Académique Documents
Professionnel Documents
Culture Documents
43) are
to be preferred in corrosive slurries. With regard to the
castings in Figs. 1 0.42 and Fig. 1 0.43, it should be kept in mind
that coal slurries can become acidic due to reactions of thei¡
sulfur content with water. The lowest pH-value, where hi_eh-
Cr irons are useful, depends on the relative amounts of
Fig. 10.40. High-Cr (ASTM A532 lllA) drag head parts for the
sand and gravel business. Parts weigh from 15 to 125 kg (-25
Fig 10.37. High-Cr (ASTM illA) AR parts for the dredging
to 300 lb). (Courtesy of Mobile Pulley and Machine)
industry. Weights of large castings can exceed 5780 kg (13,000
lb). (Courtesy of Mobile Pulley and Machine Works)
Fig 10.41. High-Cr (ASTM lllA) 135-cm (SA-in.) dia impetter for
corrosion/erosion pump slurry application. Casting is
Fig 10.38. Ni-Hard 4 (ASTM lD) 183 cm (72 in.) dia pump head positioned on a two-plane dynamic balancing machine. The
liner. The approximate we¡ght of the casting is 575 kg (1300 approximate weight of the cast¡ng is 1500 kg (3400 tb).
lb). (Courtesy of Weatherly Caating and Machine Co.) (Courtesy of Weatherly Casting and Machine Co.)
Applications 173
,¡r¡-<ion and corrosion. Chloride content increases wear loss A classic example of this combined corrosive/abrasive
rr high-Cr irons in slightly acidic slunies. Eventually, special wear behavior is that found in the mechanical pulping of
-r"-ns rr ith high-Cr:C ratios or AR stainless steels have to be wood chips. In this application, the corrosive medium is the
::¿i. In any case, however, total wearloss willbe muchhigher wood pulp liquor and the abrasive is rock particles embedded
::.n the sum of abrasive and cortosive loss alone. within the woodchips. Therefinerplate segments are mounted
onto a disk and spun against a counter-rotating disk or a
statically fixed disk. The wood chips are then fed between
these rotating disks and processed into wood fibers. Figure
10.44 shows a circle of refiner plates and Fig. 10.45 shows
several examples of separate refiner plate segments made
from ASTM IIIA. Their high Cr content (257o) andhtgh CVF
(approximately 30Vo) provides superior corrosioniabrasive
resistance. In some specialty applications, super high-Cr
grades (30% Cr) are sometimes used as refiner plate alloys to
combat corrosive wear.
Fig. 10.43b. High-Cr (ASTM lllA) casting used in asphalt Fig 10.45 High-Cr (ASTM illA) AR refiner plates ior the pulp and
mixing. Casting is approximately 74x46 cm (29x18 in.) and paper industry. The holes are about 35 mm (1.4 in.) dia and the
weighs 67 kg (150 lb). (Courtesy ot Unitecl Machine and castings weigh about 10 kg (22 lb) each. (Courtesy of
Foundry) Durametal Corporation)
Appendix G t 83
Table F3. Mesh and Grit Sizes for Abrasive paficles
Fig. Fl. Photo showing a preferred method for secüoning and mounting
Genera! Mechanical & Wear properties a5x25 mm (0.25x1.0 in.) pin in Bakeliteru or epoxy.
Diosbarg & Boric Q97g gert)
Table Cl. Type and Composition of hon and Steel Alloys
Table C2. Heat Treatment ofkon and Steel Alloys
Appendix G 2Os
Calculation of Superheat
Table C3. Mechanical Properties and Abrasion Resist¿nce of Iron and
Table Gl. Applicable Chemistries and Superheat Equations for Typical
Steel Alloys
AR Cast Irons
Hardness and Abras¡on Res¡stance Table G2. Approximate Austenite Liquidus Temperatures in
"C and ("F)
Avery (1974) (text)
Table C4. Composition and Heat T¡eatment of Grinding Mill Alloys. Appendix H 206
Table C5. Abrasion Resistance of Thin and Thick Sections of Grinding Fluidity Measurements
Mill Liner Casrings
Fig. Cla and Clb. Relationships between gouging wear, C content and Table Hl. Experimental Raw Data
various metals. Tables H2-H4. Regression Analyses
Table H5. Relationships for Fluidity
Abrasion Resistance & Fracture Toughness
Fig. Hl. Design of fluidis spiral and gating system.
Sare (1979) (text) Figs. H2-H4. Plot of spiral length vs. pour temperature for 7_39Vo
Table C6. Alloy Compositions (Wt.Zo) and Abrasion Test Data chromium irons.
Table C7. Heat Treatments
Table C8. Abrasion & Fracture Toughness Test Results
Fig. C2. Schematic of shell liners studied.
Fig. C3. Description of wear and fracture tests.
175
Appendices
Appendix A Appendix B
Hardness of Minerals, Iron phases and Carbides
Mechanical and Thermophysical properties
Appendix B consists of tables and figures that are categorized
by
Hardness ot n¡nrr"Jlil'nllnases ana caro¡aes,¡ type of AR cast iron. They are as follows:
. Pearütic White Cast Irons
Knoop(2) . Ni-Hard I and Ni-Hard 2 AR Cast hons
Vickers
. Ni-Hard 4 AR Cast kons
Minerals: -Hardnéss_ . High-Chromium AR Cast Irons
Talc... ..........20
Carbon ... 35 .
Gypsum .. 40 . ...... g6 o Pearlitic White AR Cast lrons
Calc¡te . 1gO . .....140
Fluorite .. fiS . ..... 190
Apatite . .335 . .....540 Table Bl
Mechanical and Thermophysical properties
Gtass. ".4ss. .....s00 of a Representative pearlitic White Cast lrono)
Felspar .. S5O . . 600_750
Magnetite SZS . . Chilt Cast
Orthoclase ......620 Property Sand Cast (perm. Mold)
Flint... ..820. .....9S0 Hardness, HBN .. . . .. g96i-479 ..
Quartz . 13gO . .. .. 1430
410_SlO
Topaz . 1960
Tensile Strength
Garnet .
.
kpsi (MPa) .. 30-60 (230-460) . . 35_60 (280_460)
1360 ..
Emery. 14OO .
Elastic Modutus Mpsi (Gpa) . . . . 30 (210) . . 30 (210)
Corundum ... _.. ZO2O ..... lB0O Compressive Strength
Siliconcarbidesic... ...2S8S .....2600 psi (MPa) .. . ..
19s-Z2s (1500_1750) .. .... n.a.
Diamond 7s7s . .. 10,000 Bending Strength
lron Phases: psi (MPa)(2) . . 5s-90 (37H20) . 70_105 (s1o-72s)
Ferrite. ..255. ..70_2OO Density
Pearlite, unalloyed l[/i¡.e (g/6ms) . . . . 0.27-0.28 (7.6-7.8) O.2t_0.28 (7.6_7.8)
ZOO_}2O
Pearlite,atloyed . .g00_460 Specific Heat
Austenite, 12o/oun gO5 .. Btu/lb.F(J/kg.K) ..0.195(s6s)..
170_2AO ....n.a.
Austenite, low alloy 2SG_350 Latent Heat of Fusion
Austenite,highCriron... .300-600 Btu/lb(J/kg) .....84 (195,000) ......
