EP1838888A2 - Fonte ductile et procede de fabrication associe pour l'elaboration de composants a proprietes de resistance et de tenacite desirees - Google Patents
Fonte ductile et procede de fabrication associe pour l'elaboration de composants a proprietes de resistance et de tenacite desireesInfo
- Publication number
- EP1838888A2 EP1838888A2 EP06700056A EP06700056A EP1838888A2 EP 1838888 A2 EP1838888 A2 EP 1838888A2 EP 06700056 A EP06700056 A EP 06700056A EP 06700056 A EP06700056 A EP 06700056A EP 1838888 A2 EP1838888 A2 EP 1838888A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- ductile iron
- fgdi
- piece
- fine grain
- temperature
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/08—Making cast-iron alloys
- C22C33/10—Making cast-iron alloys including procedures for adding magnesium
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C1/00—Refining of pig-iron; Cast iron
- C21C1/10—Making spheroidal graphite cast-iron
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/08—Making cast-iron alloys
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/04—Cast-iron alloys containing spheroidal graphite
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/10—Cast-iron alloys containing aluminium or silicon
Definitions
- the invention relates to ductile iron according to the preamble of claim 1.
- the invention relates also to a method according to the preamble of claim 9.
- Typical metallic initial raw materials of ductile iron known from prior art are the by-product parts of cutting carbon-steel plate intended for engineering but unsuitable for it because of their form, that is, steel scrap, correspondingly parts remaining from sheet-metal cutting packaged to sheet-metal packages, that is, package scrap.
- pig iron produced in other iron production processes is used.
- a die For performing casting, a die needs casting gates and heads which are removed from the piece after casting and are used as foundry returns.
- Raw materials are usually melted in cupola or induction melting furnaces. For specifying the composition, alloys, such as carburiser and different ferro-alloys, are added to the melt.
- An essential melting treatment of ductile iron is so-called spheroidisation, in which the prerequisites of carbon precipitation process are changed in order the graphite precipitating from iron to be formed into spheres, and which is realised either as a ladle treatment or inside a die by using magnesium-rich and/or cerium- rich ferro-silicon alloy or nickel-magnesium.
- Magnesium reacts with sulphur and other impurities, which promotes the growth of graphite as spherical instead of lamellar.
- Another ductile-iron melting treatment is inoculation in which typically grained ferro-silicon alloy is added to the melt for increasing grains of crystallisation.
- the aim of inoculation is to make the casting structure more fine-grained.
- Austempered ductile iron ADI (typically), that is, EN-GJS-800-8 (EN-1564), achieves sufficient mechanical properties in a tension bar cast separately, but its machining with chip removal is extremely difficult because of its hardness, and manufacturing ADI in over 1,000-kg weighing and 200-mm walled pieces is technically and economically difficult.
- Mechanical values in accordance with standards are defined with a separately cast test bar.
- Paper-machine components are exposed to extreme mechanical and wearing stress.
- the rates of both paper machines and paper finishing machines have doubled and tripled in the last decades.
- the web rates of finishing machines have increased from the rate of 600 m/min to the rate of more than 2,000 m/min and the development is ongoing.
- the object of the invention is to create a new grade of ductile iron which has new, exceptional combinations of material properties.
- the object of the invention is also to achieve a manufacturing process with which said properties for ductile iron may be accomplished.
- ductile iron according to the invention is mainly characterised in what is presented in the characterising part of claim 1.
- a method according to the invention is mainly characterised in what is presented in the characterising part of claim 9.
- ductile iron for use in, for example paper- or board-machine components, which ductile iron has exceptional mechanical properties and which is more economical and environmentally- friendly to manufacture compared to other materials of corresponding strength properties.
- the possibly required heat treatment is realised without oil or salt bath with controllable advantageous air, water or water mist added with desired additives harmless to the environment, and it is environmentally friendly because re-usable material may also be used.
- a blank manufactured of the grade of ductile iron according to the invention is more accurate dimensionally compared to free-forging from the viewpoint of machining, whereby cost savings are achieved.
- the best mechanical properties are achieved with ductile iron having a new, exceptionally advantageous combination of properties with a more economical and environment-friendly manner compared to alternative engineering materials.
