17-04-2002 euro adi 1 - zanardi...
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17-04-2002 Euro ADI 1
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ADI-Austempered Ductile Iron
Material standards
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ADI-Austempered Ductile Iron
• Background• What is ADI• Standards USA and
Europe• New ISO standard
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ADI Background• 1930’s Bain and Grossman Development of isothermal
transformation diagram.• Early 1940’sFlinn Application of austempering
process to flake graphite cast iron.
• 1948 Millis Development of ductile cast iron.
• 1973 Rieger First austempering of ductile iron (compressor crankshafts).
• 1986 BCIRA (GB) 3 Tentative grades of ADI.• 1987 VDG (D) VDG Merkblatt W52 (4 grades).• 1989 JIS G 5503 First standard for ADI• 1990 A 897-90 First USA (ASTM) standard
1997 EN 1564 First European standard
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ADI, Worldwide production
0
20000
40000
60000
80000
100000
120000
1975 1980 1985 1990 1995 2000Year
Tons
North AmericaAsiaEuropeOthers
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ADI-Austempered Ductile Iron
A material which combines• High strength• Toughness, ductility
• Wear resistance
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Austempered Ductile Iron
• Austempered ductile cast irons are spheroidal graphite castirons which combine higher strenth and thoughness properties as the result of a special heat treatment.
• This heat treatment, which is an integral part of theproduction process, consists of an austenitising treatmentat a temperature between 820 oC and 950 oC and an austempering treatment in the temperature range between250 oC and 400 oC to form a predominantly austenitic-ferritic structure.
• Heat treatment parameters and chemical composition haveto be selected as a function of casting size (relevant wall thickness) and required grade.
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ADI, TTT Diagram (schematic)
0100200300400500600700800900
1,E+00 1,E+01 1,E+02 1,E+03 1,E+04 1,E+05
Seconds
Tem
pera
ture
(C)
Austenite>Pearlite
Austenite > Bainite
Austenite> Martensite
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ADI, Typical heat treatment cycle
0
200
400
600
800
1000
1200
0 1 2 3 4 5 6Time
Tem
pera
ture
ta
Ta
tb
Tb
Ta, ta =austenitising temp. & time
Tb , tb =austempering temp. & time
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ADI, Austenitising heat treatment
• Austenitising temperature: 820-950 oC– Section thickness ⇑ , temperature ⇑– Tensile strength ⇑ , temperature ⇑– Elongation ⇑ , temperature ⇓– Si content ⇑ , temperature ⇑
• Austenitising time: 30-180 minutes– Section thickness ⇑ , time ⇑ (10mm=45 min., 100mm=180 min.,
nodule count)
• Carbon content in austenite:– %Cγ = (Ta/420) - 0,17 x%Si-0,95
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Cooling to austempering temperature• Cooling to austempering temperature (salt bath):
– Sufficient fast to prevent the formation of pearlite– Section thickness >, % alloying elements (Ni, Cu, Mo) >
• Cu: 0-1 %• Ni: 0-2 %• Mo:0-0,25 %
• Critical cooling rate, critical diameter Dc:– Dc = 124 (%Cγ) + 27 (%Si) + 22 (%Mn) + 16 (%Ni) - 25 (%Mo)
- 1,68x10-4 (Tb2) + 12 (%Cu x %Ni) + 62 (%Cu x %M0)
+ 88 (%Ni x % Mo) + 11(%Mn x %Cu) + 127 (%Mn x %Mo)- 20 (%Mn x %Ni) - 137 (mm) (valid for cylinder with h/D=2,5)
– casting modulus = volume casting/surface casting = 0,21 x Dc
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ADI, Critical diameter vs austenitising temperature
0
20
40
60
80
100
120
800 820 840 860 880 900 920 940 960
Austenitising temperature (oC)
Crit
ical
dia
met
er D
c (m
m)
Cu=0,56%, Ni=0,71%, Mo=0,24%Cu=0,72%, Ni=0,95%, Mo=0,30%Cu=0,74%, Ni=1,49%, Mo=0,34%
Tb =400 oC
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ADI, Austempering heat treatment
• Austempering:– Tensile strength⇑ , austempering temperature ⇓– section thickness ⇑ , austempering time ⇑
• First stage:– Upper bainite (Tb > 350 oC): γo α + [γ]– Lower bainite (Tb < 350 oC): γo (α + carbides) + [γ]
• Second stage (long austempering times):– (450 oC > Tb > 250 oC): [γ] carbides + α
γo : austenite after austenitising[γ] : retained austeniteα : ferrite
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ADI, Austempering
0
20
40
60
80
100
1,E+00 1,E+01 1,E+02 1,E+03 1,E+04 1,E+05
Austempering time (s)
vol.
