afs research report - · pdf fileafs research report - compilation cast iron fatigue...

12
AFS RESEARCH REPORT - COMPILATION Cast Iron Fatigue Properties Database for Modern Design Methods -How to use the Database DVD- Current reports contained on DVD Strain-Life Fatigue Properties Database for Cast Iron, (Austempered Ductile Iron, Compacted Graphite Iron, Ductile Iron and Gray Iron) DOE Contract No. DE-FC07-00ID13852, Published 2003 Strain-Life Fatigue Data for Heavy Section Ductile Iron AFS Agreement Number 06-07#2, Published 2008 Mechanical, Physical and Fatigue Data for 25% High Chromium White Iron AFS Agreement Number 08-09#03, September 2009 Mechanical, Physical and Fatigue Data for ASTM A897/A897M-06 Grade 110/70/11 and 750/500/11 of Austempered Ductile Iron AFS Agreement Number 08-09#01, October 2009 Strain-Life Fatigue Data for CG Iron Grade 400 with Heavy Section Size Strain-Life Fatigue Data Gray Iron Grade 40B with Normal CE and Alloying Development of Web enabled Virtual Digital Library of Cast Alloys with Engineering Properties for DLA Project (Enterprise Integration) AMC CNTS-LAF0322-71897 - Subcontract 2006-283 AFS-03, March 2012 Property Testing of Si-Mo Ductile Iron Chrysler Group, LLC contributed CRS Report No. S-10470, August 2002 Strain-Life Fatigue Data for Class 25B Gray Iron Strain-Life Fatigue Data for DI Iron Grade EN-GJS-500-7 with 1” Section Size Strain-Life Fatigue Data for DI Iron Grade EN-GJS-500-7 with 3” Section Size Castings Solutions for Readiness: Tools for Streamlining Casting Supply Chains Casting Alloy Design Selection Tool AMC contract SP4701-11-D-0025 Subcontract No. 2012-517 American Foundry Society, Inc. 1695 N. Penny Lane Schaumburg, IL 60173-4555 Phone 847/824-0181 Fax 847/824-7848 Toll Free 800/537-4237 www.afsinc.org

Upload: dotu

Post on 28-Mar-2018

246 views

Category:

Documents


10 download

TRANSCRIPT

Page 1: AFS RESEARCH REPORT - · PDF fileAFS RESEARCH REPORT - COMPILATION Cast Iron Fatigue Properties Database for Modern Design Methods ... (Austempered Ductile Iron, Compacted Graphite

AFS RESEARCH REPORT - COMPILATION

Cast Iron Fatigue Properties Database

for Modern Design Methods

-How to use the Database DVD-

Current reports contained on DVD Strain-Life Fatigue Properties Database for Cast Iron,

(Austempered Ductile Iron, Compacted Graphite Iron,

Ductile Iron and Gray Iron)

DOE Contract No. DE-FC07-00ID13852, Published 2003

Strain-Life Fatigue Data for Heavy Section Ductile Iron AFS Agreement Number 06-07#2, Published 2008

Mechanical, Physical and Fatigue Data

for 25% High Chromium White Iron AFS Agreement Number 08-09#03, September 2009

Mechanical, Physical and Fatigue Data

for ASTM A897/A897M-06 Grade 110/70/11

and 750/500/11 of Austempered Ductile Iron

AFS Agreement Number 08-09#01, October 2009

Strain-Life Fatigue Data for CG Iron Grade 400 with Heavy Section Size

Strain-Life Fatigue Data Gray Iron Grade 40B with Normal CE and Alloying

Development of Web enabled Virtual Digital Library of Cast Alloys with Engineering

Properties for DLA Project (Enterprise Integration) AMC CNTS-LAF0322-71897 -

Subcontract 2006-283 AFS-03, March 2012

Property Testing of Si-Mo Ductile Iron

Chrysler Group, LLC contributed CRS Report No. S-10470, August 2002

Strain-Life Fatigue Data for Class 25B Gray Iron

Strain-Life Fatigue Data for DI Iron Grade EN-GJS-500-7 with 1” Section Size

Strain-Life Fatigue Data for DI Iron Grade EN-GJS-500-7 with 3” Section Size

Castings Solutions for Readiness: Tools for Streamlining Casting Supply Chains – Casting