Martensite .. . 566800 . 500_1010
n_a.
Thermal Conductivity
Cement¡te .. . .. . 1025 . 840_1 100 Btu/hr.ft.F (Wm.K) ....7.5-11 (13_gO) ... ... n.a.
Carbides: Coetficient of Thermal Expansion:
.... .1tSS
Chromium Carbide (Fe,Cr)7C3 12OO_1600
0-528F (V276C); s.s-6 (1 0-1 1 )x1 oo
s28-1 263F (zZ 6-{;BaC); 8.8-9. 1 (1 s.9_1 6.4)x1 0e
...... lgOO
Molybdenumcarbide Mo2C ..... 1S0O
TungstencarbideWC... 1BOO. ....2400 n.a. = not available
VanadiumcarbideVC ... 2660. ....2800
TitaniumcarbideTic.. ..2470 (l)The numbers presented ¡n th¡s tabte are representative of
.....g200 pearlitic unalloyed white cast irons cast into gO mm (l
Boroncarbide ...2gOO .....g700 .2 in.) dia
bars. Compositions are between 2.5_3.5% C, O.io.Ozy"
S¡,
(1) Data obtained from W. Fairhurst and K. Róhrig, 0.3-0.96% Mn, batance Fe. Data obkined from Angus, H.T.,
Abrasion_ "Cast I ron : Physical and Engineering properties,,, Butterwoñhs,
Resistant High-Chromium White Cast trons," Flundry Trade
Joumal, vol. 156, No.29gg, pp.685-98 (1g74). London (1976).
(2)Transverse rupture stress ¡n a gO mm (1.2 in.)
(2) Typical values. dia bar using a
12 in. (3O5 mm) span.
Appendices
177
(Appendix B, Mechanical & Thermophysical Properties
Pearlitic White AR Cast lrons, continued)
Table 82
Eff*t ot Carbon Content on Mechanical Properties of Pearlltic Wh¡te AR Cast lron(t)
CarbonContent(7"1 ... ..1.77(31 .....2.00 .....2.22(4) .......2.30 ......2.50 .....2.57§l ......3.00....... 3.50
(1) Test bars were sand cast to 30 mm (1.2 in.). After casting, bars were tempered at 990( F (550( C) for t hr and then furnace cooled. Data
obtained from: H.T. Angus, "Cast lron: Physical and Engineering Properties," Buttewo¡1hs, London (1976).
(2) Data obtained from Ruddeck, P., Über die Quatitátsbestimmung und Quatitátsentwicklung von untegiefiem HartguB, Dr.lng. Dissertation,
Freiberg (1966).
(3) Chemical composition wds 1.77o/o total C, 0.960/0 Si, 0.22"/" Mn, 0.1% S, 0.07"/" P, balance Fe.
(4) Chemical composition was 2.22o/o total C, 1.12o/o Si, 0.22o/o Mn, 0.1% S, 0.05% P, balance Fe.
(5) Chemical composition was 2.57% total C, 1.03% Si, 0.21% Mn, 0.1"/" S, 0.07% P, balance Fe.
Table 83
Eltect of Carbon Content on
Themal Properties of Pearlitic White AR Cast lro¡11)
Table 84
Typical Range oi Mechanlcal Properties of Ni-Hard 1 and Ni-Hard 2 AR Cast lronslt)
Ni-Ha¡d I (3.F3.6%C):
$3¡{ Q¿s1(+) 55M90 4H0 (280-350) 70-90 (50H20) 0.08-0.11 (2.0-2.8) 2,+-26 (169-183) 38-56 (2S-41)
QflillQ6f{+) 600-730 sMo (35H20) 80-125 (56H50) 0.08-0.12 (2.0-3.0) 2¿l-26 (169-183) 48-75 (3s-ss)
Ni-Hard 2 (max 2.9oA C):
sand cast(¿) 53H30 45-55 (320-390) 80-100 (56H80) 0.1H.12 (2.5-3.0) (16$-183) 48-65 (35-48)
24-26
chillcast(a) 58M80 60-75 (420-530) 100-125 (680-870) 0.10-{.12 (2.5-3.0) 2¿+-26 (169-183) 65-105 (48-76)
(1) Data obtained from Ni-Hard Material Data and Applications, Edited by K. Róhrig, NiDl, Ref. Book Seies No. 11017 (1995).
(2) Transverse strength tests were performed on 30 mm (1.2 ln.) dia test bars centered over a 300 mm (12 in.) span.
(3) lmpact tests were conducted using an lzod test procedure on 1.2 in (30 mm) dia bars struck 76 mm (3 in.) above support.
(4) Samples were cast ¡nto 30 mm (1.2 in.) dia bars and have nominal compositions for their alloy range.
Table 85
Some Typical Physlcal Properties of Ni-Hard t and Ni-Hard N)
Density¡!/i¡.s(g/6¡s) ....0.274.28(2.6_7.8)
Thermal Conductivity Btu/hr.ft.F (Wm.K):
. lnstantaneous at 70F (20C) 7.8_B.g (i4_1S)
. lnstantaneous at 2S0F (j20C) . . . 7.g (14.2)
.lnstantaneous at 850F (4S0C) . . 10.4 (18.8)
(1) Dak obtained from Ni-Hard Materiat Data and Applications, Edited
by K.
Róhrig, NiDl, Ref. Book Seies No. fi017 (1995).
Table 86
Fracture Toughness ol Ni-Hard I Ailoys
700
ltltt
¡tt¡l
600
l¡ttt
lttt
500
9
! 400
it\iii
!;
tt\rr.
(¡)
§c 300 - - - - - I - - - - - -.i - - - - -
I I
-\-
t\
- - - - -:-
ll
_ _ _ _ _ _ t_ _ _ _ _ _ _
o ttl ll
:E 200 - - +r i t - _ _ _ _ _ i_ _ --|-r-----Fr
ltl I
rr\¡ I
r00 - -- - -l- --- - _ J_ _ _ _ _ _ J__ __ __ _r_-I
lttt
0
400 óm 800 t000 t200 l¡f00
Temperolure. t
Temp. F 4O1 599 797 896 1004 I 103 1202 1400 1499
remp. (C) (205) (31s) (425\ (480) (so) (5e5) (650) (760) (815)
HV 10 606 521 485 n1
416 308 138 92 75
Fig. 81. Hot hardness testing ol a heavy-*ction Ni4hrd I wting. (IHa obtained from
Ni-Ha¡d Material
Data and Appltcations, Ediad by K. Róhrig, NiDt, Ref. B@k ser*§ ¡io. tlol7, tggS)
Appendices
179
(Appendix B, Mechanical & Thermophysical Properties, continued)
' Ni-Hard 4 AR Cast lrons
Table 87
Typical Range of Mechanical Properties of Ni-Hard 4 AR Cast lrons
Ni-Hard 4f) (2.6-3.2oh C\ 550-700 70-85 (50M00) 8F115 (600-800) 0.08-0.11 (2.0-2.e) 27-29 (190-200)
Ni-Hard 4(z) (3.3o/o C, 2.1% Si) 640 not ava¡|. 100 (695) 0.026 (0.66) not avail.
Ni-Hard 4(z) (3"8o/o C, 1.6% Si) 580 not avail. 77 (533) 0.018 (0.46) not avail.