%
ferriteAusteniteRetained austenite 1 stage 2 stage
Carbides
Tb = 400 oC
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ADI, Retained austenite
0
5
10
15
20
25
30
35
200 250 300 350 400 450Austempering temperature (oC)
Volu
me%
reta
ined
aus
teni
te Ta = 860 oC
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ADI,Tensile strength and 0,2% proof stress vs austenitising temperature
200
400
600
800
1000
740 760 780 800 820 840 860 880 900
Austenitising temperature (oC)
Tens
ile s
treng
th a
nd
0,2%
pro
of s
tress
(MPa
)
Rm
Rp0,2
Tb = 400 oC
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ADI, Elongation vs austenitising temperature
02
46
810
1214
16
740 760 780 800 820 840 860 880 900
Austenitising temperature (oC)
Elon
gatio
n (%
)
Tb = 400 oC
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ADI, Tensile strength and 0,2% proof stress vs austempering temperature
400
600
800
1000
1200
1400
1600
200 250 300 350 400 450
Austempering temperature (oC)
Tens
ile s
treng
th a
nd
0,2%
pro
of s
tress
(MPa
)
Rm
Rp0,2Ta = 860 oC
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ADI, Elongation vs austempering temperature
02468
10121416
200 250 300 350 400 450
Austempering temperature (oC)
Elon
gatio
n (%
)
Ta = 860 oC
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ADI, International standards, gradesASTM 897-90
(1997)SAE J2477O
(2001)EN1564(1997)
ISO 17804(Draft)
EN-GJS-800-8 JS/800-10
850/550/10
AD 900 JS/900-8
EN-GJS-1000-5
1050/700/7 AD 1050 JS/1050-6
1200/850/4 AD 1200 EN-GJS-1200-2 JS/1200-3
1400/1100/1 AD 1400 EN-GJS-1400-1 JS/1400-1
JS/HV400
1600/1300/- AD 1600 JS/HV500
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ADI, ASTM A 897-90Grade Tensile
strengthRm
MPa(min.)
0,2% ProofstressRp0,2 MPa
(min.)
Elonga-tion
A4%
(min.)
Impactenergy
(unnotched)J
(min.)
Brinellhardness
rangeHB
(informative)
850/550/10 850 550 10 100 269-321
1050/700/7 1050 700 7 80 302-363
1200/850/4 1200 850 4 60 341-444
1400/1100/1 1400 1100 1 35 388-477
1600/1300/- 1600 1300 - - 444-555
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ADI, SAE J2477 OGrade Tensile
strengthRm
MPa(min.)
0,2% ProofstressRp0,2 MPa
(min.)
Elonga-tionA4%
(min.)
Impactenergy
(unnotched)J
(min.)
Brinellhardness
rangeHB
(informative)
AD 900 900 650 9 100 269-341
AD 1050 1050 750 7 80 302-375
AD 1200 1200 850 4 60 341-444
AD 1400 1400 1100 2 35 388-477
AD 1600 1600 1300 1 20 402-512
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ADI, EN 1564Designation Tensile
strengthRm
MPa(min.)
0,2% ProofstressRp0,2 MPa
(min.)
