Austempered Ductile Iron A Perfect Engineering Material

V.S.Saravanan Manager- Engineering & Quality Control M/s Indoshell Cast Private Limited, Coimbatore.

Synopsis:Austempered Ductile Iron(ADI) is a versatile material capable of meeting many applications with wide range of properties with a low weight to strength ratio or we can say low cost to strength ratio. This paper will briefly review the production as well as mechanical properties, important characteristics and application of this material. Already considerable effort has been made to establish the data on mechanical and physical properties on ADI. Foundries willing to produce ADI need close control on chemical composition, casting soundness and integrity and dimensional stability. Heat treatment facility needs necessary equipment and close controls. As this material exhibits the strength levels almost twice as compared to standard ductile iron at the same level of elongation and toughness with excellent wear and fatigue resistance and has conducive for work hardening treatment on the surfaces makes ADI a potential material for various applications and particularly it is best replacement material for forged steel.

Superiority of ADI can be realized through Quality Index of the material. Quality Index exhibits the relationship between tensile strength and elongation of the form of : (tensile strength ksi)2 x (elongation%) 1000 = QI For the Ductile Iron Grade 60-40-18 has the highest QI of 64.8 and 29 for Grade the 120-9002.When tensile strength increases at the cost of elongation ,QI decreases. Austenitic stainless steel with 480 Mpa Tensile strength and 30% elongation exhibits the QI of 145.4. Austempered Ductile Iron with a combination of excellent strength and elongations exhibits the remarkable QI.

As per ASTM A897-90 the grades 850-550-10 and 1050-700-7 possess the Quality Indices of 196 and 195 respectively. From the above QI values the superiority of the material can be realized. This paper is segmented into following 6 categories for better understanding,, 1. 2. 3. 4. 5. 6. About Austempered Ductile Iron Metallurgy of Austempered Ductile Iron Production of Austempered Ductile Iron Performance Benefits of Austempered ductile Iron Applications of Austempered Ductile Iron Properties of Austempered Ductile Iron

About Austempered Ductile Iron (ADI): ADI is a high strength and wear resistant material produced by Austempering heat treatment of ductile iron in controlled three stage heat treatment cycle.

Wear resistance of ADI is superior to steel at any given hardness level making it ideal for many mining, construction, agriculture and automobile industries. ADI competes favorably with steel forgings, especially for heavy-duty parts where reliability is paramount. It is used to upgrade from standard ductile irons, and as a substitute for manganese steel and nickel-hard materials. When strength is required ADI is particularly cost-effective: Tensile and yield values are twice those of standard ductile iron; fatigue strength is 50% higher and it can be enhanced by shot peening or fillet rolling. With its high strength-to-weight ratio ADI can even replace aluminium when reduced section sizes are acceptable. For the designer ADI is a most versatile material, enabling innovative solutions to new and current problems. By selecting precise heat treatment parameters a specific set of properties can be achieved. The lower hardness ductile iron castings are used in structural applications, often where weight and cost reduction are important. Wear resistance is superior to steel at any given hardness level, making the higher hardness grades ideal for mining, construction, agricultural and similar high abrasion applications.