Ni-Hard 4(z\ (3.60/o C, 1.2% Si) 530 not ava¡|. 73 (505) 0.021 (0.53) not avail.
(1 ) Data obtained from Ni-Hard Material Data and Applications, Edited by K. Róhrig, NiDl, Ref . Book Series No. 1 1 01 7 (1 995). Transverse
strengthtestswere performedonS0mm (1.2 in.) diametertestbarscenteredovera300 mm (12 in.) span.lmpacttestswere conducted
using.an lzod test procedure on 1.2 in. (30 mm) diameter bars struck 76 mm (3 in.) above suppo¡|. Samples were cast into 30 mm
(1.2 in.) diameter bars and have nom¡nal compositions for their alloy range.
(2) Data obtained from J.J. Fischer, *The Relationship of Microstructure to Propert¡es in Ni-Hard 4," AFS Transactions, vol. 91, pp. 47-
54 (1983). Other alloy elements haci nom¡nal values of 5.2% N¡, 7.8% C1 0.5% Mn. Bend tests were conducted on carefully machined
and polished bars that were 127 mm (5 in.) long by 22 mm (0.9 in.) wide by 10 mm (0.4 in.) thick. A span distance of 82.5 mm (3.25
in.)was used. Bend sampleswere cutfrom cast¡ngsuchthatthebending plane of tens¡onwasparalleltothechillface. Vatues repoñed
are from samples that are estimated to be 10 mm (0.5 in.) from the chill face.
Table 88
Some Typical Physical Properties of Ni-Hard 4lt)
Densitylb/in.3(g/cms) .....0.27(7.7)
Thermal Conductivity Btu/hr.ft.F (Wm.K) . 7-9 (12.6-15)
Specific Heat at 70F (20C) Btu/lb.F (J/kg.K) 0.119 (500)
Coetficient cif Thermal Expansion, e/F (e/C)x100:
. Average between 70-212F0-100C) (1 .. . 8.2 (14.8)
. Average between 7}-ggzF O-2OOC) (1 . . . 8.4 (1 5.2)
.Average between 70-572F (10-300C) . . . 8.8 (15.8)
. Average between 70-752F (10-400C) . . . 8.8 (1S.9)
.AveragebetweenTO-932F (10-500C) ...8.S(1S.3)
t = strength
(1) Data obtained from Ni-Hard Material Data and Applications, Edited by
K. Róhrig, NiDl, Ref. Book Series No. 11017 (1995).
Table 89
Fracture Toughness of Ni-Hard 4 Alloys
(2) Data obtained from D.E. Diesburg and F. Borik, "Optimizing Abrasion Resistance and Toughness in Steels and
lrons for the Mining lndustry," ¡n Symposium Materials for the Mining lndustry, Vail, CO. July 30-31 , 1974, pp.
15-42, Climax Molybdenum Co.
,"',lllil" "#,fiii'li
(MPa) lqc.si rpsilúea) iltñ(*; kps¡.in.rp (Mpa.mra¡
568(1) - 15Cr-3Mo (3'60/' c) 410 ,.8 (1640) 101 (696) 31-33 (215-230)
7zo 460 (3170) t1 @so) 2s.2 (2s.5)
fl1,;lll.tY:]t.t:':]^". ^.
818(1)-20cr-2Mo-1cu (2's%c)
t4o 410(2870) 1oo(689) 3i-3s(2i5-2so)
or-.3 (2rs-2so)
838(1) - 27Cr (2'40/" c) 650 419 (2890)
27.s(go.z)
1g7 (g45) 3l-m (215-230)
848*) -27Ct (3'1% C) 700 42s (2s60) 136 (938) 31-33 (215-230)
(1) Dnakobtained"fr"!,!;,i¡,',ff!rz:'^ilff,iir!;r?i){i,,;3x:;';3:r?:;;:T;i:ig2:ttrx,i,:i;;J:";xi,3:sfortheMiningtndustry,.
, mm (0.5x2x2.I2S in.).
I aa
,,t
I
ili
ri
H^[oilEss.
I
'tv3o
Fig' 82' Typical values oi co¡npressiu:
strength versus hardness Íor a serles
obtained from J'L' Parks' 'cnáracter¡stis ot high-cr AR irons.(Flgure i
iíiiast
Motybdenum white trons ¡or rn¡cx_secaiiáiJ¡ii, a!1s_ub*ittcany Heat-Treated High-chromiim'-
ers rnniait¡iíi,.lJt. *, pp. ss_t02, tsTB).
Appendices
181
(Appendix B, Mechanical & Thermophysical Properties,
High-Chromium AR Cast lrons, continued)
I I I rl tt
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-áo',
lr9
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lr5
lr4 \# 1,?
lr§
1) l5
2-0 Jr0 '/oC w ,0 .hct,
Ftg. 84. Elastic modulus (GPa 100) in high-Cr irons, as a lunction of composition and tempereture
(eft, carbon; right, chromium). (Data obtained from Typical room temperuture values lrom p.E.
Belyakova, et al., "Themophysical Properties ol Wear-Resisting Cast lrons,- translated from
Metallovedenie i Termlcheskaya Obrabotka Metallov, No. 12 pp. /r,4g, t97S).
resistance. i
il
tl
it rotares ar 20 rpm and fravels a linear distance
9::bü,
(504 in.) in seven minutes. At the end
of 12.g0 m
of this test, the pin is weighed. I
Appendices
183
(Appendix C, General Mechanical & Wear Properties, mentioned. This is a shame, considering the sensitivity of wear I
Diesburg & Boric, continued) resistant cast irons to surface flaws. Consequently, the numbers
quoted in Table C3 forcompressive and bend strength should be used I
Table Cl
Type and Composition ol lrcn and Steel AlloysQ)
Code
No. lrons c Mn Si Gr N¡ Mo Other
50 2Cr-4Ni 3.19 0.64 0.57 2.20 3.94 0.031 0.033
51 9Cr-6Ni 3.42 0.67 1.61 8.64 6.17 0.029 0.036
52 12Cr-1Mo-1Cu 3.25 0.70 0.62 12.7 0.68 1.20
53 15Cr-3Mo 2.51 0.80 0.47 14.7 2.62
54 15Cr-3Mo 3.59 0.8 0.4 15.0 2.6
55 15Cr-3Mo 3.60 0.8 0.4 15.0 2.6
56 15Cr-3Mo 3.60 0.84 0.42 14.95 2.62
57 15Cr-3Mo 3.60 0.8 0.4 15.0 2.69
58 15Cr-3Mo 3.60 0.8 o.4 15.0 2.60
59 15Cr-3Mo 3.60 0.85 0.42 14.96 2.61
60 15Cr-3Mo 3.68 0.8 0.4 15.0 2.6
61 15Cr-3Mo 3.62 0.8 0.4 15.0 2.6
62 15Cr-2Mo-1Cu 3.25 0.66 0.49 15.12 1.95 ooan *rn *r",
63 17Cr-1 .5Mo-1Cu 1.23 0.70 o.47 17.69 1_49 0.044 0.025 1.08Cu
64 17Cr-1 .SMo-1Cu 1.83 0.74 0.46 16.95 1.56 0.040 0.029 1 .1OCu
65 17Cr-1 .5Mo-1Cu 2.43 0.75 o.47 16.99 1.58 0.040 0.029 1.00Cu
66 17Cr-1 .5Mo-1Cu 3.01 0.75 0.44 17.06 1.60 0.040 0.029 1.06Cu
67 17Cr-1 .SMo-1Cu 3.65 o.76 0.s0 17.35 1.60 0.039 0.025 1 .1 3Cu
Steels c Mn S¡ Cr N¡ Mo P S Other
7 T-1 Wrought Steel 0.19 0.84 o.28 0.56 0.18 o.oil 0.021 0.02T¡, 0.05v, 0.00328
21 Cr-Ni-Mo Wrought 0.27 1.0 3.0 2.0
22 Alsl4340 0.40 0.7 0.3 0.8 1.8 0.25
30 Cr-Mo Cast Steel 0.88 0,95 0.72 2.44 0.35 o.o27
31 AlSl H-1 1 Tool Steel 0.35 5.0 1.5 0.4v
41 12Mn (0.95C)
Cast Austenitic Mn 0.93 12.97 0.50
44 12Mn (1.1C)
Cast Austenitic Mn 1.1 12.5 0.5
(1) D¡esburg and Borik, 1974.
