Vermicular graphite cast iron current state of the art

Vermicular graphite cast iron is a new addition to the family of cast irons. Various methods for producing vermicular graphite cast iron are briefly discussed in this paper. The mechanical and physical properties of cast irons with vermicular graphite have been found to be intermediate between those of gray and ductile irons. Other properties such as casting characteristics, scaling resistance, damping capacity and machinability have been compared with those of gray and ductile irons. Probable applications of vermicular graphite cast irons are suggested.

Chromium-manganese iron alloy system design cast in metal and sand moulds for erosion resistance: a positron lifetime study

Erosion characteristics of high chromium (Cr, 16-19%) alloy cast iron with 5% and 10% manganese (Mn) prepared in metal and sand moulds through induction melting are investigated using jet erosion test setup in both as-cast and heat-treated conditions. The samples were characterised for hardness and microstructural properties. A new and novel non-destructive evaluation technique namely positron lifetime spectroscopy has also been used for the first time to characterise the microstructure of the material in terms of defects and their concentration. We found that the hardness decreases irrespective of the sample condition when the mould type is changed from metal to sand, On the other hand, the erosion volume loss shows an increasing trend. Since the macroscopic properties have a bearing on the microstructure, good credence is obtained from the microstructural features as seen from light and scanning electron micrographs. Faster cooling in the metal mould yielded fine carbide precipitation on the surface. The defect size and their concentration derived from positron method are higher for sand mould compared to metal mould. Lower erosion loss corresponds to smaller size defects in metal mould are the results of quicker heat transfer in the metal mould compared to the sand mould. Heat treatment effects are clearly seen as the reduced concentration of defects and spherodisation of carbides points to this. The erosion loss with respect to the defects size and concentration correlate very well.

Effect of carbon equivalent and inoculation on residual stresses in grey iron castings

It is virtually impossible to produce castings free from internal stresses using conventional methods of founding. Castings with appreciable stresses distort during storage, transportation, machining and service. Though composition and melt treatment are known to affect the magnitude of residual stress in castings, the data on the effect of carbon equivalent and inoculation on the magnitude of residual stress in castings are limited. In the present investigation, an attempt is made to study (i) the effect of carbon equivalent on residual stress in cast iron castings, and (ii) the effect of inoculants such as calcium silicide and ferrosilicon on residual stress in iron castings in the carbon equivalent range 3.0–4.0%. The results of the investigation indicate the following: (i) the residual strains decrease linearly with increase in carbon equivalent in the uninoculated and inoculated irons; (ii) the tensile residual stresses decrease linearly with increase in carbon equivalent value of the uninoculated, calcium silicide-inoculated and ferrosilicon-inoculated cast iron castings; (iii) the ratio of UTS to residual stress increased on inoculating the grid castings. This increase is higher for calcium silicide-inoculated grids than for ferrosilicon-inoculated grid castings. This implies that from the residual stress point of view, inoculation of the iron with calcium silicide is beneficial.

Characterization of cast irons for optimum performance by overall rating method

An experimental investigation was carried out to Characterise the performance of four types of cast iron under adhesive wear, erosive wear, cavitation erosion and low frequency thermal cycling. Results indicate that vermicular graphite iron has the best rating among the cast irons investigate,based on the overall performance as well as cost consideration.

Mechanism of improvement in oil spreadability of aluminium alloy-graphite particle composites

The spreadability of SAE-30 oil on Al-12 Si base (LM-13) alloy containing dispersed graphite particles about 50 μm average size in its matrix is found to be greater than on either LM-13 with no graphite or brass. It is also found that the spreadability on LM-13 base alloys increase with increasing volume of graphite dispersion in the matrix of these alloys. Further increases in the spreadability of oil on machined LM-13-graphite particle composite test surfaces occur if these are rubbed initially against control discs of either LM-13 or grey cast iron. The formation of a triboinduced graphite-rich layer, confirmed by esca, appears to be responsible for the improved oil spreadability on the rubbed test surfaces of LM-13 base alloys as compared to the as-machined test surfaces prior to rubbing. The triboinduced layer of graphite is apparently responsible for the observed reduction in the friction, wear and seizing tendency of triboelements made from aluminium alloy-graphite particle composites.