- the limit of proportionality is adjustable even through a thick- walled (over 150 mm) piece wall from over 500 N/mm 2 to 750 N/mm 2 by varying the casting process and heat-treatment process, and at the same time, - the elongation is adjustable by varying the casting process and heat-treatment process from 4% to 8%, and
- the fatigue limit in rotational bending is adjustable to the range of 300-420 kN/mm 2 - the hardness of the piece through the piece is principally 260-300
- the grade of ductile iron according to the invention is fine grain ductile iron (FGDI) which differs from current ductile irons in that: - the metal matrix comprises of fine-lamellar pearlite and of finegrained pearlitic-ferritic or bainitic-ferritic structure, the lamella gap of which pearlite and bainite is below 1,0 ⁇ xa. (typically below 0,4 ⁇ m), and of ferrite which is in pearlitic quality on grain boundaries as desired zones and in the bainitic structure as a needle-shaped or comb-shaped structure in the vicinity of grain boundaries and interlocked in bainite,
- FGDI fine grain ductile iron
- the spheroidisation level of graphite spheres is over 85% (typically over 95%) and the sphere density is typically 150-400 pcs/mm 2 in the cutting surface of the sample depending on wall thickness
- the slow increase of temperature (50°C/h) is performed traditionally in order to avoid stresses and warpings.
- Austenising is performed in an atmosphere furnace in the temperature of 880-960 0 C. - After austenising, the piece is brought to the temperature range of 840-760°C, whereby the heat content of the piece decreases thus assisting quick quenching, at the same time, one is able to adjust the ferrite around pearlite and bainite required for achieving excellent toughness and fatigue resistance.
- 290-550°C but depending on the composition may be 100-600 0 C.
- the decomposition of austenite in low temperatures in slower than in higher temperatures, the result of which is a finegrained matrix.
- the complete decomposition of austenite, stresslessness of the structure and good machinability are ensured with tempering into which the piece is tempered slowly from the austempering or pearlitisation temperature to the tempering temperature between 520-720°C depending on the composition, piece thickness and desired strength.
- the piece is cooled to room temperature in a controlled way (desirably, for example 50°C/h) to room temperature.
- a controllably controlled heat treatment method described in patent application FI-20011954 is used advantageously in manufacturing the grade of ductile iron according to the invention.
- a grade of ductile iron is achieved according to the invention the properties of which may be varied controllably by adjusting the composition, manufacturing process and heat treatment.
- FGDI fine grain ductile iron
- GJS-FGDI-P-850/500-5C-HB280-H which is a pearlitic grade
- GJS-FGDI-BF-850/600-5C-HB280-H which is a bainitic-pearlitic grade
- GJS-FGDI-BF-750/600-7C-HB250-H which is a bainitic-ferritic grade
- GJS-FGDI-PF-850/500-7C-HB280-H which is a pearlitic-ferritic grade
- GJS-FGDI-P-900/550-4C-HB290-H which is a totally pearlitic grade.
- Hardness 250 ... 320 HB from a tension bar taken from the piece The hardness of the grade of ductile iron according to the invention is through the piece in the range of 250 ... 320 HB and no hard phases occur significantly whereby machinability is good through the piece.
- the fatigue resistance of the grade of ductile iron according to the invention is defined as rotational-bending fatigue resistance.
- a positive fact in the comparison one should consider is that fine grain ductile iron (FGDI) has low notch sensitivity compared to steels.
- fine grain ductile iron (FGDI) according to the invention, because of its even microstructure after casting and the further balancing effect of heat treatment, the structure is equal thought the piece, and if desired, one may realise a functional structure, that is, different surface and inner parts, with the manufacturing process (if required, microstructure may also be controlled).
- FGDI fine grain ductile iron
- the control of a casting event is designed with a computer-assisted simulation in which the filling of the die with melt and the solidification and cooling of melt may be ensured. Then, no internal porosity nor slag inclusions are created in the casting piece to weaken the material properties and to cause surface flaws which would act as starting points of fracture.
- Computer-assisted simulation a test of heat-treatment programme in which the simulation of heat treatment ensures the accuracy of heat treatment; the suitability of heat treatment is authenticated quality risks especially in short-run and single-piece production.
- the manufacturing process of ductile iron according to the invention differs from the normal manufacturing processes of ductile iron in many respects. The most significant differences will now be described.
- pig iron sold for manufacturing ductile iron is considered the best metallic melting material.
