Improved analytical method for chemical analysis of cast irons. Application to castings with chunky graphite

Chunky graphite is a particular form of graphite degeneracy that appears in the centre of large iron castings, with a well-defined transition from the outer unaffected area and the inner affected one. All previous works that looked for macrosegration to explain the phenomenon concluded that there are no significant composition differences between the inner and outer parts of such castings. This was challenged again because the analytical methods generally used for chemical analysis are not efficient for low-level elements. Accordingly, an ICP-MS procedure has been developed and validated to replace the usual ICP-OES method. Together with the usual methods for analysis of C, S and Si, this ICP-MS procedure has been applied to characterize chemical heterogeneities in a large block with chunky graphite in its centre, and to a standard part for comparison. It could be concluded that no macrosegregation has built up during the solidification process of the block investigated, i.e. that chunky graphite appearance is not related to any composition changes at the scale of the cast parts, in particular of elements known to affect graphite shape such as Ce, Mg, Sb, S,

Effect of mould inoculation on formation of chunky graphite in heavy section spheroidal graphite cast iron parts

The manufacturing process of heavy section ductile iron castings is strongly influenced by the risk of graphite degeneration under slow cooling rates. Appearance of this kind of defect is commonly linked to significant reductions in the mechanical properties of large castings. Studies on the effect of inoculation on chunky graphite formation in heavy sections have led to contradictory results in the literature and this triggered the present work. New experimental data are presented on the effect of mould inoculation on chunky graphite appearance during solidification of nodular irons which clearly demonstrate that mould inoculation increases the risk of chunky graphite formation in heavy sections. This is in agreement with some previous works which are reviewed, and it is suggested that the contradiction with other results could relate to the fact that these latter works dealt with chill casting

Effect of antimony on the eutectic reaction of heavy section spheroidal graphite castings

There is a strong demand for heavy section castings made of spheroidal graphite with a fully ferritic matrix, e.g. for manufacturing hubs for windmills. Such castings with slow solidification process are prone to graphite degeneration that leads to a dramatic decrease of the mechanical properties of the cast parts. Chunky graphite is certainly the most difficult case of graphite degeneracy, though it has long been known that the limited and controlled addition of antimony may help eliminate it. The drawback of this remedy is that too large Sb additions lead to other forms of degenerate graphite, and also that antimony is a pearlite promoter. As part of an investigation aimed at mastering low level additions to cast iron melts before casting, solidification of large blocks with or without Sb added was followed by thermal analysis. Comparison of the cooling curves and of the microstructures of these different castings gives suggestions to understand the controlling nucleation and growth mechanisms for chunky graphite cells

Effect of carbon equivalent on graphite formation in heavy-section ductile iron parts

The influence of post-inoculation and of cerium and antimony additions on the solidification process and on the formation of chunky graphite in ductile iron heavy-section parts have been studied previously in the case of near-eutectic alloys. It appeared of interest to complement these works by analysing the effect of carbon equivalent on graphite degeneracy. In the present work, hypo-, hyper- and near-eutectic melts have been cast in large blocks and standard cups. Analysis of the corresponding cooling curves recorded during solidification as well as microstructure observations on these casts have been carried out. A clear effect of carbon equivalent as promoter of chunky graphite formation is observed. The results have been added to the set of data already available and various correlations are discussed

Making of alloyed cast iron

Bakalářská práce je zaměřená na austenitickou litinu s kuličkovým grafitem. Zabývá se jejími druhy, mechanickými a fyzikálními vlastnostmi a vlivem legujících prvků. Dále se zaměřuje na výrobní postup a nebezpečí vzniku Chunky grafitu.This bachelor´s thesis is intent on austenitic cast iron with spheroidal graphite. This engage in their kinds, mechanical and physical properties and owing to alloying elements. Further is intent on manufacturing process and give danger rise a Chunky graphite.

