Microstructure and mechanical properties of heavy section ductile iron castings: experimental and numerical evaluation of effects of cooling rates

Ceschini, Lorella; Morri, Alessandro; Morri, An.; Salsi, Emilio; Squatrito, Rosario; Todaro, Ivan; Tomesani, Luca

doi:10.1179/1743133615y.0000000022

Cited by 26 publications

(8 citation statements)

References 19 publications

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“…The detailed description of the experimental setting, materials, methods and experimental measurements can be found in [43]. Additional information about the metallurgical and mechanical properties and the microstructure obtained for the di¤erent cubes of the casting are reported in [17].…”

Section: Cubes Testmentioning

confidence: 99%

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A Phenomenological Model for the Solidification of Eutectic and Hypoeutectic Alloys Including Recalescence and Undercooling

Chiumenti

Cervera

Salsi

et al. 2018

Journal of Heat Transfer

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In this work, a novel phenomenological model is proposed to study the liquid-to-solid phase change of eutectic and hypoeutectic alloy compositions. The objective is to enhance the prediction capabilities of the solidification models based on a-priori definition of the solid fraction as a function of the temperature field. However, the use of models defined at the metallurgical level is avoided to minimize the number of material parameters required. This is of great industrial interest because, on the one hand, the classical models are not able to predict recalescence and undercooling phenomena, and, on the other hand, the complexity as well as the experimental campaign necessary to feed most of the microstructure models available in the literature make their calibration difficult and very dependent on the chemical composition and the treatment of the melt. Contrarily, the proposed model allows for an easy calibration by means of few parameters. These parameters can be easily extracted from the temperature curves recorded at the hot spot of the quick cup test, typically used in the differential thermal analysis (DTA) for the quality control of the melt just before pouring. The accuracy of the numerical results is assessed by matching the temperature curves obtained via DTA of eutectic and hypoeutectic alloys. Moreover, the model is validated in more complex casting experiments where the temperature is measured at different thermocouple locations and the metallurgical features such as grain size and nucleation density are obtained from an exhaustive micrography campaign. The remarkable agreement with the experimental evidence validates the predicting capabilities of the proposed model.

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Section: Cubes Testmentioning

confidence: 99%

“…Hence, in the Cubes test the sensitivity to the di¤erent cooling conditions depends on: (i) the size of each cube; (ii) the distance from the center (thermal center) of the specimen. The outcome of this experimental campaign is detailed in [17].…”

Section: Microstructural Analysismentioning

confidence: 99%

A Phenomenological Model for the Solidification of Eutectic and Hypoeutectic Alloys Including Recalescence and Undercooling

Chiumenti

Cervera

Salsi

et al. 2018

Journal of Heat Transfer

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“…After successful validation of a model, numerical simulation can be an efficient tool for relatively fast verification of the designed corrections in the production technology. Nowadays, by using numerical simulations, it is possible to predict the complete process, from the technology plan [7,8,9] through castings casting [10,11], including solidification [12][13][14], stress states [13][14][15][16][17], defects prediction [13,14,18,19] and resulting metallographic structure of a casting [19][20][21].…”

Section: Introductionmentioning

confidence: 99%

Influence of the chill size on the porosity formation in ductile iron casting

Socha

FILIPEK

Gryc

et al. 2022

METAL 2022 Conference Proeedings

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This paper describes the numerical modelling of solidification of ductile iron castings intended for the shipbuilding industry. Numerical simulations we performed in the computer software MAGMASOFT ® . The purpose of numerical simulations was to predict solidification under defined casting conditions to verify whether the proposed production technology is adequate. Attention was focused mainly on the porosity occurrence in the casting, which is determined at a stated location using an ultrasonic test. Variants with different types of chills were simulated to determine their effect on the size of porosity. The results of these variants are presented in this paper. The variant with the best results was then recommended for production under operating conditions.

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“…The nodular graphite morphology is obtained by treating the iron melt with magnesium alloy, but the amount and characteristics of the graphite is also affected by other process factors, as inoculation, and factors related to the geometrical design of the casting, e.g. the local cooling rate (Ceschini et al 2015). In addition, the material behavior is highly dependent on the characteristics of the ferrous matrix, which typically contains ferrite, pearlite or a combination of these two phases into a so called "ferritic-pearlitic" matrix where ferrite has lower strength and higher ductility than pearlite.…”

Section: Introductionmentioning

confidence: 99%

Multidisciplinary Shape Optimization of Ductile Iron Castings by Considering Local Microstructure and Material Behaviour

Olofsson

Cenni²,

Cova³

et al. 2017

Advances in Structural and Multidisciplinary Optimization

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During the casting process and solidification of ductile iron castings, a heterogeneous microstructure is formed throughout the casting. This distribution is strongly influenced by the item geometry and the process related factors, as chemical composition and local solidification conditions. Geometrical changes to the geometry of the casting thus alters the local mechanical behavior and properties, as well as the distribution of stresses and strains when the casting is subjected to load. In order to find an optimal geometry, e.g. with reduced weight and increased load-bearing capacity, this interdependency between geometry and local material behavior needs to be considered and integrated into the optimization method. In this contribution, recent developments in the multidisciplinary integration of casting process simulation, solidification and microstructure modelling, microstructurebased material characterization, finite element structural analyses with local material behavior and structural optimization techniques are presented and discussed. The effect and relevance of considering the local material behavior in shape optimization of ductile iron castings is discussed and evidenced by an industrial application. It is shown that by adopting a multidisciplinary optimization approach by integration of casting simulation and local material behavior into shape optimization, the potential of the casting process to obtain components with high performance and reliability can be enabled and utilized.

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Microstructure and mechanical properties of heavy section ductile iron castings: experimental and numerical evaluation of effects of cooling rates

Cited by 26 publications

References 19 publications

A Phenomenological Model for the Solidification of Eutectic and Hypoeutectic Alloys Including Recalescence and Undercooling

A Phenomenological Model for the Solidification of Eutectic and Hypoeutectic Alloys Including Recalescence and Undercooling

Influence of the chill size on the porosity formation in ductile iron casting

Multidisciplinary Shape Optimization of Ductile Iron Castings by Considering Local Microstructure and Material Behaviour

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