Attila Diószegi

Inoculation of primary austenite in grey cast iron

Abstract Primary austenite is the least investigated microstructural component of grey cast iron. It is the first phase to be nucleated in the liquid metal and it grows in a dendritic manner, followed by growth of the eutectic phase. This paper describes an investigation on three potential nucleating agents to promote the nucleation of primary austenite in grey cast iron under industrial conditions. A direct austempering after solidification (DAAS technique) was used to determine the number of primary austenite grains. A colour etching technique was used to reveal the primary austenite grains and the eutectic cells. The results show that properly chosen nucleation agents significantly promote the number of primary austenite grains. Furthermore, the authors show that the eutectic cell size and the morphology of the graphite are obviously influenced by the primary solidification in grey cast iron. The increased nucleation of austenite grains resulted in an increased number of eutectic cells.

Effects of nodularity on thermal conductivity of cast iron

Abstract The thermal transport properties of five predominately pearlitic grades of grey, compacted graphite and spheroidal graphite iron have been investigated by the laser flash technique. Samples have been taken from cylinders cast in controlled thermal environments designed to produce three dissimilar cooling rates. Digital image analysis has been utilised in order to characterise the different graphite morphologies. The results indicated linear relationships between the thermal transport properties and the roundness of the graphite and the nodularity for compacted graphite and spheroidal graphite iron. A pronounced decrease in the thermal conductivity occurred when the lamellar graphite structure was transformed into compacted graphite. The thermal conductivity of compacted and spheroidal graphite iron has been recalculated with good accuracy over a temperature range of 25–500°C by means of regression analysis.

Inverse thermal analysis method to study solidification in cast iron

Abstract Solidification modelling of cast metals is widely used to predict final properties in cast components. Accurate models necessitate good knowledge of the solidification behaviour. The present study includes a re-examination of the Fourier thermal analysis method. This involves an inverse numerical solution of a one-dimensional heat transfer problem connected to solidification of cast alloys. In the analysis, the relation between the thermal state and the fraction solid of the metal is evaluated by a numerical method. This method contains an iteration algorithm controlled by an under relaxation term to achieve a stable convergence. The heat transfer problem is reduced to one-dimension to promote the practical application of the method. Thermo-physical properties such as the volumetric heat capacity tabulated in the calculation are introduced as a function of solidifying phases. Experimental equipment was developed in order to investigate the thermal behaviour of the solidifying metal. Three cylindrically shaped cast samples surrounded by different cooling materials were introduced in the same mould allowing a common metallurgical background for samples solidifying at different cooling rates. The proposed inverse thermal analysis was tested on both experimental and simulated data.

Shrinkage Porosity and its Relation to Solidification Structure of Grey Cast Iron Parts

Abstract The purpose of this work was to investigate the relation between shrinkage porosity and the macrostructure. Based on results from an earlier investigation regarding shrinkage porosity and its characteristic features, a test casting was developed. The macrostructure was preserved using direct austempering after solidification heat treatment. Shrinkage porosity was found in regions where it was designed to occur. It was also found that this type of porosity is connected to the atmosphere via defects located on the surface, confirming earlier findings. Beneath the surface, it extends as a three-dimensional network through the casting. The shrinkage porosity was, in some cases, found along the boundaries separating primary crystals, and in some cases, it encircled separate primary crystals. A shrinkage porosity formation mechanism is proposed based on these observations, discussing the importance of a rigid columnar zone, movement of a local thermal centre and how pressure differences developing during solidification influence the formation of shrinkage porosity.

Effects of carbon content and solidification rate on the thermal conductivity of grey cast iron

The thermal conductivity/diffusivity of pearlitic grey irons with various carbon contents was investigated by the laser flash method. The materials were cast in controlled thermal environments producing three dissimilar cooling rates. The cooling rates together with the carbon content largely influence the thermal conductivity of grey iron. Linear relationships exist between the thermal conductivity and the carbon content, the carbon equivalent, and the fraction of the former primary solidified austenite transformed into pearlite. The results show that the optimal thermal transport properties are obtained at medium cooling rates. Equations are given for the thermal conductivity of pearlite, solidified as pre-eutectic austenite, and the eutectic of grey iron. The thermal conductivity of pearlitic grey iron is modelled at both room temperature and elevated temperatures with good accuracy.