Alloy Design Selection Tool AMC contract SP4701-11-D-0025 Subcontract No. 2012-517

American Foundry Society, Inc. 1695 N. Penny Lane Schaumburg, IL 60173-4555

Phone 847/824-0181 Fax 847/824-7848

Toll Free 800/537-4237

www.afsinc.org

Page 2: AFS RESEARCH REPORT - · PDF fileAFS RESEARCH REPORT - COMPILATION Cast Iron Fatigue Properties Database for Modern Design Methods ... (Austempered Ductile Iron, Compacted Graphite

Published and distributed

by the

American Foundry Society Schaumburg, IL 60173-4555

www.afsinc.org

Copyright © 2003, 2008, 2009, 2012

On previous versions of the reports and compilations

Copyright © 2013

ISBN 978-0-87433-412-8

Printed in the United States of America

All rights reserved. No part of this DVD may be reproduced in any form or by any means, electronic, mechanical,

photocopying, recording or otherwise, without prior permission of the publisher.

The American Foundry Society, Inc., as a body, is not responsible for the statements and opinions advanced in this

publication. Nothing contained in any publication of the Society is to be construed as granting right, by implication or

otherwise, for manufacture, sale or use in connection with any method, apparatus or product covered by letters patent, nor

as insuring anyone against liability for infringement of letters patent.

This DVD contains reports previously published under the titles:

Strain-Life Fatigue Properties Database for Cast Iron DVD:

Austempered Ductile Iron, Compacted Graphite Iron, Ductile Iron and Gray Iron

Heavy Section Ductile Iron

ISBN 978-0-87433-331-2

Published 2003

Strain-Life Fatigue Properties Database for Cast Iron CD:

Heavy Section Ductile Iron

ISBN 978-0-87433-0332-9

Published 2008

Page 3: AFS RESEARCH REPORT - · PDF fileAFS RESEARCH REPORT - COMPILATION Cast Iron Fatigue Properties Database for Modern Design Methods ... (Austempered Ductile Iron, Compacted Graphite

Acknowledgments

AFS wishes to thank Element Materials technology, formerly known as Stork Climax Research Services, and

the researchers/authors for their work on these studies.

James D. DeLa’O, Ph.D.

Richard B. Gundlach,

John M. Tartaglia, Ph.D.

Questions about the material presented can be directed to the authors at:

Element Materials Technology

51229 Century Ct

Wixom, MI 48393-2074

Phone: (248) 960-4900

Page 4: AFS RESEARCH REPORT - · PDF fileAFS RESEARCH REPORT - COMPILATION Cast Iron Fatigue Properties Database for Modern Design Methods ... (Austempered Ductile Iron, Compacted Graphite

About this publication…

The material in this DVD was developed from ten studies done by Element Materials

Technology (formerly known as Stork Climax Research Services) initially as a Department

of Energy (DOE) contract and later as studies under agreements with the American

Foundry Society (AFS) contracted under AFS Research funds and subsequent AMC

(American Metalcasting Coalition) DLA (Defense Logistics Agency) projects, along with

contributed work from Chrysler Group, LLC. This disk includes material previously

contained in:

Strain-Life Fatigue Properties Database for Cast Iron, (Austempered Ductile Iron,

Compacted Graphite Iron, Ductile Iron and Gray Iron):

DOE Contract No. DE-FC07-00ID13852, (2003), ISBN 978-0-87433-267-4;

Strain-Life Fatigue Data for Heavy Section Ductile Iron: AFS Agreement Number 06-07#2, published as a single CD, ISBN 978-0-87433-0332-9,

(2008) and as a DVD combined with the 2003 report, ISBN 978-0-87433-331-2;

Cast Iron Fatigue Properties Database for Modern Design Methods:

ISBN 978-0-87433-350-3, including the 2003 and 2008 studies, plus:

▪ Mechanical, Physical and Fatigue Data for 25% High Chromium White Iron: single CD, ISBN 978-0-87433-348-0, AFS Agreement Number 08-09#03,

(September 2009), and

▪ Mechanical, Physical and Fatigue Data for ASTM A897/A897M-06 Grade

110/70/11 and 750/500/11 of Austempered Ductile Iron: single CD, ISBN 978-

0-87433-349-7, AFS Agreement Number 08-09#01, (October 2009).