Elongation
A4%
(min.)
Impactenergy(notched)
J(min.)
Brinellhardness
rangeHB
EN-GJS-800-8 800 500 8 - 260-320
EN-GJS-800-8RT 800 500 8 10 260-320
EN-GJS-1000-5 1000 700 5 - 300-360
EN-GJS-1200-2 1200 850 2 - 340-440
EN-GJS-1400-1 1400 1100 1 - 380-480
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ADI, ASTM 897/SAE J2477 O/EN 1564
• Specified minimum mechanical properties for Rm , Rp0,2and A apply to seperately cast test samples. (fromsame metal, in core)
• The size and type of test sample shall represent thecasting wall thickness.
• For all sizes and types of test samples the sameminimum requirements apply.
• No minimum requirements for cast-on samples andsamples taken from the casting are specified in thestandard; the minimum requirements shall be agreedupon by the manufacturer and purchaser.
• USA standards specify minimum elongation fororiginal gauge length L0 = 4xd, EN standard: L0 = 5xd.This results in higher values (approx. 1%)
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ADI, Elongation A4 vs A5
02468
10121416
0 2 4 6 8 10 12 14 16
Elongation A 5 (%)
Elon
gatio
n A
4 (%
)
Available dataA4 = A5ISO 17804
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ADI, ASTM 897/SAE J2477 O/EN 1564
ASTM A 897 and SAE J2477 O• Specify for all grades normative minimum impact
resistance values (unnotched) at room temperature .
EN 1564• Specifies for one grade (EN-GJS-800-8RT) a minimum
impact resistance value (notched) at room temperatur.
ASTM A 897, SAE J2477 O and EN 1564• No design data given.
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ADI, ASTM 897/SAE J2477 O/EN 1564
ASTM A 897 and EN 1564• Give informative hardness range for all grades.
SAE J2477 O• Specifies normative hardness range for all grades.
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ADI, ISO 17804 (draft)Table 1 - Mechanical properties measured on test pieces machined from
seperately cast or cast-on samplesMaterial designation
Symbol
Relevantwall
thicknesst
mm
Tensilestrength
Rm
N/mm2
min.
0,2 %proofstressRp0,2
N/mm2
min.
Elongation
A5
%min.
ISO17804/JS/800-10-10RTISO17804/JS/800-10
t < 3030 < t < 6060 < t <100
800750720
5001065
ISO17804/JS/900-8t < 30
30 < t < 6060 < t <100
900850820
600854
ISO17804/JS/1050-6t < 30
30 < t < 6060 < t <100
10501000970
700643
ISO17804/JS/1200-3t < 30
30 < t < 6060 < t <100
120011701140
850321
1400 1100 1ISO17804/JS/1400-1
t < 3030 < t < 6060 < t <100
To be agreed upon between themanufacturer and purchaser
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ADI, ISO 17804 (draft)Table B.1 - Mechanical properties measured on test pieces machined from seperately
cast or cast-on samples. Tensile test piece with original gauge length L0 = 4 x d.Material designation
Symbol
Relevantwall
thicknesst
mm
Tensilestrength
Rm
N/mm2
min.
0,2 %proofstressRp0,2
N/mm2
min.
Elongation
A5
%min.