Appendices
FE_-_
(Appendix C, General Mechanical & Wear Properties,
Diesburg & Boric, continued)
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Fig. Clb. Relationship between resistance to gouging
Carbon Content, %
abrasion and toughness of various materials. Area A =
Fig. CIa. Relationshlp between gouging wear ratio (a severe wrought and cast low-alloy steels; Area B = austenit¡c Mn
abrasive wear test) and the C content of various Upes of steels; Area C = vafiety oi heat-trcated steels; Area D = high-Cr
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speclilc lrons and steels provided in Tables C|, C2 and C3, and steels provided in Tables Cl, C2 and C3, authored by
duthored by Diesburg and Borik (1974). Diesburg and Borik (1974).
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Appendices
C, continued)
rotated against acopper trackwithin a mixture of water and abrasive.
]lrdness and Abrasion Resistance
The sample is pushed against the copper track under a nominal
Atqt Q974) pressure of 54 psi (0.4 MPa) with a velocity of 119 fl/sec (0.60 m/
H§- Avery's work ("Work Hardening in Relation to Abrasion sec). The sample is immersed in a slurry of 0.641100 by weight or
Resistance ," in Symposium Materialsfor the Mining Industry , Y a7l, O.Z.llOOby volume of sand to water. The test is run for 60 minutes
Colmado, pp. 43-78, 1974) represents another great compilation of and üe sample weighed. The wet sand abrasion factor (WSAF) is
ffiess and abrasion dataforAR steels andirons. Ofparticularnote then computed. A low value implies high abrasion resistance.
is his comparison of the hardness and abrasion resistance of castings
One of the interesting features of Avery's workis the comparison
having different section sizes (i.e., having fine- and coarse-grained
between thick- and thin-section castings. Tables C4 and C5 present
*r¡ct¡¡e,s). Aportion of his workis summarized in Tables C4 and C5
part of the data compiled by Avery. In all cases, the best abrasion
mdEg. C2.
resistance is on the surface of the casting. This effect is most
The abrasion test usedby Avery was developed at Abex Corpo- pronounced for heavy-section castings. Some alloys are more sensi-
raion and is known as the wet sand abrasion test. The sample is tive to this thickness effect than are others.
Table C4
Compos¡tion and HeatT,eatment of Grinding Mill Alloydr)
ASTM A- Heat
o/"Ct o/"Mo o/oNi
lEm Type 532 Grade o/oC %Mn %si Treatment
14 19Cr-Ni-Mo
(underalloyed) ID 2.47 0.75 0.62 19.8 0.73 0.73 AH2
15 19Cr-Ni-Mo
(overalloyed) ilE 2.83 0.71 19.5 1.24 1.24 AH2
Table C5
Abrasion Reslstane or rhin and rhick sections of Grinding
Milt Lrner castingsÍ,)
Thin Section
Th¡ck Sect¡on
2-12lo 3 ¡n. (65 to 75 mm) Thick $1 D,lo 6-1 D in (t t 5 to 1 65 mm)
Liner Surface lnter¡or
Item Type Typetzl HRC HB WSAF HRC HB WSAF HRC HB
Surface lnterlor
WSAF HRC HB WSAF
1 Aust. 13 Mn
Expectancy is 0.80
2 Pearlitic Cr-Mo
36 345 0.64
3 Pearlitic Cr-Mo
4
36 370 0.62
Mart. Cr-Mo
Expectancy is 0.71
5 Ni-Hard B 62 667 0.52 ;;; ;;; 59 600 0.56
b Ni-Hard B 52 447 0.58 51 447 0.63 52 447 0.63 49 460 0.69
7 NFHard B 59 613 0.60 56 55s 0.69 59 613 0.59 56 555 0.67
I HC-250 A 57 555 0.46 57 555 0.49 57 555 0.52 50 477 0.80
I HC-250 A 63 633 0.46 62 667 0.49 62 683 0.45 62 675 0.64
10 15-3 A 48 460 0.81 47 M4 48 460 0.81
0.86 46 444 0.87
11 15-3 A
60 652 0.77
12 Paraboloy A 60 600 0.36 58 555 0.39 63 652 0.s6 61 627 0.42
13 Paraboloy A 63 652 0.35 63 627 0.38 63 667 0.33
14
63 627 0.49
19Cr-Ni-Mo
(underalloyed) A 63 652 0.45 63 652 0.44 63 652 0.58 62 627 0.60
15 19Cr-Ni-Mo
(overalloyed) B 65 685 0.35 64 652 0.43 64 683 0.37 64 652 0.53
16 Paraboloy C 65 713 0.34 64 713 0.37 65 713 0.37 64 698 0.49
17 Paraboloy B 61 600 0.42 61 600 0.46 60 578 0.41 61 627 0.45
l8 Paraboloy A 61 627 0.39 61 627 0.41 62 627 0.40 62 627 0.46
HRC = pl66¡y¡y¿ll, C-scate hardness; HB B¡i¡s¡¡ ¡1¿rdness;
= WSAF = Wet Sand Abrasion Factor
(1) Avery, 1974.
2rAin,
(65mm)
_t
Block Type Shell Liner
T Weight
49o lb (22o ks)
19t¿ in.
(49Omm)
Slor Speed
Single Wave Shell
SingleWaveShell Liner 4%in.
(rl0mm)
H
TypeB (125to165mm)
____.-=l_
| l99l in._
' (490 mm)
3 in.
Length 3 ft (915 mm) Hg. C2. Schemafic ol Type A, Typ B and
Length 23tlz in. (595 mm) (75 mm)
We¡sht615to 820tb weight 3¡lo lb (155 kg) Type C shell liners studied.
Results are contained ln Table CS, above.
Append¡ces
( App endix C, c ontinued)
Table CG
Alloy Composition (Wto/o) and Abrasion Test Datao)
(1) 9are,1979.
crackguidirE
groow
width t
propagating creck
front
initiat¡ng notch
P P
2 2
1)Double-Torsion Bend Test: Samples were cast to size, surfaces ground flal, and the crack-
guiding groove and in¡tiat¡ng notch were machined.