Courtesy: The Sorel Metal Book of Ductile Iron

Metallurgy of Austempered Ductile Iron Ductile Cast Iron undergoes a remarkable transformation when subjected to the austempering heat process. A new microstructure of Ausferrite results with capability superior to many traditional, high performance, ferrous and aluminium alloys. ADI is sometimes referred to as "Bainitic Ductile Iron", but when speaking with metallurgical sense ADI contains little or no bainite. Bainite is a matrix of acicular (needle-like) ferrite and cementite where as ADI contains Ausferrite matrix which is a mixture of acicular ferrite and carbon stabilized austenite. This ausferrite may resemble bainite metallographically. An ausferrite matrix will be converted to bainite if the tempering time reaches the bainitic bay of its TTT curve. To optimise ADI properties for a particular application the austempering parameters must be carefully selected and controlled. Castings are first austenitised to dissolve maximum carbon in austenite, then quenched rapidly to the austempering between 230 & 350C to avoid the formation of deleterious pearlite or martensite. While the casting is held at austempering temperature the carbon rich austenite phase which is stable in ADI enhances its physical and mechanical properties. Furthermore, the austenite in ADI is thermodynamically stable, it can undergo a strain-induced transformation when locally stressed, producing islands of hard martensite that enhance wear properties. This behaviour contrasts with that of the metastable austenite retained in steels, which can transform to brittle martensite. Actually untransformed austenite ,can be called as retained austenite which is not desired phase for ADI since this retained austenite will transform into some other phases such as cementite or martensite during the coarse of service which in turn affects the toughness of the material. But this phenomenon is applied in some specific applications to produce Carbidic Austempered Ductile Iron (CADI).

Production of ADI The base SG Iron must be of high quality with good graphite nodularity( >80%) and nodule count ( 150 - 200 nodules /mm in 1inch diameter section). To obtain better hardenability some alloying elements are required except for thin- section castings. But care must be taken in selecting the alloying elements to avoid segregation and formation of alloy carbides which affects the machinability and mechanical properties. For high strength and toughness controlling the manganese percentage below 0.3% is essential. For section thickness upto 50mm addition of Nickel ( 2%) and Molybdenum( 0.3%) will improve the strength and toughness. 3 stages of heat treatment involved in producing ADI namely. 1.Austenitizing 2. Isothermal Quenching ( Austempering) 3. Cooling to room temperature 1.Austenitizing: During Austenitizing all the phases present in the microstructure is transformed into Austenite. Normally Austenite can hold the maximum of 2.06% of carbon. 2. Isothermal Quenching (Austempering): Austenitizing is followed by Iso thermal quenching. After the first stage austenitizing the castings are quickly transferred and quenched into the austempering bath held at predetermined temperature normally in the range of 230 C to 350C. Austempering baths are normally a salt bath consisting sodium and potassium nitrates. Oil baths are not preferable since it is hazardous at higher temperatures. Recently feasibility of application of controlled volume of water for austempering is being examined. Quenching temperature can be between the zone of Upper Bainite and Martensite.i.e the quenching temperature is maintained between just below the upper bainitic zone and just above the Ms temperature. Because of the sudden quenching austenite is not able to transform into some other phases and remain as it is as Austenite. After the above transformation the material is maintained at a constant temperature as described above. 2 stages of transformation takes place during iso thermal quenching. Stage 1: During this period ferrite nucleates at the grain boundary of the Austenite and starts growing. When ferrite starts growing it ejects the carbon since it can hold only a maximum 0.025% of carbon. So the enrichment of carbon in the austenite will become more since the volume of austenite is reducing continuously at the cost of increase in ferrite volume. Micro constituent at this stage is the untransformed low carbon austenite and ferrite plates. Stage 2: This enriched carbon stabilized the austenite which is thermo dynamically stable and possesses high strength and toughness. In a span of critical time interval stability is attained and the growth of ferrite stops. The resultant microstructure is ausferrtie.

Micro constituent at this stage is the Fully transformed high carbon austenite and fully grown ferrite plates called ausferrite. Stage3: This stage comes when the quenching time is extended more, then ferrite grows more in the grain boundary. As the austenite already have enough carbon the excess carbon will be precipitated as cementite and one particular time all the entire Austenite will be transformed in to ferrite and cementite and become bainite. Because of more volume of ferrite bainite reveals relatively lower hardness and strength than ausferrite. Micro constituent at this stage is the fully grown ferrite and cementite called Bainite. Therefore to obtain good ADI the treatment should contain only stage1 and stage 2. Typical Austempering cycles for different grades of ADI

. When holding time increases the graphite nodules also acts a carbon sink and liberate carbon it promotes the formation of bainitic structure. Presence of defects in the casting will affect the carbon migration and it affects the formation of Ausferrite matrix. So ADI casting should be free from deleterious castings defect such as shrinkage, oxide, silicate inclusions, gas defects etc. The critical characteristics are to be followed during Austempering Treatment are as follows: Austenitizing temperature and soaking time to get austenitie with highest carbon content. Transfer time from the austenitizing stage to austempering stage. The quench severity of the quenchant to be used for austempering Austempering temperature and soaking time shall be in such a way that no un transformed low carbon austenite ( retained austenite) present in the microstructure.

