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Casting Skin Literature Search Ductile Iron Society RESEARCH PROJECT No. 47 Literature Summary: Deteriorated Graphite in Casting Surfaces Ductile Iron Society Research Committee Report Compiled by Doug White - Elkem DUCTILE IRON SOCIETY Issued by the Ductile Iron Society for the use of its Member Companies – Not for General Distribution DUCTILE IRON SOCIETY 15400 Pearl Road, Suite 234 Strongsville, Ohio 44136 (440) 665‐3686 JANUARY 2012 Ductile Iron Society- Research Committee Report literature Summary: Deteriorated Graphite in Casting Surfaces SUMMARY DIS Research has shown that a considerable drop in the fatigue life of ductile iron castings occurs when there are surface defects or deteriorated graphite in the skin of castings. Papers demonstrate this can be due to reactions with the mold or cores due to the presence of S from seacoal or binder systems, oxygen such as moisture in greensand, or N bearing gases from some sand binder systems. Other researchers have studied additional surface quality issues that impact properties. Means to minimize or eliminate these issues have been proposed. DIS Hot Topic articles and DIS Research reports are available to members on the DIS website. AFS Transaction papers will be available to people who have previously purchased AFS Transactions. Other AFS literature such as Modern Casting articles or copies of AFS Transaction papers may be obtained by contacting AFS. Doug White: Technical Service Manager, Elkem Materials, Inc. January 2012 Literature search - Deteriorated Graphite Structures on Cast Iron Skins. DIS Literature DIS Research Project No. 17 Sulfur in Molding Sand Effect on Flake Graphite at the Cast Surface of Ductile Iron Castings George DiSylvestro and Robert Christ Ductile Iron Society Research Report No. 44 Effect of Surface Defects on Fatique properties of Ferritic Ductile Iron, Rick Gundlack (Stork Climax Research Services) and John McGoldrick (Hodge Foundry, Inc.) Ductile Iron Society Research Project No. 45 Graphite Shape Degredation at the Surface of Chemically Bonded Sand Molds and Cores. DIS Hot Topic #7- 2004 Improving Fatigue Strength (Jim Mullins) DIS Hot Topic #3- 2004 Surface Treatments for Ductile Iron (Eugene Muratore) DIS Hot Topic #7-2008 Abnormal Surface Microstructures (AI Alagarsamy) Powerpoint Presentation - DIS Meeting June 2011- Lundeen (Foseco) AFS Literature Boonmee, S., Gyesi, B., Stefanescu, D., "Casting Skin of Compacted Graphite Iron, Part 1: Evaluation and Mechanism of Formation," Transactions of the American Foundry Society, Vol. 118, pp. 205-216 (2010) Boonmee, S., Stefanescu, D., "Casting Skin of Compacted Graphite Iron, Part II: Influence on Tensile Mechanical Properties, ({Transactions of the American Foundry Society, Vol. 118, pp. 217-224 (2010) Stefanescu, D.M., Wills, S., Massone, J., Duncan, F., "Quantification of Casting Skin in Ductile and Compacted Graphite Irons and Its Effect on Tensile Properties," Transactions of the American Foundry Society, Vol. 117, pp. 587-606 (2009) Stefanescu, D.M., Juretzko, F.R., "Study ofthe Effect of Some Process Variables on the Surface Roughness and the Tensile Properties of Thin Wall Ductile Iron Castings," Transactions of the American Foundry Society, Vol. 115, pp. 637-646 (2007) Martin, F., Karsay, S. 1., "Localized Flake Graphite Structure as a Result of a Reaction Between Molten Ductile Iron and Some Components in the Mold," Transactions of the American Foundrymen's Society, Vol. 87, pp. 221-226 (1979) Duncan, F.C., Kraker, J., "A New Test Casting to Evaluate Skin Formation in CGI, "Proceedings of the American Foundry Society, 11Sth Metalcasting Congress, paper 10-023 (2011) Goodrich, G., "Effect of Cooling Rate on Pearlitic Ductile Iron Mechanical Properties," PowerPoint® presentations, copyright ©American Foundry Society (2007) La Fay, V.S., Neltner, S.L., "Drifting Away from Seacoal," Modern Casting, Vol. 94, No. 12, pp. 28-30, (December 2004) Torrance, J., Stefanescu, D., " Investigation of the Effect of Surface Roughness on the Static Mechanical Properties of Thin Walled Ductile Iron Castings," Transactions of the American Foundry Society, Vol. 112, pp. 757-772 (2004) Tinebra, J.P., Wilson, S.J., "Nobake Chemical Binder Systems: Their Effect on Microstructural and Physical Properties of Ductile Iron," Transactions of the American Foundrymen's Society, Vol. 101, pp. 169-173 (1993) Xiaogan, H., Jin, X., Wenqing, W., Xuqi, D., Yaoke, W., "Nodular Iron Surface Deterioration Due to PTSA in Resin," Transactions of the American Foundrymen's Society, Vol. 100, pp. 9-15 (1992) Kambayashi, H; Une, H; Kurokawa, Y; Ito, T; Mikamoto, S; Miyake, H., "Mold Surface Analysis Evaluation of Inclusion Defects Occurring in Cast Iron Produced in Green Sand Molds," Transactions of the American Foundry Society, Vol. 