US20040071584A1 - Spheroidal cast iron particularly for piston rings and method for obtaining a spheroidal cast iron - Google Patents

Spheroidal cast iron particularly for piston rings and method for obtaining a spheroidal cast iron Download PDF

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Publication number
US20040071584A1
US20040071584A1 US10/625,872 US62587203A US2004071584A1 US 20040071584 A1 US20040071584 A1 US 20040071584A1 US 62587203 A US62587203 A US 62587203A US 2004071584 A1 US2004071584 A1 US 2004071584A1
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cast iron
spheroidal
spheroidal cast
elements
piston rings
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US10/625,872
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English (en)
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Alberto Molinari
Dimitri Anguillesi
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ASSO WERKE Srl
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ERRE VIS SpA
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Assigned to ERRE-VIS S.P.A. reassignment ERRE-VIS S.P.A. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ANGUILLESI, DIMITRI, MOLINARI, ALBERTO
Publication of US20040071584A1 publication Critical patent/US20040071584A1/en
Assigned to ASSO WERKE S.R.L. reassignment ASSO WERKE S.R.L. MERGER (SEE DOCUMENT FOR DETAILS). Assignors: ERRE-VIS S.P.A.
Abandoned legal-status Critical Current

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    • 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
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D5/00—Heat treatments of 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
    • C22C37/10—Cast-iron alloys containing aluminium or silicon
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/18—Hardening; Quenching with or without subsequent tempering
    • C21D1/19—Hardening; Quenching with or without subsequent tempering by interrupted quenching
    • C21D1/20—Isothermal quenching, e.g. bainitic hardening
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2211/00—Microstructure comprising significant phases
    • C21D2211/001—Austenite
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2211/00—Microstructure comprising significant phases
    • C21D2211/002—Bainite
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2211/00—Microstructure comprising significant phases
    • C21D2211/006—Graphite

