Explore the vast range of titles available.

Cast iron is widely used in engineering production and in the surface alloying of workpieces, which is exploited to improve the properties of the material. Research on cast iron is still valid and needed for the manufacturing processes throughout the product life cycle. In this study, the gray, cast iron GJL 200 laser processing is described based on surface alloying with WC and SiC particulates. SEM analysis and XRD analysis, as well as microhardness testing and tribological behavior studies, were employed. It was revealed that laser alloying with carbide particulates affects structural, mechanical, and operational properties compared to cast iron in its initial state. Most importantly, the right choice of laser processing conditions can increase the wear resistance of the cast iron base. The wear resistance after WC alloying was 4–24 times higher compared to the initial material, while after SiC alloying, it was 2–18 times lower than that of the initial material.

The isothermal heat treatment process has been identified as a unique process of fabricating exceptional graphite cast iron due to its remarkable mechanical properties, such as excellent machinability, toughness, and high level of ultimate tensile strength. Austempered ductile iron (ADI), ductile iron (DI), and gray cast iron (GCI), known as spheroidal cast irons, are viable alternative materials compared to traditional steel casting, as well as aluminum casting. The graphite nodules from the microstructures of DI, ADI, and GCI are consistently encompassed by acicular ferrite and carbon-saturated austenite in the matrix, forming a distinctive ausferritic structure. All these materials are extensively used in the fabrication of engine sleeves, engine blocks, valves, gears, and camshafts in the automobile sector. With relative motion and outward loads, these components are regularly exposed to surface contact. In this project, it was observed that austempering temperature and a shorter holding period could also be used to manufacture needle-like ferrite platelets for austempered ductile iron (ADI) and other graphite cast irons. To overcome the brittleness challenges and catastrophic failures encountered by applied loads in present-day applications, it is essential to comprehend the isothermal treatments, morphological behaviors, phase analyses, processing techniques, and mechanical properties needed to properly incorporate these materials into future designs. This review article provides detailed information on the characterization and relevant potential mechanisms of ADI, DI, and GCI.

The enhancement of fuel economy and the emission of greenhouse gases are the key growing challenges around the globe that drive automobile manufacturers to produce lightweight vehicles. Additionally, the reduction in the weight of the vehicle could contribute to its recyclability and performance (for example crashworthiness and impact resistance). One of the strategies is to develop high-performance lightweight materials by the replacement of conventional materials such as steel and cast iron with lightweight materials. The lightweight composite which is commonly referred to as fiber-reinforced plastics (FRP) composite is one of the lightweight materials to achieve fuel efficiency and the reduction of CO2 emission. However, the damage of FRP composite under impact loading is one of the critical factors which affects its structural application. The bumper beam plays a key role in bearing sudden impact during a collision. Polymer composite materials have been abundantly used in a variety of applications such as transportation industries. The main thrust of the present paper deals with the use of high-strength glass fibers as the reinforcing member in the polymer composite to develop a car bumper beam. The mechanical performance and manufacturing techniques are discussed. Based on the literature studies, glass fiber-reinforced composite (GRP) provides more promise in the automotive industry compared to conventional materials such as car bumper beams.

