Predicting Delta Ferrite Content in Stainless Steel Castings

The distribution of delta ferrite fraction was measured with the magnetic method in specimens of different stainless steel compositions cast by the investment casting (lost wax) process. Ferrite fraction measurements published in the literature for stainless steel cast samples were added to the present work data, enabling an extensive analysis about practical methods to calculate delta ferrite fractions in stainless steel castings. Nineteen different versions of practical methods were formed using Schaeffler, DeLong, and Siewert diagrams and the nickel and chromium equivalent indexes suggested by several authors. These methods were evaluated by a detailed statistical analysis, showing that the Siewert diagram, including its equivalent indexes and iso-ferrite lines, gives the lowest relative errors between calculated and measured delta ferrite fractions. Although originally created for stainless steel welds, this diagram gives relative errors lower than those for the current ASTM standard method (800/A 800M-01), developed to predict ferrite fractions in stainless steel castings. Practical methods originated from a combination of different chromium/nickel equivalent indexes and the iso-ferrite lines from Schaeffler diagram give the lowest relative errors when compared with combinations using other iso-ferrite line diagrams. For the samples cast in the present work, an increase in cooling rate from 0.78 to 2.7 K/s caused a decrease in the delta ferrite fraction, but a statistical hypothesis test revealed that this effect is significant in only 50% of the samples that have ferrite in their microstructures.FAPESP (Fundacao de Amparo a Pesquisa do Estado de Sao Paulo) [95/9113-2, 96/04242-1, 03/08576-7]Fundacao de Amparo a Pesquisa do Estado de Sao Paulo (FAPESP

Chemical composition and casting thikness influence on delta ferrite quantity and distibution in austenitic stainless steels.

Os aços inoxidáveis possuem numerosas aplicações devido à boa combinação de propriedades tais como resistência à corrosão e oxidação, ductilidade, tenacidade, soldabilidade e resistência mecânica em temperaturas elevadas. No entanto suas propriedades e desempenho estão fortemente relacionados com a microestrutura que por sua vez, no caso de peças fundidas, dependem principalmente da composição química e da velocidade de solidificação. No presente trabalho o efeito destas duas variáveis foram estudados e os resultados experimentais comparados com as previsões teóricas e modelos disponíveis na literatura. Dezesseis corridas de diferentes aços inoxidáveis austeníticos foram fundidas e suas composições químicas completas (16 elementos analisados) foram determinadas. A maioria das corridas analisadas apresentou modo de solidificação do tipo C. Foram encontrados teores de ferrita (medidos com auxílio de ferritoscopia) na faixa de 0 a 11%. A influência da composição química do aço na quantidade de ferrita delta formada foi marcante, enquanto a influência da espessura foi pouco acentuada. Dentre as numerosas fórmulas testadas para a previsão da quantidade de ferrita delta, as duas que apresentaram melhor resultado foram as fórmulas de Schneider e de Schoefer, sendo que esta última é recomendada pela norma ASTM A800. A amostra contendo cerca de 10% de ferrita apresentou uma rede quase contínua, o que pode comprometer a tenacidade da peça, caso esta ferrita venha a sofrer fragilização. Nas amostras contendo por volta de 5% de ferrita, a rede de ferrita é semi-contínua, enquanto para teores baixos (por volta de 2%), a ferrita apresenta-se como ilhas isoladas. As morfologias encontradas foram classificadas como sendo todas do tipo vermicular. Os estudos de micro-análise química dos elementos Si, Mo, Cr, Fe e Ni, efetuados na ferrita e na austenita revelaram coeficientes de partição de acordo com o previsto pela literatura. O efeito da espessura nas variações de composição foi pequeno e não conclusivo.Stainless steel has numerous applications due to a good combination of properties such as corrosion and oxidation resistance, toughness, weldability and mechanical strength at high temperatures. However these properties and performance are strongly related to the microstructure and in the case of castings are mainly dependent of chemical composition and cooling rate. In this work the effect of these two factors were studied and the experimental results compared with theoretical models available in the literature. Sixteen heats of different austenitic stainless steel were cast and their complete chemical compositions (16 elements) were determined. Most of analyzed heats showed the solidification mode type C. Ferrite values (measured with ferritoscope) were found in the range from 0 to 11%. The influence of chemical composition on delta ferrite was strong while the influence of thickness was less accentuated. Among numerous tested formulas to estimate the quantity of delta ferrite two that demonstrated better results were the ones of Schneider and Schoefer, where the last one is recommended by ASTM A800 standard. The sample with approximately 10% of ferrite showed an almost continuous ferrite network microstructure that may deteriorate component part toughness if this ferrite comes to suffer embrittlement. On the samples with content ferrite around 5% the ferrite network is semi-continuous while for low values (around 2%) the ferrite showed isolated cores. The morphologies were classified as vermicular. The study of micro chemical analysis of Si, Mo, Cr, Fe and Ni on ferrite and austenite showed partition coefficient in accordance with values defined in literature. The thickness effect on chemical composition was small and not conclusive