electron microscopy, and electron backscatter diffraction (EBSD). It is shown that the heterogeneous distribution of silicon (Si), manganese (Mn), and chromium (Cr) associated to microsegregation during casting has a great impact on the final microstructure. The transformation starts in the dendritic zones where there is a lower Mn concentration and then expands to the interdendritic ones. As Mn reduces the carbon activity, the interdendritic areas with a higher Mn concentration are enriched with carbon (C), and thus, these zones contain a greater amount of retained austenite plus martensite, resulting in a heterogeneous microstructure. Higher transformation temperatures promote higher amounts of residual austenite with poor thermal/mechanical stability and the presence of martensite in the final microstructure, which has a detrimental effect on the mechanical properties. Tensile tests revealed that the ultra-fine microstructure developed by the transformation at 280 °C promotes very high values of both tensile and yield stress (≈1.8 GPa and 1.6 GPa, respectively), but limited ductility (≈2%).