Definitions

  • the present invention relates to a spheroidal cast iron that can be used for example to produce piston rings for pistons that work inside the cylinders of engines, and to a method for obtaining said spheroidal cast iron.
  • an austempered spheroidal cast iron is known from European patent application 0144907 which is used to produce mechanical parts and is suitable for producing thin parts as well as details that have a thick wall cross-section; this patent also describes that when producing this type of spheroidal cast iron there are inevitable impurities or porosities in the cast iron.
  • piston rings of internal-combustion engines are currently divided into two types: cast-iron piston rings and steel piston rings.
  • Cast-iron piston rings which in turn can be made of lamellar graphite cast iron or spheroidal cast iron, are obtained from castings that are subsequently worked on machine tools.
  • the particular workability of cast iron in fact allows to obtain piston rings that have complex geometric shapes that can adapt in an optimum manner to the internal shape of the cylinder and to the shape of the piston, achieving excellent oil-tightness, limiting blow-by in four-stroke engines, facilitating slide and therefore allowing to achieve very high sliding speeds and limited wear, all this in relation to the particular thermal expansions of the cylinder, which work in contrast with the pisytop, and to the reduced penetrations of the piston ring in the transfer ports of two-stroke engines.
  • cast iron piston rings Another substantial characteristic of cast iron piston rings is that the graphite structure of cast iron allows to have excellent tribological characteristics and high thermal conductivity, such as to allow an excellent self-lubricating capability, thus providing a better slide, a low friction coefficient and accordingly less wear in operation than achievable with steel piston rings.
  • spheroidal cast iron piston rings like all components made of spheroidal cast irons, have mechanical and strength characteristics that are in any case better than those of piston rings made of lamellar graphite cast irons, since in lamellar graphite the vertices of the lamellas produce a series of local stress intensification effects which tension and weaken said structure.
  • Steel piston rings have a far greater ultimate tensile strength, yield strength, impact strength and toughness than cast iron piston rings, and accordingly can be used without problems even in conditions of very intense physical and mechanical stress, which cannot be withstood by piston rings made of the spheroidal cast irons currently used in this sector.
  • steel piston rings are not easy to work and in view of their microstructure do not have self-lubricating characteristics: for this reason they require the use of antifriction surface coatings in order to be used without problems inside engines.
  • the aim of the present invention is to provide a spheroidal cast iron that can be used particularly for example in the production of piston rings and is capable of eliminating or substantially reducing the drawbacks of the known art.
  • an object of the invention is to provide a spheroidal cast iron that can be used in particular for example to provide piston rings and is capable of eliminating or substantially reducing the differences with respect to the steels currently used in the specific sector in terms of mechanical strength while maintaining the above cited typical advantages of spheroidal cast iron with respect to steel.
  • An object of the invention is in fact to provide a spheroidal cast iron that can be used to manufacture elastic elements that can be obtained by virtue of specific castings for cast parts that are small and have a narrow cross-section, shaped like a closed ring, by means of a single cluster casting or centrifuged casting, for example in order to provide piston rings for pistons that work within the cylinders of engines.
  • Another object of the invention is to provide a spheroidal cast iron that allows to achieve a high normal modulus of elasticity.
  • Another object of the invention is to provide a spheroidal cast iron that allows to produce elements that have a uniform and homogeneous hardness along the entire peripheral extension of the casting.
  • Another object of the invention is to provide a cast iron that must have a high ultimate tensile strength; the piston ring, for example, is in fact subjected to intense high-frequency dynamic stresses, and therefore in order to be able to work without breaking, the cast iron must have a high tensile strength and yield strength.
  • the spheroidal cast iron according to the invention is suitable for manufacturing piston rings for modern internal-combustion engines with a very high performance and low pollution, and therefore the austempering treatment has determined precise values of austenite and bainite that are suitable for this kind of use, with UTS values of 1300 N/mm 2 and Rp 0.2 of 1100 N/mm 2 .
  • Another object of the invention is to provide a cast iron that is capable of withstanding use at high temperature without tempering.
  • Another object of the invention is to provide a cast iron that is capable of high resistance to wear.
  • Another object of the invention is to provide a cast iron that has a high fatigue strength.
  • Another object of the invention is to provide a cast iron that has high impact strength.
  • Another object of the invention is to provide a particular melting process that allows excellent microstructural uniformity in all castings and allows to eliminate porosities and entrainments of inclusions along the entire peripheral region of the casting ring.
  • an austempered spheroidal cast iron which comprises, in addition to Fe, the following elements: C, Si, P, S, Mn, Cu, Mo, and is characterized in that it furthermore comprises Cr, Ni, RE, Co, and at least one of the following elements: Ti, V, Nb.
  • said austempered spheroidal cast iron comprises the elements cited above in the following percentages by weight, while the remaining percentage is constituted by Fe: 3.20-4.20% C, 2.00-4.00% Si, up to 0.10% P, up to 0.10% S, up to 0.20% Mn, up to 1.30% Cu, up to 0.50% Cr, 1.7% to 5.00% Ni+RE, 0.10-2.00% Mo, 0.1% to 2.0% of at least one among Ti, V and Nb, up to 0.20% Co.
  • an austempered spheroidal cast iron obtained by means of a process that is characterized by the following steps: a step for preparing the basic cast iron with a controlled chemical composition; a second step for melting the basic cast iron with verification of the preset chemical composition; a subsequent step for adding the intended alloying chemical elements; a step constituted by two successive inoculations of spheroidizing agents; a final step for solidification of the molten material.
  • said spheroidizing agents used in the inoculation step of the method for obtaining the cast iron according to the invention are constituted by a base of silicon and other elements such as Mg, Ca, Ce, Ta, Sr, Al and RE.
