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Metals
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Cast Irons: Properties and Applications
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Cast Irons: Properties and Applications

A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (30 November 2019) | Viewed by 42939

Printed Edition Available!
A printed edition of this Special Issue is available here.

Special Issue Editor

Prof. Dr. Paolo Ferro

E-Mail Website
Guest Editor
Department of Engineering and Management, University of Padova, Stradella San Nicola 3, 36100 Vicenza, Italy
Interests: raw materials; structural integrity of welded joints and additively manufactured components; welding and heat treatment simulation; cast iron; stainless steels; material selection
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Cast iron is one of the most used material in engineering applications thanks to its good mechanical properties and excellent castability, which allows to obtain very complex geometries without the need of joining or welding operations. Designers often need to know the mechanical properties values in each zone of the casting. In fact, such properties are very different from those declared in the standard classification of the cast iron used. At constant chemical composition, the mechanical properties of a casting will depend on the microstructure, which in turn is ruled by the cooling rate at each point of the casting. On the basis of this background, the proposed special issue is aimed to collect papers dealing with both static and fatigue strength characterization of ductile iron castings and applications in which such kinds of alloys are used. Submissions of works that correlate process parameters, as well as the solidification time with mechanical properties, are strongly encouraged.

I’m very pleased to invite you to contribute with your recent advances about cast iron to this Special Issue ‘Cast Irons: Properties and Applications’ to be published in the open access journal Metals. Mechanical properties and applications of conventional, as well as non-conventional, cast iron grades will be considered in the Special Issue.

Prof. Dr. Paolo Ferro
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Cast iron
  • Mechanical properties
  • Fatigue strength
  • Toughness
  • Defects
  • Microstructure
  • Solution strengthened ferritic ductile iron (SS-FDI)
  • Austempered ductile iron (ADI)
  • Application
  • Modeling
  • Heavy section casing
  • Process parameters

Published Papers (11 papers)