With the introduction of five new studies since the last edition (2009) and the contributed

report, AFS has combined all ten studies into one DVD, and an updated file structure by

cast iron material type, along with this Introduction document. This new DVD should

replace all prevision versions.

The objective of the program was to develop a detailed and well-documented strain-life

database for cast iron. With this new DVD, AFS has now combined all the material

contained in previous reports and restructured the data presentation first by metal type

(Austempered Ductile Iron, Compacted Graphite Iron, Ductile Iron, Gray Iron and White

Iron) and then by Grade (typically ASTM) under each metal. Work is continuing to update

with additional grades, section sizes, and material properties along with contributed data

sets.

In the coming years, AFS will update the material on a periodic basis by publishing a

revised DVD and may continue to offer each new report separately. Previously published

versions of the studies are currently available through AFS Special Publications

Department and maybe continued to be offered. Besides the DVD version, AFS is

Page 5: AFS RESEARCH REPORT - · PDF fileAFS RESEARCH REPORT - COMPILATION Cast Iron Fatigue Properties Database for Modern Design Methods ... (Austempered Ductile Iron, Compacted Graphite

investigating other electronic methods, such as a subscription service, to offer the material

contained in the database and the subsequent upgrades. The key material property design

information can also be obtained from the AFS online database tool CADS (Casting Alloy

Data Search) available at http://www.metalcastingvirtuallibrary.com/cads/cads.aspx

Technical questions about the studies can be directed to the authors or AFS Technical

Department, [email protected].

How to use the Database DVD….

Below is the File Structure on the DVD. It is organized into folders containing first,

All Reports, which contains the Original DOE Report and subsequent Special reports

for new materials tested and added to the DVD, also contained on individual reports.

These subsequent Special reports are also contained in individual file folder for the

new material contained in that report. Also contained in a paper published in the

2012 AFS Transactions and IJMC (International Jounral of Metalcasting) describing

the contents and format of the database and a Comparison of Monotonic and Cyclic

Properties of Ductile Cast Irons contained in the database.

Page 6: AFS RESEARCH REPORT - · PDF fileAFS RESEARCH REPORT - COMPILATION Cast Iron Fatigue Properties Database for Modern Design Methods ... (Austempered Ductile Iron, Compacted Graphite

The Excel File displayed on the Main Page contain data summaries and all critical

chemical, microstructural and monotonic and cyclic properties for both each Metal

Types and a All Cast Iron file with the same data summaries for each metal type

contained on individual tabs.

Austempered

Grd 750 50mm Grd 1 25mm Grd 1 (lit) Grd 2 25mm Grd 2 (contrb) Grd 3 25mm Grd 3 (contrb) Grd 4 25mm Grd 4 (contrb)

80 min. 96 80 min. 94 - - 94 - 80 min. 94 - 80 min. 94 -

- 155 - 112 - - 112 - - 112 - - 112 -

7 - 33 - 19 - - 19 - - 19 - - 19 -

6 - 54 - 48 - - 48 - - 48 - - 48 -

5 - 12 - 33 - - 33 - - 33 - - 33 -

4 - 0.66 - 1 - - 1 - - 1 - - 1 -

C - 3.67 - 3.61 - - 3.61 - - 3.61 - - 3.61 -

C.E. = %C + 1/3(%SI) - 4.43 - 4.45 - - 4.45 - - 4.45 - - 4.45 -

S - <0.005 - 0.016 - - 0.016 - - 0.016 - - 0.016 -

P - 0.02 - 0.012 - - 0.012 - - 0.012 - - 0.012 -

Si - 2.28 - 2.52 - - 2.52 - - 2.52 - - 2.52 -

Mn - 0.40 - 0.27 - - 0.27 - - 0.27 - - 0.27 -

Cr - 0.06 - 0.03 - - 0.03 - - 0.03 - - 0.03 -

Ni - 0.51 - 0.29 - - 0.29 - - 0.29 - - 0.29 -

Mo - 0.18 - <0.01 - - <0.01 - - <0.01 - - <0.01 -

V - 0.012 - - - - - - - - - -

Al - 0.017 - 0.12 - - 0.12 - - 0.12 - - 0.12 -

Cu - 0.83 - 0.54 - - 0.54 - - 0.54 - - 0.54 -

Mg - 0.034 - 0.056 - - 0.056 - - 0.056 - - 0.056 -

Ti - 0.015 - 0.01 - - 0.01 - - 0.01 - - 0.01 -

Sb <0.005 - - - - - - - - - -

Ce - 0.01 - 0.0056 - - 0.0056 - - 0.0056 - - 0.0056 -

Sn - <0.005 - 0.005 - - 0.005 - - 0.005 - - 0.005 -

241 - 302 1 238 269 - 341 1 304 302 302 - 363 1 341 340 341 - 444 1 390 387 388 - 477 1 441 418