- it is used as little as possible because its most common commercial grades are the by-products of manufacturing titanium oxide, that is, white paint pigment, and they include too much harmful metals, such as titanium, chromium, vanadinium, molybdenum and phosphorous.
- purest steel grades and purest alloys are used in the manufacturing according to the invention. Using re-usable steel-plate material is more environmentally friendly and cost-effective. Trace elements outside common foundry analyser accuracy, such as niobium, bismuth, lanthanum etc., play an essential part.
- the melting temperature is maintained precisely below 1520 0 C and loading is performed so that the melting time is as short as possible.
- shielding gas or vacuum treatment it is advantageous to use shielding gas or vacuum treatment in shielding gas in the melting for eliminating possible casting flaws.
- Magnesium treatment may be implemented, inter alia:
- a recommended grain size of the structure which is described by graphite sphere density is typically 400 ... 150 spheres/mm 2 .
- Sphere density is also added by increasing metallic die parts, that is, moulds to the die casting surface which moulds have good thermal conductivity and which speed up cooling and solidification.
- the chemical composition of the material according to the invention depends on the desired combination of properties and wall thickness and typically it is the following:
- the material in heat treatment, is first austenised in 880-960 0 C for at least 1 hour + 1 hour/25 mm of wall thickness.
- the object is to solute all carbides and other phases anomalous from the matrix to austenite.
- in atmosphere furnace is performed a decrease of temperature in a controlled way and a balancing to the level of 800-850 0 C, after which a quick controlled cooling is performed to the temperature of 650-100°C, after a temperature balancing of 2 ... 4 hours performed in which the temperature of the piece is maintained in chosen temperature, if the tempering is in the same temperature as when quenched, or is increased to the tempering temperature 55O...75O°C depending on the composition.
- the pieces are kept for 2...8 hours after which they are cooled to room temperature.
- shielding gas is used throughout the heat treatment.
- microstructure of the ductile iron according to the invention three basic structures are obtained depending on the choice of heat treatment: - fine-lamellar totally pearlitic microstructure with graphite spheres
- control of the microstructure takes place by means of the composition and the heat treatment in a controlled way, whereby the desired combination of mechanical properties may be achieved for each piece.
- the pieces manufactured from the material according to the invention are simulated in order to predict the filling of the die, the solidification of the melt, the sphere density of graphite and possible carbide phases and hardness and to define the composition with a computer-assisted simulating programme into which the material values are programmed.
- the heat-treatment programme required by mechanical properties is checked with a computer-assisted simulation beforehand.
- the purpose of using simulation is to prevent flawed products in order to gain material and cost savings and to realise the manufacturing schedule in a planned way.
- the chemical composition is checked in the casting from piece-specific melt.
- cast-on test bars are cast for tensile tests and batch-specifically a comparison piece which represents the actual casting and from which the results of destructive testing are defined.
- This sample is correspondingly simulated piece of a test piece for ensuring sample match.
- the diameter of a heavy-duty bearing chock is 500 mm when manufactured of the material according to the invention, and if being of ductile iron according to the standard it would be 650 mm.
- the bearing chock weighs 500 kg when manufactured of fine grain ductile iron (FGDI) according to the invention, if made of cast iron according to the standard, it weighs 800-900 kg. Because of the casting process used in the method according to the invention, one is able to come extremely close to the final dimensioning, which decreases the requirement of machining compared to forging products. At the same time, the consumption of material and energy are minimised.
- FGDI fine grain ductile iron
- Fine grain ductile irons (FGDI) according to the invention an exceptional combination of properties, that is, high strength and high limit of proportionality supplemented with good elongation and fatigue resistance, when also machinability is good.
- the strength is achieved with such alloying and heat treatment which weaken toughness and machinability.
- the fine grain ductile iron (FGDI) according to the invention has good fatigue resistance in a sample taken even from a thick piece. This is a result of the manufacturing process of the fine grain ductile iron (FGDI) according to the invention which process creates prerequisites for the structure not including phases weakening it and flaw regions. Such solidification conditions are created in the casting process that the casting structure is produced dense, homogeneous and unoriented.
- a special feature of the heat-treatment process used advantageously in connection with the method according to the invention is that with quick cooling, the microstructure becomes fine-grained and does not include weakening phases or flaw regions. With a quenching rate, tempering temperature and holding time chosen according to the desired properties, one is able to adjust the final microstructure and material properties in accordance with it.