  • the spheroidal cast iron according to the invention has the following chemical composition, in which the individual elements are expressed as a percentage by weight, while the remaining percentage is constituted by iron Fe: 3.20-4.20% C, 2.00-4.00% Si, up to 0.10% P, up to 0.10% S, up to 0.20% Mn, up to 1.30% Cu, up to 0.50% Cr, 1.7% to 5.00% Ni+RE, up to 2.00% Mo, 0.1% to 2.0% Ti+V+Nb, up to 0.20% Co.
  • the composition of the cast iron according to the invention can also comprise B, Ca and other elements up to an overall maximum of 1.00%.
  • the spheroidal cast iron particularly for producing piston rings according to the invention has a bainitic austenitic matrix, high impact strength, high normal modulus of elasticity, high mechanical strength, and very precise values of measurement of the graphite spheroids and low values of roundness and roughness of spheroids and a thermal expansion coefficient that can be compared with that of steel.
  • the present invention therefore relates to a spheroidal cast iron, which is particularly optimized for the production of mechanical elements that must have characteristics of elasticity, good resistance to fatigue and wear, as required for example for piston rings of internal-combustion engines, and furthermore has important properties of impact strength and toughness: spheroidal cast irons with a non-ferrite matrix, even not specifically for piston rings, that achieve appreciable impact strength values are in fact not currently known.
  • the casting matrix that must be obtained in castings for piston rings must be predominantly pearlitic, with ferrite areas, in order to have an optimum subsequent austempering treatment.
  • the high normal modulus of elasticity of the is fundamental so that it applies a contact pressure (tangential force) against the walls of the cylinder in which it is installed, said contact pressure being required in order to ensure the gas-tightness of the combustion chamber. Furthermore, a high elastic modulus is required so that the piston ring does not remain permanently (plastically) deformed following the extensive deformations required for insertion in the piston groove.
  • the normal modulus of elasticity E of the cast iron according to the invention can range from 150,000 to 200,000 N/mm 2 .
  • the piston rings produced with the spheroidal cast iron according to the invention must have uniform and homogeneous hardness along the entire peripheral extension of the casting.
  • the high ultimate tensile strength required of the cast iron according to the invention is achieved through control of the chemical composition of the cast iron but also through control of the heat treatment. In particular, it is noted that it is necessary to ensure that an amount of residual austenite greater than 20% and lower than 40% is present inside the matrix of the material.
  • the other mechanical characteristics required of the cast iron according to the invention are, as mentioned, high resistance to wear, high fatigue strength, and high impact strength.
  • the piston ring must have a high resistance to wear, which is suitable to ensure the durability of the performance and of the reliability of the engine in which it is used; for this reason, a particular chemical composition of the cast iron according to the invention has been identified, with alloy elements such as Ti, V and Nb, which are capable of controlling the submicroscopic size of primary carbides and their uniform distribution in the primary solidification structure.
  • the spheroidal cast iron according to the invention is characterized by a specific chemical composition that is optimized in order to provide, in combination with the heat treatment, a submicroscopic precipitation of primary carbides MC, which are uniformly distributed in the primary solidification structure, which compensates for the effect of reducing wear resistance caused by the presence of the austenite within the structure and due to the fact that the wear coefficient of austenite is higher than that of bainite and martensite.
  • the piston rings must have a high fatigue strength due to the extremely intense stresses that the high rotation rates (rpm) of engines produce (up to approximately 24,000 rpm on modern two-stroke engines and approximately 18,000 rpm for modern four-stroke engines), so as to ensure the durability and reliability of the engine in which the piston ring is used.
  • Another object of the invention is to provide a spheroidal cast iron with high impact strength.
  • values of impact strength higher than 15 joule are generally not observable.
  • the cast iron according to the present invention has a Charpy impact strength of 80 to 165 joule.
  • embrittling elements such as Mn, Cu, Al, Pb and W have been kept within narrow ranges and at the same time inside the metallographic matrix of the material there must be, in accordance with what was noted earlier, an amount of residual austenite that is higher than 20% and lower than 40%.
  • the cast iron according to the invention must be capable of withstanding use at high temperatures without tempering.
  • the piston ring for example, is in fact used in internal-combustion engines at high temperatures, and it is clearly necessary for the piston ring not to lose its characteristics of elasticity and mechanical strength during use.
  • One of the weak aspects of austempered cast iron is high sensitivity to tempering, since at a high temperature the austenitic-bainitic structure tends to be converted according to the TTT curve into mixed bainitic-sorbitic structures.
  • the particular chemical composition that has been identified which includes alloy elements such as Ni, Mo, Ti, V and Nb, and the particular melting process are very important for this object as well, allowing to achieve a high mechanical strength of the piston rings during use at high temperature, and so is great insensitivity to tempering, combined with high resistance to wear.
  • the spheroidal cast iron according to the present invention has been devised with a production process in which the fillers and all those refinements that are indispensable to achieve, after melting, the physical/chemical characteristics described above, have been studied specifically; the mechanical characteristics are instead achieved after a heat treatment, devised exclusively in order to optimize the structures and mechanical characteristics of small-size, small-section castings.
  • the spheroidal cast iron according to the present invention has been devised by taking into account that the castings to be performed with said cast iron are individual cluster castings or centrifuged castings with cross-sections that vary from 2 mm 2 to 50 mm 2 , meant to make compression rings for all internal-combustion engines.