Effects of transition from lamellar to compacted graphite on thermal conductivity of cast iron

Abstract Different levels of magnesium were added to a standard grey iron alloy in order to obtain a range of graphite morphologies from lamellar to compacted graphite. The thermal conductivity/diffusivity of samples, solidified at different cooling rates, was investigated by means of the laser flash technique. There is a significant decrease in the thermal conductivity as the morphology transits from lamellar to compacted graphite. The thermal conductivity of grey iron decreases considerably at elevated temperatures, whereas the thermal conductivity of compacted graphite iron is less sensitive to changes in temperature. At increased nodularities, compacted graphite irons exhibit a maximum thermal conductivity at ∼400°C. The influence from the cooling conditions on the thermal conductivity decreases as the morphology alters from lamellar graphite to compacted graphite. The effective thermal conductivity of cast iron is modelled by means of existing models for composites.

The novel application of Fourier thermal analysis in foundry technologies

The process of casting in sand moulds is used for a large volume of castings manufactured in the world. Internal channels and complex geometries of these products are formed by the placement of cores within the mould cavity. Resin-bound sand mixtures are essential ingredients in engine component manufacturing. In this study, a state-of-the-art application of Fourier thermal analysis in foundry technologies is presented. Investigation of decomposition phenomena of resin-bound moulding materials during casting production is a brand new area to use the potential of thermal sciences. Temperature measurements in test samples of standard types of moulding mixtures were performed. The registered cooling curves were processed by a numerical iteration algorithm to determine the amount of heat absorbed during degradation of the moulding material. Thermogravimetric analysis (TG) and differential thermal analysis (DTA) of sand mixtures were carried out to compare the results of the Fourier thermal analysis with TG and DTA curves.

On problems of volume change measurements in lamellar cast iron

Abstract Solidification of lamellar cast iron is a complex mechanism due to the contracting austenite phase and the expanding graphite phase precipitation. The combined effect of contraction–expansion has an influence on the volume change related defects (shrinkage porosity and penetration). Critical moments in measuring volume change are the methods used for measurement together with the interpretation of the solidification based on the macrostructure. Reliable results are obtained using displacement measurement in both axial and radial direction of a cylindrical sample in combination with using two thermocouples and a force measurement unit. Common drawback of the used method together with other methods presented in the literature is the early expansion observed before the coherence of the solidifying grains. The introduced force measurement gives a novel interpretation of the columnar to equiaxed transition, and the displacement measurement in different directions within a cast sample reveal the anisotropic character of the volume change.

Inoculation and its effect on primary solidification structure of hypoeutectic grey cast iron

Abstract The solidification of grey cast iron is controlled by the addition of inoculants. This is done in order to provide nucleation sites and hence facilitate the formation of eutectic cells and decrease the degree of undercooling. The number of eutectic cells and the graphite morphology affect the final properties of the casting. Preceding the nucleation of graphite and the eutectic cells is the nucleation of the primary austenite. It was found that the addition of inoculants also influences the primary solidification. The largest effect on the primary dendrites is obtained by inoculation using pure iron powder. It was also shown how the columnar to equiaxed transition (CET) depends on the number of equiaxed dendrites per unit volume. In addition, the primary structure was found to influence the eutectic solidification. The relationship between the secondary dendrite arm spacing and the eutectic cell size was found to correlate well with the work of others.

Inverse kinetic analysis method to study eutectic growth

Abstract Deterministic modelling is a classical method used for solidification simulation. A common procedure uses a kinetic model to describe the growth of solid phases. Formulation of the kinetic models used to be done by direct observation of the solidification process involving thermal analysis and microstructure investigation. Much effort has been invested in studying eutectic alloys and their solidification kinetics. Different growth parameters were observed which are assumed to depend on experimental conditions. The present study uses a direct simulation including a kinetic model for simulation of the eutectic phase. The simulated microstructure and cooling curves were used to carry out inverse thermal and inverse kinetic analyses. The inverse kinetic analysis method introduced indicates a strong equivalence between the direct solidification model and the inverse calculation. The position of the cooling curves used in the inverse analysis has been investigated and the best results are obtained when the cooling curves analysed are from locations closely positioned in space.