The aim of this research was to determine the factors affecting the metallurgical quality of cast iron during serial production of castings using a campaign cupola and a holding furnace. The problem to be solved, which was to obtain cast iron with the required mechanical properties while reducing the internal porosity, results from the foundry’s need to increase the metallurgical quality of the alloy. The increasing difficulty and complicated constructions of castings, for which it is not possible to introduce risers at the stage of technological design, make the stage of proper preparation of cast iron the only way to obtain castings without shrinkage defects. The article presents the results of the study of physicochemical and mechanical properties, microstructure and shrinkage tendency of ductile iron depending on the charge materials used, the amount of Mg used during spheroidization and the type of final inoculants. Step castings and wedge tests were produced on a vertical molding line. The spheroidization was carried out by injecting a core wire containing Mg alloy into the cast iron. The final inoculation of 0.2% was performed using a pneumatic dispenser equipped with a vision system to control the effectiveness of the inoculation. The ITACA Meltdeck thermal analysis system was used to study the physicochemical properties of the initial cast iron, and the ITACA X system to analyze the state of the final cast iron on the molding line. Mechanical tests were performed on samples cut from a stepped casting, and microstructure tests were carried out using a light microscope and a scanning electron microscope. The results of thermal analyses show that increasing the share of pig iron at the expense of steel increases the minimum solidification temperature of eutectic, and thus, increases the potential for graphite nucleation in cast iron. Increasing the nucleation potential can be obtained by adding anthracite, FeSi and SiC. A very important factor in obtaining cast iron of high metallurgical quality is the possible limitation during spheroidization of the length of the core wire containing Mg, which is a carbide-forming element. The lower the initial sulfur level, the greater the possibility of reducing the amount of cored wire. The inoculants containing Ce and Bi were the most advantageous final inoculants from the point of view of obtaining the best microstructure parameters and plastic properties of cast iron.

Ferritic high-Si ductile cast irons replace an unstable mixed ferrite-pearlite matrix with a unique combination of high elongation, strength and hardness (ideal for automotive drive train components) and resistance to oxidation and corrosion at high temperatures (automotive exhaust and turbocharger systems). The present paper analyses the graphite parameters of 4.5%Si, un-inoculated ductile cast iron (4.7%CE, 0.035%Mgres) as an effect of the casting section size. The structure is characterized by 10.5–11.2% graphite and 464–975 nodules/mm2, at more than 70% ferrite and no carbides, including at 3 mm wall thickness. The lower the wall thickness is, the higher the nodule count is and, consequently, the higher the ferrite amount is. The Roundness Graphite Shape Factor (RSF = 0.65–0.68) illustrates the presence of Slightly Irregular Spheroidal Graphite (Form V ISO 945). There is a big difference between the graphite nodularity evaluated according to ISO 16112:2017 [CGI] (NG1 = 79–86%) and according to ISO 945-4-2019 (DI) (NG2 = 65.2–74.6%), both of them based on RSF. Graphite Nodularity (NG3), calculated with the ISO 945-4-2019 [DI] formula, but replacing RSF with SSF, Sphericity Graphite Shape Factor, has an intermediary position. The higher the imposed minimum RSF or SSF is, the lower the Graphite Nodularity (NG4, NG5): 80–90% for min. 0.50 (minimum Form IV or Intermediate Graphite), 60–80% for min. 0.60–0.65 (minimum Form V graphite) and 35–70% for min. 0.80 (minimum Form VI graphite). The SSF is more representative than the RSF for Si-alloyed ductile cast iron, so it is recommended to use a graphite nodularity calculus considering SSF instead of the RSF formula (stipulated by ISO 945-4-2019), with SSF replacing RSF.

High chromium cast iron (HCCI) has been widely used as wear-resistant material in the industry. Alloying is an effective way to improve the microstructure and mechanical properties of HCCI. This paper added multi-component V-Fe-Ti-Nb-C-Zr-B alloy (VFC) to HCCI, showing a significant synergistic solution-strengthening effect. The results show that the added V-Ti-Nb-B are dissolved in M7C3 carbide to form the (Cr, Fe, V, Ti, Nb)7(C, B)3 alloy carbide, and a small amount of V and all Zr are dissolved in austenite and martensite. Adding VFC into HCCI improved the hardenability of HCCI, decreased the residual austenite content from 6.0 wt% to 0.9 wt%, increased the martensite content from 70.7 wt% to 82.5 wt%, and changed the structure and content of M7C3 carbide. These changes increased the hardness of as-cast and heat-tread HCCI by 1.4% and 4.1%, increased the hardness of austenite and martensite by 7.9% and 7.0%, increased the impact toughness by 16.9%, and decreased the friction coefficient and wear loss by 2.3 % and 7.0 %, respectively. Thus, the hardness, toughness, wear resistance, and friction resistance of HCCI alloy are improved simultaneously.