€ RubberWheel Abrasive WearTest; All tests were conducted using -1 00, +150 mesh SiC
gr¡1.Results are reported as the weight loss of the m¡ld steel standard d¡vided by the weighl
loss of the wear test specimen.
N¡Cr4 a As cast
NiCr 1 a 719 1.32+0.06 25.6
b 4hr,1472F (800C); AC
b 691 1.38t0.06 26.2
Ni-Cr-Mo steel B b 1 796F (980C); AC; 6 hr, 608F c 7O4 1.¿14+0.06 26.2
(320C);AC
Ni-Cr-MoSteel A b 540 88.5
Ni-Cr-Mo steel C b 1 724F (940C); OQ; 6 hr, 608F
(320C);AC Ni-Cr-MoSteel B b 493 70.1
Appendlces 193
Appendix D the spherical projectile used in the indentation process. The reported
ha¡dness value is derived from the impact (V¡-ou") and rebound
Hardness Measurements (V,"¡orn¿) velocities of a spherical indenter as:
o
Fl ü
Z7//\D,
r%;/tt////t
. . - //////,/////al
Tabte Dl
Genera I ized Co m pa ri so n ot
Errorc in Hardness Measurementdt)
Tabte D2
Hardness Conversion Equations
Equation
Range 12lErroft)
Equotip (Lp):
L¡{z) -396.U+0.626.HB 340-700 HB 0.976 & +9.5 Lo
Lp{z) = 499.6 + 0.0848 . HRC(s)
34.H1.1 HRC 0.967 & 11 1.0 Lo
Brinell (tO/3000):
I
I I I
f 4Éf'
i ¡
55 I
I
-'j-
I
t
'.
.:
r
I
¿
¡
I
I
J
800
rso
o .d
Íso t I I
I o
-l- J. -!
r 700
ul
v/
I
45 I
65(t
I
I
/ f,
4
/a(¡
_ _¡_ -t- I
I I
35 t
300 350 ¡¡00 ¡rg, 500 550 600 650 700 750 800 300 350 400 450 500 550 6{¡0 650 700 750 800
HB HB
Ftg. Its- Comparison oi curue-fitting errors between HB and Fig. D4. Comparison of curue-fitting errors between HB and Lp
,lRC &ta. data.
Table D3
Approximate Hardness Conversion Data ior AR White Cast lrons
Eqwtip Lo to B¡inell and Rocl<well C Hardness Numbers: Brinell Hardness to EquotiP Lo and
Rocl<well C Hardness Numbers:
Equo- HB Rock- Equo- HB Rock-
üp Lo 10/3000 well C tip Lo 10/3000 well C HB Equo- Rock- HB Equo- Bock-
10/3000 tiP, Le well C 10/3000 tiP, Lp well G
820 700 61.7 700 513 50.3
700 819 61 .1 500 694 49.3
810 685 61.0 690 497 49.1
680 806 60.2 480 681 47.7
800 669 60.2 680 482 47.8
660 794 59.2 460 669 46.1
790 653 59.4 670 466 46.5
640 781 58.2 440 656 44.4
780 638 58.5 660 451 45.2
620 769 57.2 420 644 42.6
T?O 622 57.7 650 435 43.8
600 756 s6.0 400 631 40.8
760 607 56.7 640 419 42.4
580 744 54.8 380 618 38.9
750 591 55.7 630 404 41 .0
388
s6o 731 53.s 360 606 36.9
740 575 54.7 620 39.5
593
540 719 52.2 340 34.9
730 560 53.7 610 373 37.9
520 706 50.7
720 544 52.6 600 357 36.4
48 482 685
(1) Brinell numbers above 630 are not recommended by ASTM. 1000 857(1) 70 680 576 57
Neveñheless, Brinell numbers up to 700 HB are industrially
accepted.
980 840 69 660 558 56
Testins Int., vol 12, pp. 274-278 (1979). 700 593 58 380 312 35
Parks, J.L., Relationships Between Brinell, Rockwell C and Vicke¡s Hard-
ness Values for AlloyedWhite Irons, AFS Transactions, vo1. 81, pp. 195- (1) Brinell numbers above 630 are not recommended by ASTM.
202 (1979). Nevertheless, Brinell numbers up to 700 HB are industrially
Tabo¡, D., The Hardness of Metals, Clarendon Press, Oxford, U.K. (1952).
Appendices 197
Appendix E
Standards Table E8 presents the specifications for the new European Stan-
dard EN I 2 5 1 3, which has been issued and will probably be effecüve
Worldwide specifications are presented in Tables El through E7 from 2001 onward. From then on, all national standards of the EU
(currentas of 1999). These tables shouldbeviewed as agood starting member countries will not be officially valid anymore. Table E9 is
point and not the final word. a synoptic table, showing the comparisons of EN and ASTM grades.
Table E1
National Standard Designations Correlatlng Nearest Equivalent Gndes
1A 1
1B 2
1C 3
Ni-Hard Type 2 FB Ni4 Cr2 BC G-X 260 NiCr 4 2 2A Type 1a. NiLCr 30/500 05 12 Class l, Type B
Ni-Hard Type 1 FB Ni4 Cr2 HC G-X 330 NiCr 4 2 2B Type 1a. NiLCr 341550 05 13 Class l, Type A
Ni-Hard Type 3 FBA Class l, Type C
Ni-Hard Type 4 FB Crg Nis G-X 300 CrNiSi 9 5 2 2C +2D +2E Type 1b. NiHCr 04 57 Class l, Type D
FB Cr15 Mo Ni c-X 300 CrMo 15 3 3A Type2. CTMoLC 281500 Class ll. Type B
G-X 300 CrMoNi 15 2 'l 3B Type2. GTMoHC 34/500 Class ll. Type C
Table E3
Germa ny Speclfi catio n s
-
Appendices
199
(Appendix E, Standards, continued)
Table E4
United Kingdom Specifications
-
Speci-
fication compos¡t¡on |l¿¡d¡sss(t)
No. Grade c Si Mn --chemical
N¡ Cr Mo Cu P."t S.", HB, min
BS 4844 2A 2.7-3.2 0.3-0.8 0.2-0.8 3.0-5.5 1.5-2.5 0.5 max 0.3 0.15 500
Part2-. 28 3.2-3.6 0.3-0.8 0.2-0.8 3.0-5.5 1.5-2.5 0.5 max 0.3 0.15 550
1972 2C 2.4-2.8 1.5-2.2 0.2-0.8 4.M.0 8.0-10.0 0.5 max 0.3 0.15 500
2D 2.8-3.2 1.5-2.2 0.2-0.8 4.H.0 8.0-t 0.0 0.5 max 0.3 0.15 550
2E 3.2-3.6 1.5-2.2 0.2-0.8 4.H.0 8.0-10.0 0.5 max 0.3 0.15 600
BS 4844 3A 2.4-3.0 1.0 max 0.5-1 .5 0.-1.0 14.0-17.0 0.0-2.5 0.0-1 .2 0.1 450 (as-cast)
Part 3: 3B 3.0-3.6 1.0 max 0.5-1 .5 0.-1 .0 14.0-17.O 1.0-3.0 0.0-t.2 0.1 500 (as-cast)
1974 3C 2.2-3.0 1.0 max 0.5-l.5 0.-1.0 17.0-22.0 0.0-3.0 0.0-1.2 0.1 450 (as-cast)
3D 2.4-2.8 1.0 max 0.5-1 .5 0.-1.0 22.0-28.0 0.0-t.5 0.0-1 .2 0.1 400 (as-cast)
3E 2.8-3.2 1.0 max 0.5-1 .5 0.-1.0 22.0-28.0 0.0-1 .5 0.0-1 .2 0.1 450 (as-cast)
(1) Part 1 : ln castings with a section thickness of greater than 50 mm (2.0 in.), HB may be 50 less than spec¡f¡ed.