- heat- treatment processes including accurate and quick coolings require the use of oil or salt bath.
- an advantageously controlled special heat-treatment process is used in which one achieves sufficiently quick, controlled cooling rates with air and a medium added to it. Because the cooling agent is advantageously air and water with added natural particles, no emissions to the environment occur.
- the raw material base of ductile iron according to the invention consists mainly of re-usable materials, its melting temperatures are lower compared to steels, the energy requirement is lower compared to forging, and the piece is cast very close to the final dimensions whereby the material waste from the blank is small.
- the material according to the invention may be totally re-used: inside foundry, the casting systems are utilised immediately in the melting of next castings, and the foundry buys the components manufactured of the material according to the invention when removed for re-usable raw material.
- the intermediate products of casting, such as casting gates, are re-used, die material is recycled, machining chips are re-melted, and the end-product is re-usable iron material.
- Atmosphere quenching air quenching
- Table B shows the values of standard test bars (SFS-EN 1563+A1) cast in connection with the casting of different pieces.
- Table shows mechanical properties in the different parts of the piece.
- Figure 1 schematically shows a manufacturing flow chart of cast iron GJS 800 known from prior art.
- FIG. 2 schematically shows a manufacturing flow chart of fine grain ductile iron (FGDI) according to the invention.
- FIG. 3 schematically shows a flow chart of the URVA 850 heat treatment of fine grain ductile iron (FGDI) according to the invention.
- Figure 4 schematically shows a process chart of the simulation of heat treatment for a multiform piece.
- Figures 5A and 5B show the cooling rate of the piece in different points of the piece related to the simulation of the heat treatment of the piece.
- Figure 6 shows a picture of a typical microstructure of the grade of ductile iron according to the invention in a 100-fold enlargement.
- Figure 7 shows a 400-fold enlargement of Figure 6.
- Figure 8 shows a 700-fold enlargement corresponding Figure 6.
- Figure 9 shows a picture of a typical microstructure of cast-iron material in accordance with prior art in a 100-fold enlargement.
- Figure 10 shows a 700-fold enlargement corresponding Figure 9.
- FIG. 1 schematically shows a manufacturing flow chart of prior-art material, GJS-800.
- processes known from prior art use steel scrap, pig iron, re-used materials and carburisers ferro-silicon and alloys as raw material, and if required, a spectrometer analysis is performed.
- Melting takes place as induction melting 11, after which in melt treatments, in the spheroidisation phase 12, a spheroidising alloy is added to the melt.
- inoculation 13 in which an inoculant is added to the melt, after which the melt is cast in the casting phase 14 after a possible spectrometer analysis and casting temperature is monitored.
- the casting is shaken out in the shake-out phase 15, after which take place the secondary operations 16: surface cleaning, removal of extra castings and grinding.
- quality control is performed as ultra sonic testing 17 and a possible tensile test 18 is performed.
- Figure 2 schematically shows a flow chart of the manufacturing process of the grade of ductile iron according to the invention.
- Steel scrap, pig iron, re-used materials, carburisers, ferro-silicon and alloys are used as raw material, after which a spectrometer analysis is performed if required.
- Melting is performed as induction melting 21, and in the melt treatment phase, in spheroidisation 22, a spheroidising alloy is added.
- After spheroidisation 22 follows the adding of an inoculant and inoculation 23, after which a spectrometer analysis is performed and casting temperature is checked, after which the melt is cast in the casting phase 24.
- FIG 3 schematically shows an advantageous embodiment of the URVA 850 heat treatment of the grade of ductile iron according to the invention.
- the heat treatment first the temperature of the piece is heated to around 900°C, in which temperature pieces are kept for a certain period of time, after which the temperature is lowered to around 800°C, in which the temperature is balanced for a short period of time, after which the material is quickly cooled to 400°C, in which temperature the pieces are kept for a certain period of time, after which the piece is re-heated to temperature around 580°C, in which temperature the pieces are kept for a certain period of time, after which the piece is cooled with desired cooling rate.
- the URVA 850 heat treatment is described in more detail, inter alia, in patent application FI-20011954.
- Figure 4 schematically shows a simulation process chart of the heat treatment for multiform pieces.
