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Fatigue Properties and Simulation of Thin Wall ADI and IADI Castings

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Abstract

In this study, microstructure and mechanical properties of thin wall austempered and intercritically austempered ductile iron with a chemical composition of 3.37%C, 2.7%Si, 0.30%Mn, 0.01%S, 0.01%P, 0.47%Cu, and 0.0371%Mg were investigated. Thin ductile iron samples with different thicknesses of 5, 10, and 15 mm were cast and then heat treated with two different austempering techniques. The first sample was austenitizing below upper critical temperature at 810 °C for an hour and then rapidly quenched in a salt bath at 375 °C and held for 1 h (IADI). The second treatment was carried out at austenitizing temperature of 900 °C, which was above upper critical temperature, for an hour and then rapidly quenched in a salt bath at 375 °C for 1 h (ADI). The mechanical properties of the austempered and intercritically austempered thin wall samples were evaluated and compared to the as-cast samples. The fatigue properties of all samples were simulated using ANSYS software, and the best condition was experimentally tested using plane bending fatigue testing machine. Maximum ultimate strength (1056) MPa and hardness (396 HV) were obtained for 5 mm ADI sample. Maximum impact toughness (43 J) was achieved for 15 mm IADI sample due to existing proeutectoid ferrite in matrix. Maximum simulated fatigue strength (435 MPa) was reported for 5-mm ADI sample and minimum simulated fatigue strength (160 MPa) was registered for as-cast DI sample. For both ADI and IADI castings, fatigue strength decreased with increasing sample thickness. For 10-mm ADI sample, the simulated fatigue strength was (407 MPa) which was close to the experimental result (417 MPa).

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Authors and Affiliations

  1. Central Metallurgical Research and Development Institute, Cairo, Egypt

    Mervat M. Ibrahim & Khaled M. Ibrahim

  2. Modern Academy for Engineering and Technology, Cairo, Egypt

    A. M. Negm

  3. Faculty of Engineering at Shoubra, Benha university, Cairo, Egypt

    S. S. Mohamed

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  1. Mervat M. Ibrahim
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  2. A. M. Negm
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  3. S. S. Mohamed
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  4. Khaled M. Ibrahim
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Correspondence to Khaled M. Ibrahim.

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Ibrahim, M.M., Negm, A.M., Mohamed, S.S. et al. Fatigue Properties and Simulation of Thin Wall ADI and IADI Castings. Inter Metalcast 16, 1693–1708 (2022). https://doi.org/10.1007/s40962-021-00711-7

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  • DOI: https://doi.org/10.1007/s40962-021-00711-7

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