>110 (750) 101 >130 ksi 153 (1060) 140 (966) > 150 ksi 168 (1160) 165 (1140) > 175 ksi 197 (1360) 190 (1310) > 200 ksi 225 (1550) 220 (1520)

>70 (500) 73 > 90 ksi 109 (752) 110 (759) > 100 ksi 126 (869) 130 (897) > 125 ksi 157 (1080) 160 (1100) > 155 ksi 180 (1240) 180 (1240)

>11% 7.2 > 10 % 13.3 11 > 7.0 % 13 10 > 4.0 % 6.7 7 > 1.0 % 3.1 5

- 7.7 - 12 10 - 13 9 - 8.6 6 - 2.9 4

- 0.133 - 0.16 0.143 - 0.124 - - 0.085 - - 0.148 -

- 155 - 231 (1600) 218 (1500) - 238 (1640) - - 265 (1830) - - 386 (2660) -

-25800

(178000)-

23800

(164000)

23600

(163000)-

23600

(163000)

23200

(160000)-

23100

(159000)

22900

(158000)-

23300

(161000)

22600

(156000)

- 0.298 - 0.275 0.25 - 0.262 0.25 - 0.278 0.25 - 0.27 0.25

- 0.1256 - 0.125 0.1252 - 0.132 0.1376 - 0.116 0.1465 - 0.130 0.1600

- 180.5 (1245) - 235 (1620) 253 (1740) - 279 (1920) - - 322 (2220) - - 467 (3120) -

- 0.2055 - 0.5255 0.1150 - 0.3452 0.1780 - 0.3951 0.3960 - 0.2323 0.4880

- -0.6527 - -0.7319 -0.5940 - -0.6970 -0.6280 - -0.7855 -0.7520 - -0.8224 -0.8480

- 148.0 (1020) - 208.6 (1440) 211 (1460) - 253.4 (1750) 394 (2720) - 400.3 (2760) 450 (3100) - 439 (3030) 728 (5020)

- -0.0820 - -0.0864 -0.0900 - -0.0985 -0.1460 - -0.1371 -0.1600 - -0.1459 -0.2050Fatigue Strength Exponent (b)

Footnotes

(1) These hardness ranges are only typical and are not ASTM requirements.

The gray shaded columns denote data taken from literature

The blue shaded columns denote contributed data. Although the strain-rates and waveforms used to generate the contributed data may differ from those used in tests conducted at CRS, the tests were reportedly conducted in accordance with ASTM Standard E 60

Cyclic Strain Hardening Exponent (n')

Cyclic Strength Coefficient (K'), ksi (MPa)

Strain-life Properties

Fatigue Ductility Coefficient (e'f)

Fatigue Ductility Exponent (c)

Fatigue Strength Coefficient (s'f), ksi (MPa)

Percent Reduction in Area (%)

Strain Hardening Exponent (n)

Strength Coefficient (K), ksi (MPa)

Elastic Modulus (E), ksi (MPa)

Poisson's Ratio (m or n)

Cyclic Stress-Strain Properties

Element (wt%)

.

Brinell Hardness (HBW3000)

Ultimate Tensile Strength (SU), ksi (MPa)

Tensile 0.2% Offset Yield Strength (Sys), ksi (MPa)

Percent Elongation (%)

Austenite &

Acicular Ferrite

Austenite &

Acicular

Ferrite

Substantially

Austenite &

Acicular Ferrite

Austenite &

Acicular Ferrite

Austenite &

Acicular Ferrite

Chemical Analysis

Austenite &

Acicular Ferrite

Austenite &

Acicular

Ferrite

Substantially

Austenite &

Acicular Ferrite

Austenite &

Acicular Ferrite

Austenite &

Acicular

Ferrite

Substantially

Austenite &

Acicular Ferrite

Nodule Count (mm-2

)