  • the filler used to obtain these structures has been conceived by taking into account some important considerations regarding the production of spheroidal cast iron, such as: composition of the basic alloy, spheroidizing pretreatment, percentage of alloy added, inoculation, final chemical composition of the spheroidal cast iron, microstructure, mechanical properties.
  • the determination of the basic master alloy for obtaining the spheroidal cast iron is therefore particularly important: some chemical elements are in fact distinctly dangerous in a cast iron for piston rings, and if they exceed a limit value of concentration in the master cast iron they hinder the nodulization of the graphite.
  • These elements are constituted, in the specific case, by a combination of a mixture of metals that belong to the lanthanide group, known in metallurgy as “mischmetall”, with many other metallic elements in the form of oxides.
  • the combination of this mixture of lanthanides with oxides of other metals forms so-called rare earths (RE).
  • RE rare earths
  • said mixture of rare earths which is used in metallurgy to produce alloys and superalloys, is used as inoculant, and its particular properties for control and purification of the microimpurities contained in the basic cast iron are used.
  • the melting process has been optimized by providing two successive inoculations that have the compositions specified hereafter merely by way of non-limitative example:
  • the spheroidizing agents used are constituted by a base of silicon with Mg, Ca, Ce, Ta, and RE;
  • the molten metal is solidified with a solidification time comprises between 50 and 400 seconds, depending on the cast cross-section.
  • the various elements that compose the cast iron according to the invention have been chosen to allow better hardenability of the material and therefore raise the bainitic transformation threshold, and also to obtain mechanical characteristics, such as tensile strength (UTS and Rp 0.2 ), percentage elongation (A %), toughness, impact strength and fatigue strength that are better than in spheroidal cast irons for piston rings currently in use.
  • the variation ranges of the elements that compose the cast iron according to the invention have been determined by means of tests repeated in order to optimize the mechanical characteristics of the material without exceeding values that might compromise castability, spheroidization, workability and/or brittleness of said cast iron.
  • the carbon variation range has been determined in order to have an optimum graphite structure, so as to achieve high toughness and strength while ensuring good forming and spheroidal graphite distribution.
  • the nickel content has been limited to the values cited above in order to avoid compromising the castability and workability of the cast iron.
  • the molybdenum content was limited to the value indicated above in order to avoid compromising the mechanical characteristics of the cast iron due to the forming of complex structures of free cementite and due to segregation.
  • the heat treatment to which the cast iron is subjected in castings according to the invention comprises an austenitization treatment, with holding of the cast iron up to 120 minutes at a temperature of 840-1000° C. and an isothermal hardening (austempering) treatment, with holding of the cast iron for 5 to 100 minutes at a temperature of 250-450° C.
  • the heat treatment can be completed by a stress relieving treatment at a temperature that is higher than the isothermal hardening temperature.
  • austempering is an already-known heat treatment for spheroidal cast irons in general, in the case being considered said treatment has been optimized in order to balance, in the specific case of the production of piston rings for internal-combustion engines, a high mechanical strength (UTS and Rp 0.2 ) with high fatigue strength and high impact strength and toughness.
  • the spheroidal cast iron according to the invention is a spheroidal cast iron with a type VI uniform graphite distribution, with size 5 to 8 graphite spheroids (according to the ISO 945 standard “Cast iron: Designation of microstructure of graphite”).
  • the concentration of the graphite spheroids with respect to the matrix is comprised between 6 and 12%, ensuring optimum self-lubrication.
  • the roundness of the graphite spheroids is comprised between 1.0 and 1.4, ensuring a low coefficient of stress intensification.
  • the roughness of the graphite spheroids is comprised between 1 and 1.3 and ensures optimum fatigue strength.
  • the cast iron according to the invention has a matrix structure of the bainitic-austenitic type, with austenite percentages that can vary between 20 and 40%.
  • the cast iron according to the invention has uniform and homogeneous hardness along the entire peripheral distribution of the casting, with hardness values comprised between 103 HRB and 115 HRB (250-600 HV 0.1 on the Vickers scale).
  • the cast iron cooling gradient, during the heat treatment, is kept as uniform and homogeneous as possible in order to avoid hardness variations, on a same, of more than 4 HRB points, which might compromise significantly the elastic behavior of the piston ring in contact with the cylinder of the engine during operation.
  • the cast iron according to the invention has excellent tensile strength (R m >1100 N/mm 2 ), high strength and toughness [impact strength on unnotched test specimens (Impact Energy) KC>80 Joule] and a high percentage elongation (A %>2.5%).
  • FIG. 1 is a view of a round tension test specimen (according to the ASTM standard E8M);
  • FIG. 2 is a view of a Charpy impact test specimen (according to the ASTM standard E23).
  • Test no. 3 930° C. ⁇ 30 min 330° C. ⁇ 60 min 1066 772 4.17 150.73 Test no.
  • the spheroidal cast iron according to the invention fully achieves the intended aim and objects, since it allows to produce piston rings with mechanical strength characteristics that are comparable with those of piston rings made of steel while preserving all the advantages that are typical of spheroidal cast iron.
  • the cast iron according to the invention has been conceived in particular for the production of piston rings of internal-combustion engines, it may be used advantageously also to produce piston rings for compressor units or for the production of rings for hydraulic or pneumatic units or for other uses.
US10/625,872 2002-07-26 2003-07-24 Spheroidal cast iron particularly for piston rings and method for obtaining a spheroidal cast iron Abandoned US20040071584A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT2002MI001670A ITMI20021670A1 (it) 2002-07-26 2002-07-26 Ghisa sferoidale particolarmente per la realizzazione di segmenti elastici di tenuta per pistoni di motori a combustione interna
ITMI2002A001670 2002-07-26

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US (1) US20040071584A1 (de)
EP (1) EP1384794B1 (de)
AT (1) ATE327351T1 (de)
DE (1) DE60305389T2 (de)
ES (1) ES2264507T3 (de)
IT (1) ITMI20021670A1 (de)
PT (1) PT1384794E (de)

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