Chunky graphite formation in ductile cast irons: effect of silicon, carbon and rare earths

Use of rare earths, high silicon and carbon contents, and low cooling rates are reported as possible reasons for formation of chunky graphite in ductile iron castings. The understanding of this graphite degeneration is however limited, and the above conclusions are still controversial. To get further insight into this topic, ductile cast iron melts have been prepared with various carbon and silicon contents and using nodularizing alloys with various rare earth levels. These melts have been cast in blocks with different sizes to include also the effect of cooling rate on graphite degeneration. Metallographic investigation revealed that the chunky-affected areas enlarge when decreasing the cooling rate, when increasing the silicon content and without low-level addition of rare earth. In the discussion, a schematic based on change of liquid/graphite interfacial energy with alloying elements is proposed which describes the conditions for the formation of chunky graphite instead of nodular graphite

Effect of Antimony and Cerium on the Formation of Chunky Graphite during Solidification of Heavy-Section Castings of Near-Eutectic Spheroidal Graphite Irons

Thermal analysis is applied to the study of the formation of chunky graphite (CHG) in heavysection castings of spheroidal graphite cast irons. To that aim, near-eutectic melts prepared in one single cast house were poured into molds containing up to four large cubic blocks 30 cm in size. Four melts have been prepared and cast that had a cerium content varying in relation with the spheroidizing alloy used. Postinoculation or addition of antimony was achieved by fixing appropriate amounts of materials in the gating system of each block. Cooling curves recorded in the center of the blocks show that solidification proceeds in three steps: a short primary deposition of graphite followed by an initial and then a bulk eutectic reaction. Formation of CHG could be unambiguously associated with increased recalescence during the bulk eutectic reaction. While antimony strongly decreases the amount of CHG, it appears that the ratio of the contents in antimony and cerium should be higher than 0.8 in order to avoid this graphite degeneracy

Statistical Analysis of the Influence of Some Trace Elements on Chunky Graphite Formation in Heavy Section Nodular Iron Castings

To study the formation of chunky graphite (CHG) in heavy section castings, 68 nodular cast irons of both pearlitic and ferritic grades were cast in cubic blocks 30 cm in edge. The volume fraction of the blocks affected by this degenerate graphite was quantified and related to the chemical analysis of the materials by means of a multivariate analysis. For the composition domain investigated, the effects of Ce, Cu, La, P, Sb, and Sn were statistically established with a high R 2 correlation coefficient

A fundamental approach to adhesion: Synthesis, surface analysis, thermodynamics and mechanics

The effects of composites as adherends was studied. Several other variables were studied by fractography: aluminum powder adhesive filler, fiber glass cloth scrim or adhesive carrier, new adhesives PPQ-413 and LARC-13, and strength-test temperature. When the new results were juxtaposed with previous work, it appeared that complex interactions between adhesive, adherend, bonding, and testing conditions govern the observed strength and fracture-surface features. The design parameters likely to have a significant effect upon strength-test results are listed

Chunky graphite in spheroidal graphite iron: review of recent results and definition of an predicting index

International audienceGraphite degeneracy in heavy-section spheroidal graphite cast irons is mostly associated with the formation of chunky graphite which consists of large eutectic cells with interconnected graphite strings. At low level, appearance of chunky graphite is limited to its non-aesthetic effect on machined surfaces, while at higher level it is detrimental for mechanical properties of the components. Chunky graphite is often related to high silicon levels and too high cerium additions during the spheroidization treatment. The appearance of this defect may be limited by controlled additions of antimony that is thought to tight the excess of cerium, but other impurities and low level elements may have to be considered during melt preparation. This contribution proposes a review of recent results and approaches on chunky graphite appearance, primarily but not exclusively in the case of heavy-section cast irons. Based on this literature review and series of experimental data, a predictive index for evaluating the risk of chunky graphite appearance is proposed. Lines for further research work aimed at a better understanding of graphite degeneracy are finally suggested. Introduction The need for melt control before casting of spheroidal graphite cast irons have led for long to look for graphite degeneracy as resulting from melt chemistry. Thielemann developed a trace element evaluation number S b for assessing the ability of the charge to give well-formed nodules [1]