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13 pages, 4246 KiB  
Article
A Comparative Study on the Influence of Chromium on the Phase Fraction and Elemental Distribution in As-Cast High Chromium Cast Irons: Simulation vs. Experimentation
by U. Pranav Nayak, María Agustina Guitar and Frank Mücklich
Metals 2020, 10(1), 30; https://doi.org/10.3390/met10010030 - 23 Dec 2019
Cited by 25 | Viewed by 4641
Abstract
The excellent abrasion resistance of high chromium cast irons (HCCIs) stems from the dispersion of the hard iron-chromium eutectic carbides. The surrounding matrix on the other hand, provides sufficient mechanical support, improving the resistance to cracking deformation and spalling. Prior knowledge of the [...] Read more.
The excellent abrasion resistance of high chromium cast irons (HCCIs) stems from the dispersion of the hard iron-chromium eutectic carbides. The surrounding matrix on the other hand, provides sufficient mechanical support, improving the resistance to cracking deformation and spalling. Prior knowledge of the microstructural characteristics is imperative to appropriately design subsequent heat treatments, and in this regard, employing computational tools is the current trend. In this work, computational and experimental results were correlated with the aim of validating the usage of MatCalc simulations to predict the eutectic carbide phase fraction and the elemental distribution in two HCCI alloys, in the as-cast condition. Microstructural observations were carried out using optical microscopy and SEM. The chemical composition and fraction of each phase was measured by electron probe microanalysis and image analysis, respectively. In all cases, the values predicted by the pseudo-equilibrium diagrams, computed with MatCalc, were in accordance with the experimentally determined values. Consequently, the results suggest that time and resource intensive experimental procedures can be replaced by simulation techniques to determine the phase fraction and especially, the individual phase compositions in the as-cast state. Full article
(This article belongs to the Special Issue Cast Irons: Properties and Applications)
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13 pages, 8565 KiB  
Article
Niobium Additions to a 15%Cr–3%C White Iron and Its Effects on the Microstructure and on Abrasive Wear Behavior
by Arnoldo Bedolla-Jacuinde, Francisco Guerra, Ignacio Mejia and Uzzi Vera
Metals 2019, 9(12), 1321; https://doi.org/10.3390/met9121321 - 7 Dec 2019
Cited by 15 | Viewed by 3477
Abstract
From the present study, niobium additions of 1.79% and 3.98% were added to a 15% Cr–3% C white iron, and their effects on the microstructure, hardness and abrasive wear were analyzed. The experimental irons were melted in an open induction furnace and cast [...] Read more.
From the present study, niobium additions of 1.79% and 3.98% were added to a 15% Cr–3% C white iron, and their effects on the microstructure, hardness and abrasive wear were analyzed. The experimental irons were melted in an open induction furnace and cast into sand molds to obtain bars of 45 mm diameter. The alloys were characterized by optical and electron microscopy, and X-ray diffraction. Bulk hardness was measured in the as-cast conditions and after a destabilization heat treatment at 900 °C for 30 min. Abrasive wear resistance tests were undertaken for the different irons according to the ASTM G65 standard in both as-cast and heat-treated conditions under three loads (58, 75 and 93 N). The results show that niobium additions caused a decrease in the carbon content in the alloy and that some carbon is also consumed by forming niobium carbides at the beginning of the solidification process; thus decreasing the eutectic M7C3 carbide volume fraction (CVF) from 30% for the base iron to 24% for the iron with 3.98% Nb. However, the overall carbide content was constant at 30%; bulk hardness changed from 48 to 55 hardness Rockwell C (HRC) and the wear resistance was found to have an interesting behavior. At the lowest load, wear resistance for the base iron was 50% lower than that for the 3.98% Nb iron, which is attributed to the presence of hard NbC. However, at the highest load, the wear behavior was quite similar for all the irons, and it was attributed to a severe carbide cracking phenomenon, particularly in the as-cast alloys. After the destabilization heat treatment, the wear resistance was higher for the 3.98% Nb iron at any load; however, at the highest load, not much difference in wear resistance was observed. Such a behavior is discussed in terms of the carbide volume fraction (CVF), the amount of niobium carbides, the amount of martensite/austenite in matrix and the amount of secondary carbides precipitated during the destabilization heat treatment. Full article
(This article belongs to the Special Issue Cast Irons: Properties and Applications)
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13 pages, 5328 KiB  
Article
The Role of Microstructure on Tensile Plastic Behavior of Ductile Iron GJS 400 Produced through Different Cooling Rates, Part I: Microstructure