Part 2: ln cast¡ngs with a section thickness of greater than 125 mm (5.0 in.), HB may be 50 less than spec¡f¡ed.
Table E5
lndia Specifications
-
Specifica- Chemical Gomposition, o/- HB, mi¡(t)-
tion No. Grade s¡ Mn Ni Cr Mo Sr", P.r, As-Cast
-Hardness,
Hardened Annealed
-
154771 Type la
1972 NiLCr 30/500 2.7-3.3 0.3-0.6 0.3-0.6 3.0-5.5 1 .5-2.5 0.5 max 0.1 5 0.3 500
NiLCr 34i550 3.2-3.6 0.3-0.6 0.3-{.6 3.0 -5.5 1 .5-2.5 0.5 max 0.15 0.3 550
Type lb
NiHCr 271500 2.5-2.9 1.5-2.2 0.3-0.6 4.H.0 8.0-10.0 0.5 max 0.15 0.3 500
NiHCr 30/550'- 2.8-3.3 1.5-2.2 0.3-0.6 4.0-6.0 8.0-10.0 0.5 max 0.15 0.3 550
NiHCr 34/600 3.2-3.6 1.5-2.2 0.3-0.6 4.0-6.0 7.5-9.5 0.5 max 0.15 0.3 600
Type2
CTMoHC 341500 3.'l-3.6 0.3-0.8 0.4-0.9 0.5 max 14.0-18.0 2.5-3.5 0.15 0.3 500 600 380 max
CTMoLC 28/500 2.4-3.1 0.3-0.8 0.4-0.9 0.5 max 14.0-18.0 2.5-3.5 0.15 0.3 500 550 380 max
Type 3
HCrNi2T/400 2.3-3.0 0.2-1.5 1.5 max 1.2 max 24.O-28.O 0.6 max 0.15 0.3 400 550
HCt 27l4OO 2.3-3.0 0.2-1.5 1.5 max 0.5 max 24.0-28.0 0.6 max 0.15 0.3 400 550 380 max
(1 ) lS 4771 - 972 for castings with a sect¡on thickness greater than
1 125 mm (5 in.), HB may be 50 less than specified.
(2) lS 7925 - 1976 composition is specified; purchaser can request specified hardness vatues.
Table E7a
U.S.A. - ASTM A 532 / A S32M - l99g Compositionat Specificat¡ons
Composition, ol
class Type llesignation c Mn s¡ Ni cr Mo cu p s
I A Ni-Cr-HC 2.8-9.6 2.0 max 0.8 max 3.3_S.O 1.44.0 1.0 max 0.3 max 0.15 max
-Chemical
I B Ni-cr-LC z.r-3.0 2.0 max 0.8 max 3.3-5.0 1.H.0 .r.0 max 0.3 max 0.15 max
I C N¡-Cr-GB 2.5-g.Z 2.0 max O.g max 4.0 max .O_2.5 .O max 0.3 max 0.1 5 max
1 1
I D Ni-HiCr 2.5-3.6 2.0 max 2.0 max 4.5_7.0 7.0_1 1.0 1.S max O.1O max 0.15 max
ll A 127" Ct 2.0-3.3 2'0 max 1.5 max 2.5 max 11.0-14.0 3.0 max 1.2 max o.1o max 0.06 max
ll B 15olo Cr-Mo 2.0-3.3 2.0 max 1.5 max 2.5 max 14.0-18.0 3.0 max 1.2 max 0.10 max 0.06 max
ll D 20o/" cr-Mo 2.0-3'3 2'o max .o-2.2 2.5 max 18.0-23.0 3.0 max .2 max 0.10 max 0.06 max
1 1
lll A 25o/o cr 2.0-3.3 2.0 max 1.5 max 2.5 max 23.0-30.0 3.0 max 1.2 max 0.10 max 0.06 max
Designation: HC = high carbon; LC = low carbon; GB Great Britain
=
Table E7b
U.S.A. - ASTM A 532 / A gg2w - t99J Hardness Requirements
Appendices
201
Table E8
AR White Cast lrons According to European Standard 12 513
of
Designation ChemicalComposition % (Mass Fraction) Vickers
(r)
Mat'|. Gracles (Contents are max. unless range is indicated) Hardness
Symbol Number C S¡ Mn P S Cr N¡ Mo Cu HVm¡n
High-Chromium: (2,a,+)
EN-GJN- EN-JN
HV600(XCr11) 3019 1.8-3.6 1.0 0.5-1.5 0.08 0.08 11.0-14.0 2.0 3.0 1.2 600
EN-GJN. EN-JN
HV600(XCr14) 3029 1.8-3.6 1.0 0.5-1.5 0.08 0.08 14.0-18.0 2.0 3.0 1.2 600
EN-GJN- EN.JN
HV600(XCr18) 3039 1.8-3.6 1.0 0.5-1.5 0.08 0.08 18.0-23.0 2.0 3.0 1.2 600
EN-GJN- EN.JN
HV600(XCr23) 3049 1.8-€.6 1.0 0.5-1.5 0.08 0.08 23.0-26.0 2.0 3.0 1.2 600
NickeFChromium: (2,+)
EN-GJN- EN.JN
HV520 2029 2.5-3.0 0.8 0.8 0.10 0.10 1.H.0 3.0-5.5 520
EN-GJN. EN-JN
HV550 2039 3.0-3.6 0.8 0.8 0.10 0.10 1.5-3.0 3.0-5.5 550
EN-GJN- EN-JN
HV600 2049 2.5-3.5 1.5-2.5 0.3-0.8 0.08 0.08 8.0-10.0 4.ffi.5 600
(z)
Unalloved o¡ Low-Alloy Chilled lron:
EN-GJN- EN-JN
HV350 20 tg 2.+-3.9 0.¿t-1 .5 0.2-1 .0 2.0 350
(1) The material designation by symbol is in accordance with EN 1560 with additional information in brackets regarding their chemical
composition. The material designation by number is in accordance with EN 1560
(2) Both toughness and resistance to repeated impact increase as the catbon content decreases.
(3) The microstructure of high-Cr AR cast irons depends on the cool¡ng rate and is therefore sensitive to the casting thickness. To obtain
specific properties (within the ranges in this table) some adjustments to the percentage contents of the alloying elements given may
be necessary, depending on the casting dimensional variations.
(4) ln the case of castings with low alloy contents supplied in the as-cast condition and castings with greater thicknesses, it can be difficuft
to obtain the minimum hardness. The requirementsfor such castings should be agreed on between the manufacturer and the purchaser.