Nodule Size Distribution (%)

(ASTM A-247)

Matrix CompositionFerrite &

Austenite

Ferrite &

Austenite

Substantially

Austenite &

Acicular Ferrite

25 mm

Y-block

~25 mm

section

Material Code (Folder Title)

Microstructure

Nodularity (%)

Austempered Austempered

Cast Section Size50 mm thick

casting

25 mm

Y-block

~25 mm

section

25 mm

Y-block

~25 mm

section

25 mm

Y-block

~25 mm

section

Austempered Austempered

ASTM Standard

Austempered Austempered

ASTM Standard

Material Condition

ASTM Standard ASTM Standard

Austempered Austempered

ASTM Standard

Iron Type Austempered Ductile Iron

Grade: ASTM A 897/A 897M110/70/11

[750/500/11]

125-80-10 (130/90/09)

[850-550-10] (900/650/09)

150-100-7 (150/110/07)

[1050-700-7] [1050/750/07]

175/125/04

[1200/850/04]

200/155/01

[1400/1100/01]

Page 7: AFS RESEARCH REPORT - · PDF fileAFS RESEARCH REPORT - COMPILATION Cast Iron Fatigue Properties Database for Modern Design Methods ... (Austempered Ductile Iron, Compacted Graphite

The DATABASE MAP AND MATERIAL INDEX file is the general layout for

materials that were tested in the first two tabs and how data is stored in the last tab.

Page 8: AFS RESEARCH REPORT - · PDF fileAFS RESEARCH REPORT - COMPILATION Cast Iron Fatigue Properties Database for Modern Design Methods ... (Austempered Ductile Iron, Compacted Graphite

Let us now look at an example of the structure of data and information contained in

the next level, the Metal Type folder for Ductile Iron and then a Specific grade of

Ductile Iron.

If you open the folder for a specific grade (60-40-18), you get the different section

sizes that were tested (25 mm, 76mm –HeavySect) or conditions (AC – AsCast, AN

Annealed)

Page 9: AFS RESEARCH REPORT - · PDF fileAFS RESEARCH REPORT - COMPILATION Cast Iron Fatigue Properties Database for Modern Design Methods ... (Austempered Ductile Iron, Compacted Graphite

And opening those Individual files takes you to the data contained for each material

tested, including the detailed analysis, micrographs, and the Raw Data. Since this

was a material tested after the initial report, it also contains the Special report

detailing how the properteis were obtained.

Detailed Analysis:

Elastic strain regression Plastic Strain Regression

ε-N Curve Template Log N = M (S) + B M = -13.37988 26.59799 = B M = -1.3087173 -0.417624691 = B Data for Regression Curve Plot

0.888178 1.521667 0.0400741 0.130225013

Modulus 24,633.33 0.915301 0.329186 0.9806898 0.157179375 N Strain/2 N Plastic Elastic

F1 = 226.9367 21 F1 = 1066.5055 21 Total Strain Strain Strain

24.59158 2.275627 26.348399 0.518812475 100 1.0994 100 0.836878 0.2625

300 0.6033 300 0.361488 0.2418

Coefficients for Correct equation: Coefficients for Correct equation: 1000 0.3651 1000 0.144066 0.2210

Log(2N) = B + m * log(Stress/2) Log(2N) = B + m * log(P-Strain/2) 3000 0.2659 3000 0.062229 0.2036

B for printed formula = 26.5980 3.96278E+26 B for printed formula = -0.4176 0.3822962 2.4115497 10000 0.2109 10000 0.024801 0.1861

M for printed formula = -13.3799 M for printed formula = -1.3087 100000 0.1610 100000 0.004269 0.1567

1000000 0.1327 1000000 0.000735 0.1319

Coefficients for equation solved as: Log(Strain) = B' + m' * log(N)Coefficients for equation solved as: Log(Strain) = B' + m' * log(N)

B' = -(b/m) = 1.9879 B' = -(b/m) = -0.3191

M' = 1/m = -0.0747 M' = 1/m = -0.7641

10^B' = 97.2523 10^B' = 0.4796

(10^B')/E = 0.0039

Customer: AFS Test Program: AME449-07-06-04476 Customer: AFS Test Program: AME449-07-06-04476