by Giuliano Angella, Dario Ripamonti, Marcin Górny, Stefano Masaggia and Franco Zanardi
Metals 2019, 9(12), 1282; https://doi.org/10.3390/met9121282 - 29 Nov 2019
Cited by 8 | Viewed by 3148
Abstract
A series of samples made of ductile iron GJS 400 was cast with different cooling rates, and their microstructural features were investigated. Quantitative metallography analyses compliant with ASTM E2567-16a and ASTM E112-13 standards were performed in order to describe graphite nodules and ferritic [...] Read more.
A series of samples made of ductile iron GJS 400 was cast with different cooling rates, and their microstructural features were investigated. Quantitative metallography analyses compliant with ASTM E2567-16a and ASTM E112-13 standards were performed in order to describe graphite nodules and ferritic grains. The occurrence of pearlite was associated to segregations described through Energy Dispersive X-ray Spectroscopy (EDS) analyses. Results were related to cooling rates, which were simulated through MAGMASOFT software. This microstructural characterization, which provides the basis for the description and modeling of the tensile properties of GJS 400 alloy, subject of a second part of this investigation, highlights that higher cooling rates refines microstructural features, such as graphite nodule count and average ferritic grain size. Full article
(This article belongs to the Special Issue Cast Irons: Properties and Applications)
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13 pages, 4766 KiB  
Article
Investigation of Drilling Machinability of Compacted Graphite Iron under Dry and Minimum Quantity Lubrication (MQL)
by Yang Li and Wenwu Wu
Metals 2019, 9(10), 1095; https://doi.org/10.3390/met9101095 - 11 Oct 2019
Cited by 9 | Viewed by 2757
Abstract
Compacted graphite iron (CGI), which is used as a potential material in the auto industry, is a hard-to-machine material for the different minor elements and for the geometry of graphite with grey cast iron. The machinability of CGI in the drilling process was [...] Read more.
Compacted graphite iron (CGI), which is used as a potential material in the auto industry, is a hard-to-machine material for the different minor elements and for the geometry of graphite with grey cast iron. The machinability of CGI in the drilling process was investigated with a 4-mm diameter fine-grain carbide twist drill under four lubrication conditions, dry (no compressed air), dry (with compressed air), MQL 5 mL/h, and MQL 20 mL/h in this paper. The maximum flank wear, types of wear, and cutting loads were studied for identifying the wear mechanism in drilling of CGI. The tool life in the four experiments of CGI drilling is 639 holes, 2969 holes, 2948 holes, and 2685 holes, respectively. The results showed that the main wear mechanism in drilling of CGI is adhesion and abrasion. Carbon, which originates from the graphite of CGI, can improve the lubrication in the drilling process by comparing with MnS in drilling grey cast iron. The thrust force and torque are more than 1000 N and 150 N*cm after 2700 holes in CGI drilling. Drilling of CGI under dry conditions (with compressed air) and MQL 5 mL/h is feasible. Full article
(This article belongs to the Special Issue Cast Irons: Properties and Applications)
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14 pages, 2085 KiB  
Article
The Role of Microstructure on the Tensile Plastic Behaviour of Ductile Iron GJS 400 Produced through Different Cooling Rates—Part II: Tensile Modelling
by Giuliano Angella, Riccardo Donnini, Dario Ripamonti, Marcin Górny and Franco Zanardi
Metals 2019, 9(9), 1019; https://doi.org/10.3390/met9091019 - 19 Sep 2019
Cited by 10 | Viewed by 3808
Abstract
Tensile testing on ductile iron GJS 400 with different microstructures produced through four different cooling rates was performed in order to investigate the relevance of the microstructure’s parameters on its plastic behaviour. Tensile flow curve modelling was carried out with the Follansbee and [...] Read more.
Tensile testing on ductile iron GJS 400 with different microstructures produced through four different cooling rates was performed in order to investigate the relevance of the microstructure’s parameters on its plastic behaviour. Tensile flow curve modelling was carried out with the Follansbee and Estrin-Kocks-Mecking approach that allowed for an explicit correlation between plastic behaviour and some microstructure parameters. In the model, the ferritic grain size and volume fraction of pearlite and ferrite gathered in the first part of this investigation were used as inputs, while other parameters, like nodule count and interlamellar spacing in pearlite, were neglected. The model matched very well with the experimental flow curves at high strains, while some mismatch was found only at small strains, which was ascribed to the decohesion between the graphite nodules and the ferritic matrix that occurred just after yielding. It can be concluded that the plastic behaviour of GJS 400 depends mainly on the ferritic grain size and pearlitic volume fraction, and other microstructure parameters can be neglected, primarily because of their high nodularity and few defects. Full article
(This article belongs to the Special Issue Cast Irons: Properties and Applications)
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11 pages, 8868 KiB  
Article
Influence of Heat Treatment in the Microstructure of a Joint of Nodular Graphite Cast Iron when Using the Tungsten Inert Gas Welding Process with Perlitic Grey Cast Iron Rods as Filler Material
by Francisco-Javier Cárcel-Carrasco, Manuel Pascual-Guillamón, Fidel Salas-Vicente and Vicente Donderis-Quiles
Metals 2019, 9(1), 48; https://doi.org/10.3390/met9010048 - 7 Jan 2019
Cited by 5 | Viewed by 4852
Abstract
The present article analyses the influence of preheating and a postweld heat treatment in the microstructure, mechanical properties and wear behaviour of a joint of nodular graphite cast iron when using the tungsten inert gas (TIG) welding process with perlitic grey cast iron [...] Read more.
The present article analyses the influence of preheating and a postweld heat treatment in the microstructure, mechanical properties and wear behaviour of a joint of nodular graphite cast iron when using the tungsten inert gas (TIG) welding process with perlitic grey cast iron rods as filler material. Data obtained from the tests and the microstructural study of the samples show that the absence of a postweld heat treatment and of preheating leads to the apparition of hard structures and a notable reduction in elongation. Preheating or annealing the weld avoid the presence of these hard structures and increase the ductile behaviour of the joint although at the cost of a further loss of mechanical strength. Wear rate was found to be higher at the weld bead than at the base metal, even when the hardness of both areas is the same. Full article
(This article belongs to the Special Issue Cast Irons: Properties and Applications)
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12 pages, 5133 KiB  
Article
Effect of Solidification Time on Microstructural, Mechanical and Fatigue Properties of Solution Strengthened Ferritic Ductile Iron
by Thomas Borsato, Paolo Ferro, Filippo Berto and Carlo Carollo
Metals 2019, 9(1), 24; https://doi.org/10.3390/met9010024 - 28 Dec 2018
Cited by 15 | Viewed by 4534
Abstract
Microstructural, mechanical, and fatigue properties of solution strengthened ferritic ductile iron have been evaluated as functions of different solidification times. Three types of cast samples with increasing thickness have been produced in a green sand automatic molding line. Microstructural analyses have been performed [...] Read more.
Microstructural, mechanical, and fatigue properties of solution strengthened ferritic ductile iron have been evaluated as functions of different solidification times. Three types of cast samples with increasing thickness have been produced in a green sand automatic molding line. Microstructural analyses have been performed in order to evaluate the graphite nodules parameter and matrix structure. Tensile and fatigue tests have been carried out using specimens taken from specific zones, with increasing solidification time, inside each cast sample. Finally, the fatigue fracture surfaces have been observed using a scanning electron microscope (SEM). The results showed that solidification time has a significant effect on the microstructure and mechanical properties of solution strengthened ferritic ductile iron. In particular, it has been found that with increasing solidification times, the microstructure becomes coarser and the presence of defects increases. Moreover, the lower the cooling rate, the lower the tensile and fatigue properties measured. Since in an overall casting geometry, same thicknesses may be characterized by different microstructures and mechanical properties induced by different solidification times, it is thought that the proposed methodology will be useful in the future to estimate the fatigue strength of cast iron castings through the numerical calculation of the solidification time. Full article
(This article belongs to the Special Issue Cast Irons: Properties and Applications)
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13 pages, 3602 KiB  
Article
Estimating the Effective Elastic Parameters of Nodular Cast Iron from Micro-Tomographic Imaging and Multiscale Finite Elements: Comparison between Numerical and Experimental Results
by Andre Pereira, Marcio Costa, Carla Anflor, Juan Pardal and Ricardo Leiderman
Metals 2018, 8(9), 695; https://doi.org/10.3390/met8090695 - 5 Sep 2018
Cited by 11 | Viewed by 3946
Abstract
Herein, we describe in detail a methodology to estimate the effective elastic parameters of nodular cast iron, using micro-tomography in conjunction with multiscale finite elements. We discuss the adjustment of the image acquisition parameters, address the issue of the representative-volume choice, and present [...] Read more.
Herein, we describe in detail a methodology to estimate the effective elastic parameters of nodular cast iron, using micro-tomography in conjunction with multiscale finite elements. We discuss the adjustment of the image acquisition parameters, address the issue of the representative-volume choice, and present a brief discussion on image segmentation. In addition, the finite-element computational implementation developed to estimate the effective elastic parameters from segmented microstructural images is described, indicating the corresponding computational costs. We applied the proposed methodology to a nodular cast iron, and estimated the graphite elastic parameters through a comparison between the numerical and experimental results. Full article
(This article belongs to the Special Issue Cast Irons: Properties and Applications)
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12 pages, 5094 KiB  
Article
Strength Prediction for Pearlitic Lamellar Graphite Iron: Model Validation
by Vasilios Fourlakidis, Ilia Belov and Attila Diószegi
Metals 2018, 8(9), 684; https://doi.org/10.3390/met8090684 - 31 Aug 2018
Cited by 6 | Viewed by 3759 | Correction
Abstract
The present work provides validation of the ultimate tensile strength computational models, based on full-scale lamellar graphite iron casting process simulation, against previously obtained experimental data. Microstructure models have been combined with modified Griffith and Hall–Petch equations, and incorporated into casting simulation software, [...] Read more.
The present work provides validation of the ultimate tensile strength computational models, based on full-scale lamellar graphite iron casting process simulation, against previously obtained experimental data. Microstructure models have been combined with modified Griffith and Hall–Petch equations, and incorporated into casting simulation software, to enable the strength prediction for four pearlitic lamellar cast iron alloys with various carbon contents. The results show that the developed models can be successfully applied within the strength prediction methodology along with the simulation tools, for a wide range of carbon contents and for different solidification rates typical for both thin- and thick-walled complex-shaped iron castings. Full article
(This article belongs to the Special Issue Cast Irons: Properties and Applications)
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17 pages, 14232 KiB  
Article
Determination of the Effective Elastic Modulus for Nodular Cast Iron Using the Boundary Element Method
by Adrián Betancur, Carla Anflor, André Pereira and Ricardo Leiderman
Metals 2018, 8(8), 641; https://doi.org/10.3390/met8080641 - 15 Aug 2018
Cited by 3 | Viewed by 3577
Abstract
In this work, a multiscale homogenization procedure using the boundary element method (BEM) for modeling a two-dimensional (2D) and three-dimensional (3D) multiphase microstructure is presented. A numerical routine is specially written for modeling nodular cast iron (NCI) considering the graphite nodules as cylindrical [...] Read more.
In this work, a multiscale homogenization procedure using the boundary element method (BEM) for modeling a two-dimensional (2D) and three-dimensional (3D) multiphase microstructure is presented. A numerical routine is specially written for modeling nodular cast iron (NCI) considering the graphite nodules as cylindrical and real geometries. The BEM is used as a numerical approach for solving the elastic problem of a representative volume element from a mean field model. Numerical models for NCI have generally been developed considering the graphite nodules as voids due to their soft feature. In this sense, three numerical models are developed, and the homogenization procedure is carried out considering the graphite nodules as non-voids. Experimental tensile, hardness, and microhardness tests are performed to determine the mechanical properties of the overall material, matrix, and inclusion nodules, respectively. The nodule sizes, distributions, and chemical compositions are determined by laser scanning microscopy, an X-ray computerized microtomography system (micro-CT), and energy-dispersive X-ray (EDX) spectroscopy, respectively. For the numerical model with real inclusions, the boundary mesh is obtained from micro-CT data. The effective properties obtained by considering the real and synthetic nodules’ geometries are compared with those obtained from the experimental work and the existing literature. The final results considering both approaches demonstrate a good agreement. Full article
(This article belongs to the Special Issue Cast Irons: Properties and Applications)
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2 pages, 691 KiB  
Correction
Correction: Fourlakidis, V., et al. Strength Prediction for Pearlitic Lamellar Graphite Iron: Model Validation. Metals 2018, 8, 684
by Vasilios Fourlakidis, Ilia Belov and Attila Diószegi
Metals 2019, 9(1), 6; https://doi.org/10.3390/met9010006 - 20 Dec 2018
Viewed by 1784
Abstract
First of all, the authors would like to apologize for any inconvenience regarding the misleading errors that occurred in the paper. [...] Full article
(This article belongs to the Special Issue Cast Irons: Properties and Applications)
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