Table Eg
Comparison ol EN and ASTM Grades
and Common Tradenames
Trade-
EN 12 513 Number ASTM A532 name
EN-GJN-HV35O EN-JN2O19
For metallographic purposes, our preference is to EDM a small- It should be kept in mind that there is no one . right, way to
diameter cylinder (i.e., 5 mm/0.25 in. dia by 25 mm/1.0 in. long) metallographically grind and polish samples. This brief section is
using a graphite/copper thin-wall tube electrode. This small cylinder merely meantto illustrate one popular technique thathas been shown
can then easily be sectioned using a high-speed abrasive wheel, and to be effective for AR cast irons.
mounted in BakeliterM orepoxy for subsequentpolishing. Figure Fl
shows a photograph of how such a sample would be mounted.
Table Fl
General Metallographlc Etchants to Reveal WhiE lron Microstructures
2o/" nilal 2 ml HNOg,98 ml ethyl Swab from a few Good general etchant for
or methyl alcohol (95o/o or to 1 5 seconds Ni-Hard 1, 2 and4 alloys.
absolute; also amyl alcohol) to reveal structure. Gives maximum contrast between pearlite
and other phases. ls not recommended for
as-cast high-Cr irons or other austenitic or
ferritic grades of AR cast irons.
(1) Any of these etchants can be used to reveal m¡crostructure.
Appendices
203
( App endix F, c ontinue d )
Table F2
Specific Metattographic Etchants to Reveal Various Carbide Structurcs
(2) This stain does a superb job differentiating between the various carb¡des, especially the MsC and MTCa
types.
Table Fg
Mesh and Grit Sizes for Abrasive Particles
60 270 -FEFPA(í)--
274
80 190 194
150 80 97
180 70 81
220 62 58
280 35 41 41 .5 52.2
Fig. Fl. Photograph showing a prcferred method for 600 17 20 14.3 22.8
sectioning and mounting a 5x25 mm (0-25x1.0 in-) pin (1) Federat¡on Europeane des Fabriacants des Produits Abrasifs.
in Bakelite or epory.
Appendix G
Calculating Superheat for AR Cast Irons Table Gl gives the applicable chemiskies and base equations
used to generate the subsequent superheat tables. Tables G1 andG2
The purpose of this section is provide quick reference tables for are specified by the iron's base chromium content. For irons that fall
calculation of liquidus start temperatures for standard commercial outside of this Cr content, liquidus temperatures can be direct§
grades ofAR cast irons. All equations were derived from the data calculated based on the Fe-Cr-C ternary phase diagram provided in
provided in A¡nold and Sare, "A Thermal Analysis Study of Alloy Chapter 2, Solidification. Table G2 will provide the austenite liquidus
White Cast kots," The Foundryman, vol. 80, pp. 330-335 (1987). temperatures.
Table Gl
Applicable Chemistries and Superheat Equatlons for Typical AR Cast lrondt)
@) The 25% Cr iron has a very broad eutectic valley. According to Arnotd and Sare (1987), the eutectic valley
stretches from 2.8 to
Tabte G2
Approximate Austenite Liquidus Temperatures in "C (F)
carbon Ni-Hard 1 & 2
o/o Ni-Hard 4 ASTM !l B, 15yo ct cr
ASTM ll D,2oo/o ASTM lll A,25o/o Ct
1.*2.5o/o C¡ .H.oo/o c¡
7 14.0-16.0ol" Cr Cr
, l 8.0-20.0% 24.É26.,0o/o ct
2..... ....1315(2400) . ..1340(2444). ...1325(24't6) . ..1335(2435)
2.1 .....1s07(238s) . ..1332(2430). ...1319(2405) . ..1328(2422)
2.2... ....1298(2369). ..1324(2415). ...1s12(23e5). ..1320(2408)
2.3 ... . "..1290(2354) . .. 1316 (2401) . ...1306(2384) . .. 1313(239s)
2.4......:..- ....1281(2339). ..1308(2386). ...1300(2s73). ..1305(2381)
2.5... 1320(2408) .1273(2323) ....t300(2372). ...12s4(2s62). ..1298(2368)
2.6... 1311(2391) .1264(2308) ...12s2(2358). ...1288(2351). ..1290(2s54)
2.7... 1301(2374) .1256(2293) ...1284(2343). ...1282(2340). ..1283(2341)
2.8 ... 1292(2357) .1247(2277) ...1276(2329). ...1276(232e). ..1275(2327)
2.e... 1282(2340) .1239(2262) ...1268(2314). ...1270(2s18)
3..... 1273(2323) .1230(2247) ...1260(2300). ...1264(2307)
3.1 ...1263 (2306) . 1222(2231) ... 1252(2286) . .. . 1258 (22e6)
3.2... 1254(2285) .121s(2216) ...1244(2271). ...1252(2285)
3.3... 1244(2272) .1205(2200) ...1236(22s7). .._1246(2274)
3.4... 1235(2255) .11e6(2185) ...1228(2242). ...1240(226s)
3.5 ... 1226(2238) .1187(2170) ...1220(2228)
3.6 . . . 1216 (2221) .117s (2154)
3.7 . . . 1207 (2204) .1170 (213s)
3.8 ... 1197(2187)
3.s ... 1188(2170)
4..._. 1178(2153)
4.',1 ...1169(2136)
4.2 ... 1160(21 19) t
4.3 ... 1150(2102)
Appendices 205
Appendix H Multiple-linear regression analysis was used to describe correlation
between chemistry, pouring temperature and fluidity. When datawas
Fluidity Measurements grouped into sufficiently narrow ranges ofcomposiúon, the resulting
equations showed outstanding predictive capability. For ease ofuse,
This appendix was developed from work authored by B. T Hodge of
these equations are presented in a format that allows the calculation
the Durametal Corporation in Muncy, Pennsylvania in cooperation
of fluidity based on pouring temperature and chemistry.
with the AFS 5-D Technical Committee. The complete work can be
found in AFS Trans actions, vol. 107, pp. 7 43-7 49, 1999. Table Hl gives a list of the raw data collected during this
experiment. A total of 41 spirals were poured. Chromium content of
An alloy's fluidity is often thought of as a physical property,
these alloys ranged from lVo to 39Vo. For brevity, phosphorus and
much akin to its liquidus and solidus temperatures. In foundry
practice, fluidity has no simple clean definition. Over the years, an
sulfur are not included in the report. However, in all samples,
phosphorus was below 0.057o. Sulfur was not reported for all
alloy's fluidity has come to denote its ability to flow within the
samples, but is assumed to be below the limits specified in ASTM
confines of a narrow horizontal channel. This foundry definition has
4532.
little to do with the more classical definiüon of fluidity as the
reciprocal of viscosity. For example, molten steel's viscosity varies The information in this Appendix should be useful to foundrymen
only slightly with temperahfe yet its fluidity is known to vary who must make castings with abrasion resistant i¡ons. It would be
significantly with temperature (SCRATA). most desirable to predict the fluidity of an al1oy in the simplest
possible way. An initial attempt was made to correlate fluidity to
When foundrymen ask about an alloy's fluidity, they want know
superheat and freezing range, because they have an intuitiverelation-
how the alloy will flow or, more directly, whether or not it will fill
ship to fluidity. Superheat (temperature above freezing point) would
their mold. To address these concerns, the concept of maximum
seem more directly related to fluidity than absolute pouring tempera-
fluidity length (Feliu etal.,1962) was developed to quantitatively
ture. Freezing range (liquidus minus solidus temperatures) would
indicate the maximum distance the metal can flow within a channel.
seem to be a good indicator of how close the composition is to a
In the tests described in this report a standard fluidity spiral (AFS,
eutectic "spike" in the fluidity curve. This approach also helps solve
1989) is used to measure this maúmum fluidity length (Fig. H1).
the rather messy problem one has to deal with by having so many
This length is then reported as üe fluidity of a specific abrasion
elements of significance in AR iron compositions; they are all
resistant cast i¡on.
factored in to the liquidus and solidus temperatures.