Material: 60-40-18 Heavy Section Date: 21-Jul-07 Material: 60-40-18 Heavy Section Date: 21-Jul-07

Specimen Group: ROUND, 8 mm dia. Modulus: 24,633 ksi Specimen Group: ROUND, 8 mm dia. Modulus: 24,633 ksi

Waveform: Triangular Yield Strength: 38.2 ksi Waveform: Triangular Yield Strength: 38.2 ksi

R-Ratio: -1.0 Strain Rate: 2%/sec R-Ratio: -1.0

Test Temperature: Room Temperature Test Temperature: Room Temperature

Test Machine: TestStar, 10 kip Test Machine: TestStar, 10 kip

Data For Plot Data for Calculating Elastic Data for Calculating Plastic Data For Plastic Strain Plot Data for Elastic Strain Plot

TEST Specimen Frequency Maximum Strain Stress Range at Plastic Strain Range Cycles Cyclic Strain (%) Reversals Delta(Stress)/2 = S'f (2Nf)^b Delta(P-Strain)/2 = E'f(2Nf)^c

ORDER ID (Hz) Amplitude (De/2) Half Life (Ds) (ksi) at Half-Life (Dep) Cycles (Nf) to Failure (2Nf) Log(2Nf) Log(Ds/2) Log(2Nf) Log(P-Strain/2) Cycles Plastic Strain Cycles Elastic Strain

1 6F1 0.476 1.05% 122.03 1.553% 120 120 1.0500 240 2.3802 1.7854 2.3802 -2.1097 120 0.77671 120 0.2476989

2 7F3 0.476 1.05% 121.60 1.559% 86 86 1.0500 172 2.2355 1.7839 2.2355 -2.1082 86 0.77951 86 0.246816

3 6F2 0.476 1.05% 133.93 1.553% 76 76 1.0500 152 2.1818 1.8259 2.1818 -2.1098 76 0.776575 76 0.2718532

4 6F3 0.658 0.76% 119.34 0.988% 197 197 0.7600 394 2.5955 1.7758 2.5955 -2.3061 197 0.494181 197 0.2422348

5 4F2 0.658 0.76% 116.47 1.000% 132 132 0.7600 264 2.4216 1.7652 2.4216 -2.3010 132 0.500005 132 0.2363972

6 5F2 0.658 0.76% 117.46 0.996% 228 228 0.7600 456 2.6590 1.7688 2.6590 -2.3028 228 0.4979285 228 0.2384107

7 2F2 1.14 0.44% 111.84 0.412% 633 633 0.4400 1,266 3.1024 1.7475 3.1024 -2.6860 633 0.206084 633 0.2269993

8 1F4 1.14 0.44% 114.89 0.398% 937 937 0.4400 1,874 3.2728 1.7592 3.2728 -2.7012 937 0.1989805 937 0.2331982

9 5F3 1.14 0.44% 114.59 0.393% 1,363 1,363 0.4400 2,726 3.4355 1.7581 3.4355 -2.7069 1,363 0.1963665 1,363 0.2325974

10 7F2 1.14 0.44% 113.62 0.387% 1,034 1,034 0.4400 2,068 3.3156 1.7544 3.3156 -2.7130 1,034 0.193636 1,034 0.2306123

11 2F3 1.666 0.30% 104.86 0.158% 1,378 1,378 0.3000 2,756 3.4403 1.7196 3.4403 -3.1033 1,378 0.0788295 1,378 0.2128376

12 2F1 1.666 0.30% 107.76 0.150% 2,287 2,287 0.3000 4,574 3.6603 1.7314 3.6603 -3.1252 2,287 0.074949 2,287 0.218724

13 5F1 1.666 0.30% 107.46 0.148% 3,149 3,149 0.3000 6,298 3.7992 1.7302 3.7992 -3.1315 3,149 0.0738835 3,149 0.2181089

14 2F4 2.083 0.24% 103.25 0.051% 10,694 10,694 0.2400 21,388 4.3302 1.7129 4.3302 -3.5920 10,694 0.0255832 10,694 0.2095758