112, pp. 787-799 (2004) Lawerenz, M., "Shot Peening Ductile Iron," Modern Casting, Vol. 80, No.2, pp. 51-53 (Feb 1990) Watmough, T., Malatesta, M.J., "Strengthening of Ductile Iron for Crankshaft Applications," Transactions of the American Foundrymen's Society, Vol. 92, pp. 83-99 (1984) Shrikhande, V., "Sulfur Control at the Mold/Metal Interface of Cast Ductile Iron," Modern Casting, Vol. 85, No. 1, p. 44 (Jan 1995) Mampaey, F., Li, P.l., Wettinck, E., "Variations in Strength along the Casting Diameter", "Transactions of the American Foundrymen's Society" 2003, AFS Library Copy 20030283A.pdf Other literature Influence of Surface Quality on Fatigue Behavior of Nodular Cast iron, M.Kokavec and R. Konecna University of Zilina, Slovakia and G. Nicoletta University of Parma, Italy. Acta Metallurgica Slovaca, volume 17, 2011, No.2, pp 99-105 The Mechanism of Formation of Casting Skin in CGI and its Effect on Tensile Properties, Boon me and Stefa nescu www.scientific.net/KE M .457.11 Factors Influencing the Surface Graphite Degeneration in Ductil.e Iron Castings in Resin Mold Technology. R.iposan, Chisamera, Stan, Skaland TSINGHUA Science and Technology ISSN 1007-0214 08/20 pp157- 163 Volume 13 Number 2 April 2008 Flake Graphite Layers at the cast Surfaces of Nodular Iron Castings. BCIRA Broadsheet 234 Private communication A Comparison of the Fatigue Strength of Machined and As-Cast Surfaces of SG Iron, Starkey and Irving, July 1982 Int'l Journal of Fatigue Gray Iron Layer on Ductile Iron, Starkey and Irving, July 1982 Int'l Journal of Fatigue (not included) SULFIJR IN MOLDING S&"''D uncr ON FLAKE GRAPHITE AT THE CAST SURFACE OF DUCTILE IRON CASTINGS Ductile Iron Society · ProjectP17 A Research Project of the Committee on Structmal Control by Project Direction - George Di Sylvestro Project Assistance- Amertcan Colloid Company Project Summary - Robert J. Christ SUMMARY DOl contdbullC P1fur. Pa:ioctic addi.ti0113 of new sand to the sysu:m are often required and This project investigated the role of sulfur in a~gu)ar sulfur auditing program is desimblc. molding sand on the formation of a layer offlake graphite just below the ~-urface of ductile iron • Rcpcal8bilityandconsistalcyofsulfurinsand castings. Information was compiled by analyses within an individual foundry is very questionnaire from 28 member foundries on the good. although a lack of sta.ndaldi2ation prevalence of this condition and procedures results in only fair reproducibility between used to control sulfur in system molding sands. differatt laboratories. Six volunteers participated in round robin resting to determine reproducibility of sulfur • Prom a sampling of 13 foundries, four operate analyses methods. Eleven foundries then provided statistical data on system sand sulfur at sulfur JcveJs aaaling O.lK. and the analyses from their own facilities using balance maiDtain a DDF of 0.040-0.070CJ,. recommended practices identified in this study. A literature survey identified information on effec1s of sulfur and threshold levels. • The prevalence of flake graphite and the adverse effects wns confmned by ~ ·of producers, but . few foundries routinely monitor sulfur in sand. Those tbat do. generally use Leco type equipment. although no standaids exist with regard to instrument models or procedures. • Unless the f1ako graphite is comple1dy removed by machining, the surface hardness and bending fatigue properties of the casting will be reduced. • It is recommended that sulfur in system sand be controlled to <0.10%, and prefctably <0.07%. Scacoals are universally required in green sand mixes to provide a reducing atmosphere under which ductile iron castings must solidify. Sulfur levels in sand can be reduced by using low sulfur varieties of scacoal and by selecting core processos, washes, coatings, mold releases, etc., that do DIS Research Project No. 44 DIS RESEARCH PROJECT NO. 44 EFFECT OF SURFACE DEFECTS ON FATIGUE PROPERTIES OF FERRITIC DUCTILE IRON ABSTRACT The fatigue strength offerritic ductile iron, Grade EN-GJS-400-18U-LT. was determined for large section castings measuring 4 by 24 by 24 inches. Fatigue testing was conducted in bending fatigue in order to determine the influence of surface conditions on fatigue strength. Test specimens with various surface conditions were evaluated, including notched and un-notched specimens, as well as those containing surface defects typical of heavy section ductile iron castings. In addition, smaller, round axial fatigue test specimens were tested to produce the more typical laboratory fatigue test properties for comparison with other materialS tested for the Ductile Iron Society. Bending fatigue testing was conducted on two groups of specimens. A large number of specimens of intermediate size and obtained from the drag surface were
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