The mass of the load relative to the quenchant volume and type of quanchant.. The maximum section thickness of the casting and type of casting being quenched

The use of a correctly designed austempering system with a suitably high quench severity and the correct loading of castings in the batch will facilitate in getting desired properties of the castings resulting in significant savings in alloy costs. Researches are going on in various Austempering methods to obtain Ausferrite matrix in Cryogenic treatments, Polymer quench instead of salt bath etc. To Produce low strength with high elongation grades (low grades) austempering temperature is maintained at the higher side ( about 350C) which will produce coarse ausferrite matrix with more amount of carbon stabilized austenite. Similarly to get higher grade with high strength and low elongation tempering temperature is maintained below 300C. Recent study shows optimum Si/Mn ratio to about 1.5 will improve hardness, tensile properties, impact property and wear property. Manganese is a potent hardenability promoter that delays the beginning of stage 1 and stage 2 reactions during Austempering. So that possibility of formation of pearlite which is undesirable due to small delay in transferring the material to austempering bath can be reduced. The section sensitivity of ADI component can be reduced by adding Nickel and Molydenum. Further to this Nickel addition will increase the toughness. The Performance Benefits 1. Strength is comparable to steel. ADI competes favourably with steel forgings, especially for heavy-duty parts where reliability is paramount. It is used to upgrade from standard ductile irons, and as a substitute for manganese steel and nickel-hard materials.

2. ADI is three times stronger than the best cast or forged Aluminium and weighs only 2.5 times as much When strength is required ADI is particularly cost-effective: Tensile and yield values are twice those of standard ductile iron; Fatigue strength is 50% higher and it can be enhanced by shot peening or fillet rolling.

3. Excellent fatigue strength

4. Improved noise damping capacity: Damping capacity of Austempered Ductile Iron is better than that of steel due to the presence of graphite within the microstructure. The unique microstructure of ADI further enhances internal damping, especially in grades 4 and 5 with finer ausferrite, Studies completed on Kymenite ADI gears in Finland have shown that vibrations are damped 40% faster in ADI than in steel components.

5. Superior wear and abrasion resistance: RAR ( Relative Abrasive Resistance) of the alloyed ADI is almost equal to the NiHard steel.

6. Considering its high strength, ADI has very good Fracture toughness

7. Relatively good Machinablity ADI has surprisingly double benefit of increased strength and wear resistance along with good machinability. We can do machining economically in two ways, 1. The machinability of the softer grades of ADI is equal or superior to that of steels with equivalent strength. 2. Machining before ADI Treatment is possible to machine a soft as cast material, which allows faster machining speeds, and increased tool life.

Relative machinability of several ferrous materials.

Comparison of the mechanical properties of forged steel, Pearlitic Ductile Iron and Grade 150/100/7 ADI.

Cast Iron ADI ASTM Specification Tensile Strength, N/mm2 (103 p.s.i) Yield Strength, N/mm2 (103 p.s.i) Elongation % --862 - 380 (125 - 200) Grey A48 138 - 414 (20-60) Malleable A602 345 - 724 (50 - 105) Ductile A536 414 - 690 (60 - 100) Cast A27 414 - 483 (60 - 70)

Steel Forged A290, A-D 552 - 1172 (80 - 170)

586 - 965 (85 - 140)

--(32 - 85)

221 - 586 (40 - 70)

276 - 493 (30 - 40)

207 - 276 (45 - 145)

310 - 1000 ---

10 - 2.