15 3F2 2.083 0.24% 101.33 0.063% 5,531 5,531 0.2400 11,062 4.0438 1.7047 4.0438 -3.4986 5,531 0.031722 5,531 0.2056827

16 1F2 2.083 0.24% 103.75 0.054% 8,885 8,885 0.2400 17,770 4.2497 1.7149 4.2497 -3.5696 8,885 0.0269373 8,885 0.2105825

17 6F4 2.94 0.17% 81.53 0.012% 80,744 80,744 0.1700 161,488 5.2081 1.6103 5.2081 -4.2281 80,744 0.0059147 80,744 0.1654839

18 4F1 2.94 0.17% 80.92 0.013% 53,696 53,696 0.1700 107,392 5.0310 1.6070 5.0310 -4.1741 53,696 0.0066971 53,696 0.1642498

19 3F1 2.94 0.17% 81.52 0.011% 42,525 42,525 0.1700 85,050 4.9297 1.6103 4.9297 -4.2438 42,525 0.0057037 42,525 0.165475

20 3F3a 3.571 0.14% 69.20 0.006% 225,992 225,992 0.1400 451,984 5.6551 1.5391 5.6551 -4.5286 225,992 0.0029608 225,992 0.1404536

21 7F4 0.909 0.55% 113.55 0.604% 450 450 0.5500 900 2.9542 1.7542 2.9542 -2.5197 450 0.302226 450 0.2304824

22 1F1 3.571 0.140% 69.13 0.004% 395,698 395,698 0.1400 791,396 5.8984 1.5387 5.8984 -4.7290 395,698 0.0018663 395,698 0.1403241

23 4F3 2.5 0.200% 92.92 0.028% 9,117 9,117 0.2000 18,234 4.2609 1.6671 4.2609 -3.8467 9,117 0.0142344 9,117 0.188606

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

Fatigue - Life Calculations

The fatigue life relationships listed in ASTM E606, Paragraph X1.1.2 were calculated using regression

techniques to solve for fatigue life as a function of stress and strain.

The regression equations were then converted to the following standard forms:

Ds/2=s' f * (2Nf)^b

Ds/2 = 97.3 * (2Nf)^-0.0747 ksi r = 0.915

Ds/2 = 671 * (2Nf)^-0.0747 MPa

Der/2=e' f * (2Nf)^c

Der/2 = 0.4796 * (2Nf)^-0.7641 r = 0.981

De/2=(s' f / E) * (2Nf)^b + e' f * (2Nf)^c

De/2 = 0.0039 * (2Nf)^-0.0747 + 0.4796 * (2Nf)^-0.7641

Where the variables are: and the calculated constants are:

Ds = true stress range s' f = fatigue strength coefficient = 97.3 ksi

Der = true plastic strain range (s' f = fatigue strength coefficient = 671 MPa)

De = true strain range b = fatigue strength exponent = -0.0747

Nf = cycles to failure e' f = fatigue ductility coefficient = 0.4796

2Nf = reversals to failure c = fatigue ductility exponent = -0.7641

r = coefficients of determination E = Young's modulus = 24.6 Mpsi

(E = Young's modulus = 170 GPa)

0.1

1.0

10.0

10 100 1,000 10,000 100,000 1,000,000

To

tal S

tra

in A

mp

litu

de

(D

e/2

) (%

)

Fatigue Cycles (Nf)

LCF Strain-Life Curve

0.001

0.010

0.100

1.000

10 100 1,000 10,000 100,000 1,000,000

Pla

sti

c S

tra

in A

mp

litu

de

(D

ep

/2)

(%)

Fatigue Cycles (Nf)

Plastic Strain - Life Curve

0.1

1.0

10 100 1,000 10,000 100,000 1,000,000

Ela

sti

c S

tra

in A

mp

litu

de

(D

ee

/2)

(%)

Fatigue Cycles (Nf)

Elastic Strain - Life Curve

These values are used to plot the regression curves on the charts

Page 10: AFS RESEARCH REPORT - · PDF fileAFS RESEARCH REPORT - COMPILATION Cast Iron Fatigue Properties Database for Modern Design Methods ... (Austempered Ductile Iron, Compacted Graphite

Example of Photomicrographs included in report

Raw Data Folder – Fatigue Data:

Tensile Data:

Page 11: AFS RESEARCH REPORT - · PDF fileAFS RESEARCH REPORT - COMPILATION Cast Iron Fatigue Properties Database for Modern Design Methods ... (Austempered Ductile Iron, Compacted Graphite