ISO17804/JS/800-10-10RTISO17804/JS/800-10
t < 3030 < t < 6060 < t <100
800750720
5001177
ISO17804/JS/900-8t < 30
30 < t < 6060 < t <100
900850820
600965
ISO17804/JS/1050-6t < 30
30 < t < 6060 < t <100
10501000970
700754
ISO17804/JS/1200-3t < 30
30 < t < 6060 < t <100
120011701140
850432
1400 1100 2t < 30ISO17804/JS/1400-1 30 < t < 60
60 < t <100To be agreed upon between the
manufacturer and purchaser
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ADI, ISO 17804 (draft)Table 2 - Minimum impact resistance values measured on test pieces
machined from seperately cast or cast-on samples
Minimum impact resistance values inJoules
at room temperature (23oC+5) ºC
MaterialDesignation
Symbol
Relevantwall
thicknesst
mm Mean value of 3tests
Individual value
ISO17804/JS/800-10-10RTt < 30
30 < t < 6060 < t < 00
1098
987
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ADI, ISO 17804 (draft)Table A.1 -Abrasion resistant spheroidal graphite ausferritic cast irons
Other properties(for information only )
Material designation
Symbol
Vickershardness
HVminimum
RmN/mm2 *)
Rp0,2N/mm2 *)
A5%
ISO17804/JS/HV400 400 1400 1100 1
ISO17804/JS/HV500 500 1600 1300 -
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ADI, ISO 17804 (draft)Table D.1 - Guidance values for tensile strength and elongation for test pieces
machined from samples cut from the casting
Tensile strengthRm
N/mm2
min.
ElongationA5
%min.
Relevant wall thickness t (mm)
Material designation
Symbol
0,2 % proofstressRp0,2
N/mm2
min.
t < 30
30 <t
< 60
60 <t
< 100t
< 30
30 <t
< 60
60 <t
< 100
ISO17804/JS/800-10/C 500 790 740 710 8 5 4
ISO17804/JS/900-8/C 600 880 830 800 7 4 3
ISO17804/JS/1050-6/C 700 1020 970 940 5 3 2
ISO17804/JS/1200-3/C 850 1170 1140 1110 2 1 1
ISO17804/JS/1400-1/C 1100 1360 To be agreed upon between themanufacturer and purchaser
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ADI, ISO 17804 (draft)Table C.1 - Guidance values for hardness
Material designationSymbol
Brinell hardness rangeHB
ISO17804/JS/800-10-10RTISO17804/JS/800-10
250 - 310
ISO17804/JS/900-8 280 - 340
ISO17804/JS/1050-6 320 - 380
ISO17804/JS/120-3 340 - 420
ISO17804/JS/1400-1 380 - 480
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ADI, ISO 17804 (draft)Table E.1 - Unnotched impact resistance for spheroidal graphite ausferritic
cast iron
Material designationSymbol
Minimum impact resistance values 1)in Joules at room temperature
(23 + 5) oCISO17804/J S/800-10-10RT
ISO17804/J S/800-10ISO17804/J S/800-10/C
110
ISO17804/JS/900-8ISO17804/JS/900-8/C 100ISO17804/JS/1050-6
ISO17804/JS/1050-6/C 80ISO17804/JS/1200-3
ISO17804/JS/1200-3/C 60ISO17804/JS/1400-1
ISO17804/JS/1400-1/C 35
ISO17804/JS/400HV 25
ISO17804/JS/500HV 20
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ADI, ISO 17804 (draft)Table F.1 - Typical properties of spheroidal graphite ausferritic cast iron
GradeISO17804/SJ/Technical data for spheroidal
graphite ausferritic cast iron 800-10800-10-10RT
900-8 1050-6 1200-3 1400-1400HV
500HV
Characteristic Unit Minimum values for properties A (informative)
Compression strength σdb N/mm2 1300 1450 1675 1900 2200 25000,2% proof stress N/mm2 620 695 840 1040 1220 1350
Shear strength σaB
0,2% proof stress
N/mm2
N/mm2
720 800 940 1080 1260 1400
Torsional strength τtB N/mm2 720 800 940 1080 1260 1400
0,2% proof stress N/mm2 350 420 510 590 770 850Impact resistance valuesCharpy unnotched, at(23 + 5) oC
J 110 100 80 60 35
Fracture toughness Klc MPa√m 62 60 59 54 50
Fatigue limit (Wöhler)(rotating bending)unnotched(dia. 10,6 mm)
N/mm2 375 400 430 450 375 300
Fatigue limit (Wöhler)(rotating bending)notched 2)
(dia. 10,6 mm)
N/mm2 225 240 265 280 275 270
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