Effect of Casting Design to Microstructure and Mechanical Properties of 4 Mm Twdi Plate

Abstract

Casting design is chosen by Soedarsono et al to maintain cooling rate in producing thin wall ductile iron (TWDI). Cooling rate should be maintained to prevent carbide formation. This paper discusses the effect of gating system design on microstructure and mechanical properties of 4 mm TWDI plate. A casting design based on vertical gating system is made to produce TWDI plates with the thickness of 1, 2, 3, 4, and 5 mm. This vertical system allows plates to function as runner which will helps in preventing premature solidification. Three designs were made. These designs are coded as T1, T2, and T3. These three designs were also used in making 1, 2, 3, and 5 mm TWDI plates of which the result has been published. Z-Cast is used to conduct a casting design simulation for filling flow and solidification. The result of flow simulation shows that the filling flow is resulted in two kinds. The result of solidification specifies that the 4 mm TWDI plates solidify in the third place. The result of the experiment highlights that in all of the designs, which have microstructure and consisted of nodule graphite in ferrite matrix, no trace of carbide and skin effect are formed. The length of skin effect varies in all of the designs. The highest nodularity is only 80% while nodule count is 931 nodules/mm2. Brinell hardness number for all of the design is beyond the standard given by JIG G5502. As for UTS, yield strength and elongation none of the designs exceeds the minimal standard. The result of the experiment does not confirm the result of the simulation. In sum, compared to the previous result, the curve trends of 4 mm TWDI plates look similar to 2 mm TWDI plates.

Thin-Wall Ductile Iron Castings

“…Soedarsono, Soemardi and Sulamet-Ariobimo proposed three types and all of them produced TWDI plates with ferrite matrix. After evaluating the microstructures and tensile properties of every plates resulting from every types [3,4,[31][32][33], they chose the first type which is presented in Figure 13a for further developments.…”

The Effect of Vertical Step Block Casting to Microstructure and Mechanical Properties in Producing Thin Wall Ductile Iron

“…Followed by Schrems et al [1] who created horizontal casting design, INTEMA group developed special horizontal and vertical gating system [2,3,13]. In addition, Labrecque and his associates [10][11][12] created their own casting design as well as Soedarsono et al [5,[14][15][16][17][18][19] together with his colleagues developed several special vertical casting designs which can be classified into 2 groups. In the first group, the designs were developed from Stefanescu et al vertical casting design [3].…”

“…In the first group, the designs were developed from Stefanescu et al vertical casting design [3]. Soedarsono et al modified the gating system designs purposed by Stefanescu et al with three variations, that are: the bottom gating, the bottom gating with supporting gates, and the top gating gravity [5,[14][15][16][17][18][19]. While in the other groups Soedarsono et al applied the Y-block principle, which can improve the casting yield.…”

Thin Wall Ductile Iron Castings

“…After evaluating the microstructures and tensile properties of every plates resulting from every types [3,4,[31][32][33], they chose the first type which is presented in Figure 13a for further developments.…”

“…Therefore, as long as the liquid metal runs along the system, the thinnest part will not solidify and premature solidification Figure 13. Soedarsono designs [3][4][5][6][7][8][31][32][33]. Vertical casting.…”