Fracture Failure Analysis of Ductile Cast Iron Crankshaft in a Vehicle Engine

Hou, Xueqin; Liu, Ying; Jiang, Tao

doi:10.1007/s11668-010-9406-z

Cited by 13 publications

(5 citation statements)

References 8 publications

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“…Another advantage of this cast iron is that its structure can be created without any heat treatment by simply controlling the alloying elements. Fatigue fractures, the manufacturing cost and mechanical strength are the most important factors compared to steel [4][5][6][7][8]. Amiri Kasvayee [9] studied the deformation behavior of ductile cast iron in a tensile test using digital image correlation and measured the tensile strength in situ.…”

Section: Introductionmentioning

confidence: 99%

Mechanical Properties and Fracture Toughness Prediction of Ductile Cast Iron under Thermomechanical Treatment

Abdellah,

Alharthi,

Alfattani

et al. 2024

Metals

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Temperature has a great influence on the mechanical properties of ductile cast iron or nodular cast iron. A thermomechanical treatment was carried out at various elevated temperatures of 450 °C, 750 °C and 850 °C using a universal testing machine with a tub furnace. Specimens were held at these temperatures for 20 min to ensure a homogeneous temperature distribution along the entire length of the specimen, before a tensile load was applied. Specimens were deformed to various levels of uniform strain (0%, 25%, 50%, 75%, and 100%). These degrees of deformation were measured with a dial gauge attached to a movable cross plate. Three strain rates were used for each specimen and temperature: 1.8×10−4 s−1, 9×10−4 s−1 and 4.5×10−3 s−1. A simple analytical model was extracted based on the CT tensile test geometry and yield stress and a 0.2% offset strain to measure the fracture toughness (JIC). To validate the analytical model, an extended finite element method (XFEM) was implemented for specimens tested at different temperatures, with a strain rate of 1.8×10−4 s−1. The model was then extended to include the tested specimens at other strain rates. The results show that increasing strain rates and temperature, especially at 850 °C, increased the ductility of the cast iron and thus its formability. The largest percentage strains were 1 and 1.5 at a temperature of 750 °C and a strain rate of 1.8×10−4 s−1 and 9×10−4 s−1, respectively, and reached their maximum value of 1.7 and 2.2% at 850 °C and a strain rate of 9×10−4 s−1 and 4.5×10−3 s−1, respectively. In addition, the simple and fast analytical model is useful in selecting materials for determining the fracture toughness (JIC) at various elevated temperatures and different strain rates.

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Section: Introductionmentioning

confidence: 99%

Mechanical Properties and Fracture Toughness Prediction of Ductile Cast Iron under Thermomechanical Treatment

Abdellah,

Alharthi,

Alfattani

et al. 2024

Metals

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“…The relevant development of these cast alloys is such that the required structures can be commonly obtained without any heat treatment by controlling the content of some alloying elements. As the main mode of failure of high-security parts for both cast iron and steel [3][4][5][6] is fatigue fracture, the combination of their cost and resistance to mechanical damage becomes the factor of competitive advantage. In this context, both cast iron grades and steel grades have evolved in an attempt to broaden their field of application, though remaining niche markets with differentiated technical-economic requirements.…”

Section: Introductionmentioning

confidence: 99%

Tensile properties and fracture toughness at service temperatures of an optimized pearlitic ductile iron alloy for automotive crankshafts

Artola

Monzón

Lacaze

et al. 2022

Materials Science and Engineering: A

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“…Casting stresses have also been found to cause premature cracking in gray cast iron crank cases 3 due to excessive or rapid cooling during the casting process. Hou and Jiang performed an investigation on an engine crankshaft that suddenly fractured, and they concluded the failure occurred in the ductile iron due to fatigue from bending and twisting with cracks originating at subsurface shrinkage 4 . Computed tomography has been used to characterize defects in castings 5 , and has been shown to have excellent sensitivity in revealing casting defects.…”

Section: Introductionmentioning

confidence: 99%

Metallurgical and Mechanical Failure Analysis of an Aftermarket Flywheel

Kar

2021

JotNAFE

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A failure analysis investigation was performed on the remnants of an aftermarket gray cast iron flywheel that catastrophically fractured during operation in a vehicle after 24 miles of operation. Light microscopy, 3D X-ray micro-computed tomography (micro-CT), scanning electron microscopy (SEM), metallography, and hardness/tensile testing techniques were utilized to characterize manufacturing quality, mode(s) of failure, microstructural variation, fracture surfaces, and mechanical properties of the failed component. Light microscopy examination of the remnant surfaces showed that the flywheel shattered with signs of radial heat checking fissure cracks. A metallurgical examination of the flywheel showed that it was manufactured from cast gray iron, with evidence of microstructural changes near heat-affected zones from graphite flakes in a ferrite/pearlite matrix to needle and lath formations similar to bainite or martensitic phases. The CT scan slices and fracture surface examination in the SEM showed signs of porosity and dendritic formations along a fracture surface believed to be the crack initiation location. The analysis suggests manufacturing flaws found within the flywheel were a likely contributing factor leading to premature failure during service.

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Fracture Failure Analysis of Ductile Cast Iron Crankshaft in a Vehicle Engine

Cited by 13 publications

References 8 publications

Mechanical Properties and Fracture Toughness Prediction of Ductile Cast Iron under Thermomechanical Treatment

Mechanical Properties and Fracture Toughness Prediction of Ductile Cast Iron under Thermomechanical Treatment

Tensile properties and fracture toughness at service temperatures of an optimized pearlitic ductile iron alloy for automotive crankshafts

Metallurgical and Mechanical Failure Analysis of an Aftermarket Flywheel

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