The following is an example of Modulus and Poissons taken from report and

presented in file, also Montonic Strain Hardening with Stress-Strain Curves . Job Number: AME449-07-06-04465

Sample ID: 8

Technician: TAM Job Number: AME449-07-06-04465

Sample ID: 8Lower

Stress

Upper

Stress

Trial Modulus 0.300 12.000 Poisson's Ratio Technician: TAM

Final Modulus 2.000 12.000 27-Nov-12

PrimaryModulus = 24,600,000

Axial Trial Modulus Length 0.16 r^2 = 1

Trans Trial Modulus Length 0.08 Secondary Modulus = 85,400,000 Poisson's Ratio = 0.288

r^2 = 0.9992

Axial Final Modulus Length 0.18

Trans Final Modulus Length 0.052

Data Detect 0.01

0

2

4

6

8

10

12

14

16

18

20

0.00 0.02 0.04 0.06 0.08

Str

ess (

ps

i)

Strain (%)

Trial Modulus

0

2

4

6

8

10

12

14

16

18

20

-0.004% -0.002% 0.000% 0.002% 0.004%

Axial Strain Deviation

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

45.00

50.00

0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50

Final Modulus

0

2

4

6

8

10

12

14

16

18

20

-0.004% -0.002% 0.000% 0.002% 0.004%

TransverseStrain Deviation

0

10

20

30

40

50

60

70

0 5 10 15 20 25 30

En

g.

Str

ess

(ksi

)

Eng. Strain (%)

Engineering Stress/Strain Curve

Page 12: AFS RESEARCH REPORT - · PDF fileAFS RESEARCH REPORT - COMPILATION Cast Iron Fatigue Properties Database for Modern Design Methods ... (Austempered Ductile Iron, Compacted Graphite

Finally, below is a summary of properties contained on the spreadsheets and also in

the AFS CADS online database for a specific Metal (Ductile), Grade (60-40-18).

Heavy Section

As-Cast

4018-ScAn-

HeavySect

- 90

- 125

7 - 15

6 - 47

5 - 36

4 - 2.2

C 3.20 - 4.101 3.48

C.E. = %C + 1/3(%SI) - 4.32

S 0.005 - 0.0351 <0.005

P 0.015 - 0.101 0.023

Si 1.80 - 3.001 2.53

Mn 0.10 - 1.001 0.18

Cr - 0.03

Ni - 0.11

Mo - 0.02

Al - 0.011

Cu - 0.09

Mg - 0.046

Ti - 0.009

Ce - 0.0089

Sn - 0.005

[<170] 148

>60 ksi 59.3 (409)

>40 ksi 38.1 (263)

>18 % 25

- 22

- 0.187

- 98.2

-24600

(170000)

- 0.289

-24600

(170000)

- 0.0983

- 105 (721)

- 0.4796

- -0.7641

- 97.3 (671)

- -0.0747

Iron Type

Material Condition

Strain-life Properties: Strain-life Method (ASTM E606; SAE J1099)

Grade: ASTM A 536 [SAE J434]

Strain Hardening Exponent (n)

Strength Coefficient (K), ksi (MPa)

Percent Elongation (%)

Percent Reduction in Area (%)

Chemical Analysis

-Matrix Composition

Elastic Modulus (E), ksi (MPa)

Cyclic Strength Coefficient (K'), ksi (MPa)

Elastic Modulus (E), ksi (MPa)

Poisson's Ratio (m)

Cyclic Strain Hardening Exponent (n')

Cyclic Stress-Strain Properties: Strain-life Method (ASTM E606; SAE J1099)

Cast Section Size

Nodule Size Distribution (%)

(ASTM A-247)

Nodule Count (mm-2

)

Ultimate Tensile Strength (SU), ksi (MPa)

Element (wt%)

Monotonic Properties (Hardness and Tension)

Fatigue Ductility Coefficient (e'f)

Fatigue Ductility Exponent (c)

Fatigue Strength Coefficient (s'f), ksi (MPa)

60-40-18

[D4018]

Nodularity (%)

Material Code (Folder Title)

ASTM Standard

[SAE Standard]

Tensile 0.2% Offset Yield Strength (Sys), ksi (MPa)

>98% Ferrite

<2% Pearlite

76 mm

Y-block

Brinell Hardness (HBW3000)

Fatigue Strength Exponent (b)