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AFS Proceedings 2010 American Foundry Society, Schaumburg, IL USA
G. L. Pioszak
University of Michigan
UTS
min
psi / MPa
60 000 / 414
65 000 / 448
80 000 / 552
100 000 / 689
120 000 / 827
Yield Strength
min
psi / MPa
40 000 / 276
45 000 / 310
55 000 / 379
70 000 / 483
90 000 / 621
% Elongation
min
18
12
6
3
2
(b)
Grade 80-55-06
Fig. 1. Photomicrographs of commonly used grades
of ductile iron taken at the same magnification.
Etched with 5% Nital.
(a)
Grade 60-45-12
Tensile
Strength
(MPa/ksi)
Yield
Strength
(MPa/ksi)
Elon
g.
(%)
Typical
Hardness
(HBW)
750 / 110
500 / 70
11
241-302
1
900 / 130
650 / 90
9
269-341
2
1050 / 150
750 / 110
7
302-375
3
1200 / 175
850 / 125
4
341-444
4
1400 / 200
1100 / 155
2
388-477
5
1600 / 230
1300 / 185
1
402-512
*Note: All properties are minimum requirements except
hardness which is typical.
(a)
Grade 900-650-09
DYNAMIC PROPERTIES
Dynamic properties include such measures as fatigue
strength (rotating bending, rolling, gear tooth contact and
bending), wear resistance, galling resistance and
toughness.
Figure 7 shows the typical 10 million cycle allowable
rotating bending stress of ADI compared to several
material/process combinations. Examination of these
results shows that ADI is very competitive with neutral
hardened, medium carbon steel.
Fig. 8. A comparison of the allowable bending stress
for ADI (as machined and shot peened) vs. other,
conventional steel material/process combinations.
Material
Grade 900 ADI
Grade 1050 ADI
Grade 1600 ADI
C/A 8620 Surface
C/H 8620 Surface
SAE 660 Bronze
Fig. 9. Relative volume loss to abrasion of several
material/process combinations at 40 HRC.
Volume
Loss
(mm3)
10.9
10.7
9.4
10.6
10.6
70.1
Hardness
(HRC)
30
40
52
54
60
27(HRB)
Galling
Threshold
(MPa)
1527+
894
941
512
882
311+
OTHER PROPERTIES
These other properties are as varied as the applications
being considered. They may include such measures as
density (specific gravity), corrosion resistance, coefficient
of thermal expansion, thermal conductivity, damping
coefficient and other measures as specific as magnetic
permeability and electrical resistivity.
Today, designers are often pressed for weight reductions
to either reduce energy requirements on moving systems
or to reduce shipping costs or to reduce the structural
needs of a system made up of many components. Figure
13 compares the densities of several material/process
combinations. The popularity of aluminum stems largely
from its low density and good manufacturability.
Low density, by itself, is insufficient to compare
materials. For instance, Styrofoam and balsa wood have
low densities, but their strengths are insufficient for most
component designs. Figure 14 compares the relative
weight per unit of yield strength of various materials.
Material/Process
Coarse Flake (damped)
Gray Iron
Fine Flake Gray Iron
Austempered Ductile
Iron (ADI)
Ductile Iron
Carbon Steel
Carbidic (White) Iron
Aluminum (typical)
Grade of ADI
750-500-11
900-650-09
1050-750-07
1200-850-04
1400-1100-02
1600-1300-01
Maximum Operating
Temperature
315C (600F)
315C (600F)
300C (572F)
290C (554F)
280C (536F)
260C (500F)
3.
SUMMARY/CONCLUSIONS
ADI offers the designer an economical alternative to steel
and aluminum castings, forgings and weldments.
ADIs high strength-to-weight ratio allows the designer to
even replace aluminum sand castings and forgings at
equal mass in applications with a minimum ADI wall
thickness of 3mm.
ADIs bending and contact fatigue strength makes it
superior to aluminum and competitive with steel at a
similar hardness.
ADI offers the mechanical designer a practical material
choice at low cycle stress levels above 450 MPa.
It is impossible to capture the entire design process and to
address all the questions encountered in the design of
mechanical components in a single paper. The authors
have attempted to speak from a design perspective about a
material that is new to most designers. The comparative
relationships are insufficient for part design, but the
references referred to below would lead the designer to
the necessary documents and formulae to answer his/her
specific questions to allow for designing with ADI.
REFERENCES
1.
ACKNOWLEDGMENTS
The authors would like to thank the employees and
customers of the AP Companies and our worldwide
network of licensees for their contributions to the
information and case studies referred to in this paper.
Special thanks to Terry Lusk, Justin Lefevre, Smith
Foundry, Dotson Company, Walther EMC, Benteler,
Toro, Citation Corporation and Chrysler.
DEFINITIONS/ABBREVIATIONS
In the comparative properties graphs the Key references
to various CF materials represent carbon fiber
materials.
There exists mixed convention regarding the
capitalization of the various forms of the words
Austenite and Austemper. The A is rightly
capitalized as the pre-fix Aus is a formal derivation
from the name of the metallic phase Austenite and its
principal discoverer, Sir William Chandler RobertsAusten (1843-1902), British metallurgist.
The same conundrum arises with the various conjugations
of Bainite, the metallurgical mixture of phases named
after its discoverer, Edgar Bain, and Martensite, a mixture
of phases named after the German investigator Adolph
Martens.
HBW is the convention for Brinell hardness taken from
an indentation made from the ISO required tungsten (W)
ball.