Medium-alloy ductile iron with a SiMo ferritic matrix has very good heat resistance. The addition of chromium and aluminum also increases this resistance. This article presents the impact of chromium and aluminum on the structure of SiMo cast iron, especially their impact on the deformation of the spherical graphite precipitates and the formation of M6C and M3C2 carbide phases. These carbides are formed in a ferritic matrix or at the grain boundaries, resulting in increased hardness and a drastic reduction in impact strength. The article presents the influence of heat treatment on the material’s microstructure and resistance to abrasive wear. Chromium and aluminum additions can also indirectly reduce the abrasive wear resistance of SiMo cast iron. The presented research shows the possibility of doubling the abrasive wear resistance of SiMo cast iron.

Rather than focusing on the residual stress generated from casting, machining, or heat treatment unilaterally, a comprehensive research method to consider the whole dynamic evolution of residual stress is proposed. The cast iron piston is taken as the research object to establish a continuous simulation model for its manufacturing. Firstly, a simulation model of piston casting is established to analyze the stress change. Subsequently, through the machining and heat treatment simulation of the piston, the variation law of residual stress before and after machining is analyzed. Different process parameters are designed to study the redistribution mechanism of residual stress. Residual stress tests are further conducted on the processed piston products. The results indicate that shakeout can effectively remove 60% to 80% of the residual stress. The removal of materials results in overall residual stress release and redistribution for the piston, and the piston releases 10% to 40% of the residual stress after machining. The heat treatment of the machined piston can effectively reduce the residual stress with a maximum reduction of 27.1%. The good consistency between experimental results and simulation results further confirms the feasibility of the comprehensive research method. This study is beneficial for achieving low stress manufacturing of pistons and improving their working performance.

Tensile and low-cycle fatigue tests of high-strength compacted graphite cast iron (CGI, RuT450) were carried out at 25 °C, 400 °C, and 500 °C, respectively. The results show that with the increase in temperature, the tensile strength decreases slowly and then decreases rapidly. The fatigue life decreases, and the life reduction increases at high temperature and high strain amplitude. The oxide layer appears around the graphite and cracks at high temperature, and the dependence of crack propagation on ferrite gradually decreases. With the increase in strain amplitude, the initial cyclic stress of compacted graphite cast iron increases at three temperatures, and the cyclic hardening phenomenon is obvious. The fatigue life prediction method based on the energy method and damage mechanism for compacted graphite cast iron is summarized and proposed after comparing and analyzing a large amount of fatigue data.

The purpose of the foundry is to provide the consumer with blanks for general machine-building (special) purposes which are as close as possible to the size of the future part in full compliance with the requirements. The competitiveness of these products is primarily dependent on the use of efficient and reliable smelting equipment which meets the necessary cost. The replacement of high-value ironworks and ironworks iron with steel scrap using induction melting furnaces (ICFs) reduces the cost of producing synthetic cast iron. However, this results in temperatures greater than 1500 °C, reduced lining stability and increased downtime of the smelter. As a result of the research carried out, a technology for the use of quartzite is proposed. Thereby, the purpose of this work is to establish temperature regimes for the smelting of synthetic pig iron, allowing the use in metal filling up to 70–90% of steel scrap; this leads to a reduction in the cost of purchasing bulk materials (depending on the brand of cast iron) up to 50% and, thus, increases the efficiency of synthetic cast iron smelting and castings production in general. After removal of the original moisture and the subsequent sintering of the manufactured lining, it provides the possibility of melting using the melting temperatures 1550–1600 °C. It increases the efficiency of the operation of the melting furnaces and eliminates the consumption of the ironworks and the melting of the cast iron in the blast furnace, as well as the cost of the lost alloy. As a result, metallurgical production will be able to reduce the volume of production and supply of cast iron for ironworks, which will improve their environmental situation during the production and processing of necessary raw materials.