- the desired microstructure 32 temperature curves
- the thermal properties of materials 33 are defined, which data are input to the heat- treatment simulation 30.
- data on desired material properties 34 and data on the geometry of the piece are input to the heat-treatment simulation 30.
- the target heat-treatment programme 38 based on which furnace control parameters 39 are defined on the basis of both the target heat-treatment programme 38 and furnace parameters 40.
- furnace parameters 40 one also defines the transfer of heat into the environment 36 which is taken into consideration in the heat-treatment simulation 30.
- Figures 5A and 5B show the simulation of the heat treatment and the cooling rate of the piece in different points of the piece.
- Figure 5A shows temperatures T as a function of time t, in which heat-treatment curves, in the item with reference S, occur the pearlitic and bainitic regions transferred with doping which are dependent on material additives.
- References Pj and P2 refer to the points P 1 ja P 2 of the sample piece in Figure 5B from which points the affecting factors are heat flows Q to different sides of the piece depending on the form of the piece.
- Figure 6 shows a picture of a typical microstructure of the grade of ductile iron according to the invention. The enlargement of the picture is 100-fold. The picture shows the graphite spheres of the microstructure on pearlitic base, and according to the invention, this is fine-grained pearlite. The picture also shows ferlite on grain boundaries, which increases the toughness of the material.
- Figure 7 shows a 400-fold enlargement of Figure 6 of fine grain ductile iron (FGDI) according to the invention.
- the figure shows graphite spheres on pearlitic base 2 and ferrite on grain boundaries which is marked with reference numeral 1.
- Figure 8 shows a 700-fold enlargement of fine grain ductile iron (FGDI) according to the invention which figure illustrates the fine-grained lamellar structure in which the lamellar distance is ⁇ 0,4 ⁇ m.
- the grain size is 10-20 ⁇ m.
- Figure 9 shows a picture of a typical microstracture of prior-art material which picture shows graphite spheres on pearlitic base, and around 1-2% of carbides which are designated with the reference A and the graphite spheres are designated with reference B.
- This structure does not typically include ferrite.
- Figure 10 schematically shows a 700-fold enlargement of a material known from prior art which enlargement illustrates a typical pearlitic structure of a good- quality material.
- the grain size is typically 50-100 ⁇ m.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
- Heat Treatment Of Articles (AREA)
Abstract
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FI20055010A FI118738B (fi) | 2005-01-05 | 2005-01-05 | Pallografiittivalurauta ja menetelmä pallografiittivaluraudan valmistamiseksi lujuutta ja sitkeyttä vaativia koneenrakennusosia varten |
PCT/FI2006/050002 WO2006072663A2 (fr) | 2005-01-05 | 2006-01-02 | Fonte ductile et procede de fabrication associe pour l'elaboration de composants a proprietes de resistance et de tenacite desirees |
Publications (1)
Publication Number | Publication Date |
---|---|
EP1838888A2 true EP1838888A2 (fr) | 2007-10-03 |
Family
ID=34112661
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP06700056A Withdrawn EP1838888A2 (fr) | 2005-01-05 | 2006-01-02 | Fonte ductile et procede de fabrication associe pour l'elaboration de composants a proprietes de resistance et de tenacite desirees |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP1838888A2 (fr) |
FI (1) | FI118738B (fr) |
WO (1) | WO2006072663A2 (fr) |
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US7824605B2 (en) | 2006-12-15 | 2010-11-02 | Dexter Foundry, Inc. | As-cast carbidic ductile iron |
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CN105369116B (zh) * | 2014-08-29 | 2017-03-08 | 中原内配集团股份有限公司 | 一种离心铸造生产的花斑气缸套及其生产工艺 |
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2005
- 2005-01-05 FI FI20055010A patent/FI118738B/fi not_active IP Right Cessation
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2006
- 2006-01-02 WO PCT/FI2006/050002 patent/WO2006072663A2/fr active Application Filing
- 2006-01-02 EP EP06700056A patent/EP1838888A2/fr not_active Withdrawn
Non-Patent Citations (1)
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Also Published As
Publication number | Publication date |
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FI20055010A (fi) | 2006-07-06 |
FI20055010A0 (fi) | 2005-01-05 |
WO2006072663A3 (fr) | 2007-05-18 |
WO2006072663A2 (fr) | 2006-07-13 |
FI118738B (fi) | 2008-02-29 |
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