<1

10 - 1.

18 - 3.

24 - 22

22 - 10.

Typical Applications: Agricultural and construction applications make use of the excellent wear resistance of ADI in combination with impact energy. ADI parts have especially performed well in contact with soil. Agricultural Applications: Rasp Bars, Internal tines, Thrashing elements, Rasp buckets, Aerator Flights, Wear Plates, Plough points, digger teeth, grader blades, pavement breakers and fertilizer knives etc. There are numerous miscellaneous industrial applications that require a combination of wear resistance and strength in addition to high impact energy. Examples of these applications include: conveyor components, pump components, dies, wear plates and housings. Rail road Applications Railroad applications require good wear resistance along with high static and fatigue strength. ADI can provide this as well as the possibility for lighter design. Railroad applications include: top caps, wear shoes, nipper, hooks, shock absorbers and engine parts. Construction and Mining Digger teeth, tip holders, Hammers, Crusher rollers, Housings, Chutes etc. Industrial Conveyor Wear Parts, Pump Impellor, Wear Housing Plates, Rollers etc

Automotive Camshafts, Crank Shafts, Cam followers, Gear wheels, Gear shafts etc. Austempered Ductile Iron Grades, Physical & Mechanical Properties
ASTM 897 (in-lb units) ASTM 897M (SI units) "Grade" Properties Min. Tensile Strength (ksi/MPa) Min. 0.2% Offset Yield Strength (ksi/MPa) Min. Elongation (% in 2 in/50mm gage) Typical Brinell Hardness (BID mm) Typical Density (lb./in3 / g/ cm3) Typical Thermal expansion (in/in/F / mm/mm/C) 125/850 80/550 10 302 (3.50) .2562 / 7.0965 8.1/14.6 150/1050 175/1200 200/1400 230/1600 100/700 7 340 (3.30) .2555 / 7.0779 8.0/14.3 125/850 4 387 (3.10) .2555 / 7.0779 7.8/14.0 155/1100 185/1300 1 418 (3.00) .2552 / 7.0686 7.7/13.8 n/a 460 (2.85) .2548 / 7.0593 7.5/13.5 125 80 10 850 550 10 1 150 100 07 175 125 04 200 155 01 1400 1100 01 4 230 185 00 1600 1300 00 5

1050 700 1200 850 07 04 2 3

Typical Thermal conductivity (BTU153/22.1 151/21.8 149/21.5 147/21.2 145/20.9 in/h-ft2 / W-MK) Typical Internal Damping (log decrement X .0001) 5.26 5.41 5.69 12.7 19.2

Conclusion: ADI has the potential to make the Cast Iron Foundry industry more viable and competitive to cater the need of new materials in the engineering industry in near future. Automobile industry will become a largest single user of this material once the importance and excellence of this material is understood fully by the engineers. Foundries following good disciplined melting practices and having impeccable heat treatment facilities with good controls will have bright opportunities in the coming years if they start developing and establishing the production methods of ADI from today onwards.

References 1. Ductile Iron Data for design Engineers- www.ductileiron.org 2. A study on the influence of Heat treatment on the Wear resistance of Alloyed ADIIndian Foundry Journal March 2009. 3. The Challenge and Opportunity presented to the S.G.Iron Industry by the development of Austempered Ductile Iron by D.Forrest, Chief Foundry Metallurgist , QIT-Fer et Titane Inc. 4. ADI: Another Avenue for Ductile Iron Foundries by Kathy L. Hayrynen, Applied Process Inc,Livonia,Michigan. 5. The Production of Austempered Ductile Iron (ADI) by Kathy L. Hayrynen, Applied Process Inc,Livonia,Michigan. 6. WWW.Key to Steel.com 7. Cast Iron Technology Illiot Roy. 8. High Si & Mn contaning ADI for Wear Applications by S.M.Lee,S.S.Park and B.M.Moon.