Improved damping capacity and machinability of graphite particle-aluminum alloy composites

The damping capacity of cast graphitic aluminum alloy composites has been measured using a torsion pendulum at a constant strain amplitude. It was found that flake-graphite particles dispersed in the matrix of aluminum alloys increased the damping capacity; the improvement was greater, the higher the amount of graphite dispersed in the matrix. At sufficiently high graphite contents the damping capacity of graphitic aluminum composites approaches that of cast iron. The ratio between the damping capacity and the density of graphitic aluminum alloys is higher than cast iron, making them very attractive as light-weight, high-damping materials for possible aircraft applications. Machinability tests on graphite particle-aluminum composites, conducted at speeds of 315 sfm and 525 sfm, showed that the chip length decreased with the amount of graphite of a given size. When the size of graphite was decreased, at a given machining speed, the chip length decreased. Metallographic examination shows that graphite particles act as chip breakers, and are frequently sheared parallel to the plane of the

Running-in wear of a compression ignition engine: Factors influencing the conformance between cylinder liner and piston rings

The conformance between the liner and rings of an internal combustion engine depends mainly on their linear wear (dimensional loss) during running-in. Running-in wear studies, using the factorial design of experiments, on a compression ignition engine show that at certain dead centre locations of piston rings the linear wear of the cylinder liner increases with increase in the initial surface roughness of the liner. Rough surfaces wear rapidly without seizure during running-in to promote quick conformance, so an initial surface finish of the liner of 0.8 μm c.l.a. is recommended. The linear wear of the cast iron liner and rings decreases with increasing load but the mass wear increases with increasing load. This discrepancy is due to phase changes in the cast iron accompanied by dimensional growth at higher thermal loads. During running-in the growth of cast iron should be minimised by running the engine at an initial load for which the exhaust gas temperature is approximately 180 °C.

Mechanical Properties of Al-Mica Particulate Composite Material

Cast aluminium alloy mica particle composites of varying mica content were tested in tension, compression, and impact. With 2.2 percent mica (size range 40µm – 120µm) the tensile and compression strengths of aluminium alloy decreased by 56 and 22 percent, respectively. The corresponding decreases in percent elongation and percent reduction are 49 and 39 percent. Previous work [2] shows that despite this decrease in strength the composite with 2.5 percent mica and having an UTS of 15 kg/mm2 and compression strength of 28 kg/mm2 performs well as a bearing material under severe running conditions. The differences in strength characteristics of cast aluminium-mica particle composites between tension and compression suggests that, as in cast iron, expansion of voids at the matrix particle interface may be the guiding mechanism of the deformation. SEM studies show that on the tensile fractured specimen surface, there are large voids at the particle matrix interface.

Laboratory studies on ball wear in the grinding of a hematite-magnetite ore

Marked-ball grinding tests were carried out under different grinding conditions and environments. Three types of balls were used, namely, cast hyper steel, high chrome cast iron and EN-31 (forged), which cover a wide range of chemical composition, microstructure and media hardness. The effect of pulp density on ball wear and grinding efficiency was also studied. Relative pulp viscosities at different percent solids for the ore slurry were also determined. As the Kudremukh ore contained about 0.2% pyrite, the effect of addition of pyrite on ball wear was studied separately. Results of marked-ball grinding tests indicated that ball wear increased with time and showed a sharp increase for wet grinding over dry grinding. Ball wear under wet grinding conditions was also influenced by the gaseous atmosphere in the mill. At 70% solids, the best results in terms of reduced ball wear coupled with satisfactory grinding efficiency were obtained. The influence of oxygen on the corrosive wear of grinding balls was increasingly felt only if sulphide minerals such as pyrite were also present in the ore. The various ball materials could be arranged in the following order with respect to their overall wear resistance: high chrome cast iron > EN-31 (forged) > cast hyper steel.Possible ball wear mechanisms involved in the grinding of Kudremukh ore are discussed.

Ball wear and its control in the grinding of a lead-zinc sulphide ore

Marked ball grinding tests were carried out in the laboratory with a lead-zinc sulphide ore under different experimental conditions using high carbon low alloy steel (cast and forged) and high chrome cast iron balls. Relative ball wear as a function of grinding period and milling conditions was evaluated for the different types of ball materials. The role of corrosion and abrasion-erosion in the wear of grinding media is brought out. Methods to minimise ball wear through control of mill atmosphere and addition of reagents are discussed.

Ball wear mechanisms and control in the grinding of sulfide and phosphate ores

Marked ball grinding tests were carried out in the laboratory using high carbon low alloy steel (cast and forged) and high chrome cast iron balls. Relative ball wear as a function of grinding period and milling conditions was evaluated for the different type of ball materials in the grinding of lead-zinc sulphide and phosphate ores. Results indicated that ball wear increased with time and showed a sharp increase for wet grinding over dry grinding. Ball wear under wet grinding conditions was also influenced by the gaseous atmosphere in the mill. The influence of oxygen on the corrosive wear of grinding balls was increasingly felt in case of sulphide ore grinding. The grinding ball materials could be arranged in the following order with respect to their overall wear resistance: