Energy Saving Melting and Revert Reduction Technology: Aging of Graphitic Cast Irons and Machinability

Technical Report · Wed Sep 19 04:00:00 EDT 2012

DOI:https://doi.org/10.2172/1054341· OSTI ID:1054341

Richards, Von L. ^[1]

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1. Advanced Technology Inst., Virginia Beach, VA (United States); Advacned Technology Institute

The objective of this task was to determine whether ductile iron and compacted graphite iron exhibit age strengthening to a statistically significant extent. Further, this effort identified the mechanism by which gray iron age strengthens and the mechanism by which age-strengthening improves the machinability of gray cast iron. These results were then used to determine whether age strengthening improves the machinability of ductile iron and compacted graphite iron alloys in order to develop a predictive model of alloy factor effects on age strengthening. The results of this work will lead to reduced section sizes, and corresponding weight and energy savings. Improved machinability will reduce scrap and enhance casting marketability. Technical Conclusions: Age strengthening was demonstrated to occur in gray iron ductile iron and compacted graphite iron. Machinability was demonstrated to be improved by age strengthening when free ferrite was present in the microstructure, but not in a fully pearlitic microstructure. Age strengthening only occurs when there is residual nitrogen in solid solution in the Ferrite, whether the ferrite is free ferrite or the ferrite lamellae within pearlite. Age strengthening can be accelerated by Mn at about 0.5% in excess of the Mn/S balance Estimated energy savings over ten years is 13.05 trillion BTU, based primarily on yield improvement and size reduction of castings for equivalent service. Also it is estimated that the heavy truck end use of lighter castings for equivalent service requirement will result in a diesel fuel energy savings of 131 trillion BTU over ten years.

• Research Organization: Advanced Technology Institute, Virginia Beach, VA (United States)
• Sponsoring Organization: USDOE; USDOE EE Office of Technology Development (EE-20)
• DOE Contract Number: FC36-04GO14230
• OSTI ID: 1054341
• Country of Publication: United States
• Language: English

Related Subjects

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
cast iron
casting
machining iron castings
metalcasting