Fluidity measurements were made on a wide range of abrasion
There remains the problem, however, of determining liquidus and
resistant irons. Most of the samples have compositions which fall
solidus temperatures. Few, if any, production foundries have DTA
within the range of the grades listed in ASTM 532 (1993). However,
equipment to determine liquidus and solidus temperatures. Litera-
some samples were nonstandard compositions. Measureme[ts were
ture is available that can be used to determine liquidus and solidus
made at participating foundries under foundry conditions using sand
temperatures from C and Cr composition (Arnold and Sare, 1987).
molds created from the same fluidity spiral pattern that was passed
However, many of the 4532 grades contain significant amounts of
from foundry to foundry.
elements other than C and Cr. This approach would also require a
Foundries participating in üe project include: Durametal Corpo- three-step process for üe foundryman to determine fluidity: (1)
ration, Muncy, PA, Eagle Foundry Co., Eagle Creek, OR, Columbia determine liquidus and solidus temperatures from composition; (2)
Steel, Portland, OR, Weatherly Casting and Machine Co., Weatherly, determine freezing range and superheat; and (3) determine fluidity.
PA, Texaloy Foundry, Floresville, TX, and GIW Industries, Inc.,
Grovetown, GA. Additional technical and analytic support was After additional analysis, it was determined üat correlation as good
provided by the National Research Council, Albany, OR, Climax or better could be obtained directly by using chemis§ and pour
Research Services, Farmington Hills, MI, and Predictive Engineer-
temperature as independent variables, and fluidity as the dependent
Table Hl
Expefimental Raw Data
SL
Fdy. Alloy c Si Mn Cr Mo N¡ Cu PT LT ST (inJ
1 A iltA (1) 2.52 0.74 0.72 28.18 0.650 0.770 0.070 1498 1283 1272 30.0
2 A iltA (1) 2.52 0.74 0.72 28.18 0.650 0.770 0.070 1509 1283 1272 35.5
3AIIE 3.09 0.64 0.66 20.05 1 .980 0.1 80 0.970 1461 1255 1238 33.5
4AIIE 3.09 0.64 0.66 20.05 1 .980 0.180 0.970 1462 1255 1238 34.0
sAIIE 3.09 0.64 0.66 20.05 1.980 0.180 0.970 1472 1255 1238 35.5
6 A iltA (2) 2.85 0.68 0.66 25.69 0.210 0.300 0.100 1468 1285 1268 30.0
7 A iltA (2) 2.85 0.68 0.66 25.69 0.2't0 0.300 0.100 1492 1285 1268 30.0
sAIA 3.28 0.64 o.41 2.11 0.190 4.420 0.044 1426 1240 1120 29.0
9AIA 3.28 0.64 0.41 2.11 0.190 4.420 0.044 1445 1240 1120 30.5
10 B iltA 2.59 0.86 0.96 26.21 0.260 1.060 0.120 1452 1268 1260 32.5
11 B iltA 2.59 0.86 0.96 26.21 0.260 1.060 0.120 1443 1268 1260 28.5
12 B iltA 2.59 0.86 0.96 26.21 0.260 1.060 0.120 1375 1268 1260 22.5
13 B iltA 2.59 0.86 0.96 26.21 0.260 1.060 0.120 1333 1268 1260 17.5
14 B Non-Std. 3.96 0.6 2.63 39.09 0.330 0.500 0.044 1518 1399 1269 10.0
15 B Non-Std. 3.96 0.6 2.63 39.09 0.330 0.500 0.044 1474 1399 1269 6.0
16 B Non-Std. 3.96 0.6 2.63 39.09 0.330 0.500 o.0M 1401 1399 1269 3.5
17BID 3.24 1.92 0.59 9.15 0.270 5.520 0.260 376 1203 1168 35.5
18BID 3.24 1.92 0.59 9.15 0.270 5.520 0.260
1
20c IA 3.74 0.57 0.45 1.85 0.320 3.350 0.046 1383 1200 1110 29.0
21 C IA 3.74 0.57 0.45 1.85 0.320 3.350 0.046 1 509 1200 1110 42.5
22C IA 3.74 0.57 0.45 1.85 0.320 3.350 0.046 1489 1200 1110 41 .0
23C IA 3.64 0.53 o.M 1.86 0.280 3.440 0.055 1431 112s 1066 32.0
24C IA 3.64 0.53 0.44 1.86 0.280 3.440 0.055 1424 125 066 31 .5
25C IA 3.64 0.53 0.44 1.86 0.280 3.440 0.055 1297
1 1
Appendiccs
207
Bibliography 45.0
40.0
Arnol( B.K., Sa¡e, I.R., 'AThermal Analysis Study of Alloy White Cast 35.0
ko¡s," The Foundryman, vol. 80, pp. 330-335 (1987). 30.0
ASTM A532-93, Standard Specifications for Abrasion- Re sistant Cast lrons, =
E 25.0
Arerican Society for Testing and Materials, Philadelphia, PA (1993). o 20.0
J
Feliu S., Graphs of Flow, AFS Transactio¿s, vol. 70, pp. 838-844, 1962. E 15.0
Fluidity of Ste€l, SCRATATech. Bull. No. 5, p.3. o
o
1o.o
Metalcaster's Reference and Guide, American Foundrymen's Society, Inc.,
Des Plaines, tr-, p. 407, 1989. 5.0
oo
1250 1300 1350 1400 1450 1500 1550
Pour Témp {C)
Fig. H2. Line ftt plot of spiral length vs. pour temperature fot
14o/o Cr irons.
Table H2
Regression Analysis for 14% Chromlum lrons
Regression Stat¡stics:
MultipleR..... 0.975406901
RSquare .....0.951418623
Adjusted RSquare .....0.924919691
Standard Error .. ......2.422201474
Observations . .. .. .. ... 18
ANOVA:
df SS MS F Significance F
Regression 6 1263.906785 210.651 1 35.90404 1.33687E-06
Residual 11 64.53765981 5.86706
Toial 17 1328.M4444
'Íl
t;l
llr
,.
.'ii
ili
208 Ab¡asion-Resistant Cast lron Handbook 'tt
1i
l
t¡
tli
( App endix H, c ontinue d )
Table H3
Regression Analysis for 7-15% Ch¡omium
Regression Statistics:
MultipleR.... 0.967534544
R Square 0.9361 23093
Adjusted R Square 65535
Standard Error . .
Observations
ANOVA:
df ss MS F Significance F
Regression 6 699.9526098 1 16.6588 0 #NUM!
Residual O 47.76167599 65535
Total 6 747.7142857
RESIDUAL OUTPUT:
Predicted Actual
Observation Length (in.) Length (in.) Difference
1 33.1 30.0 -3.1
2 12.9 16.0 3.1
3 35.0 35.5 0.5
4 12.6 12.5 -0.1
5 9.9 9.5 -0.4
6 25.2 29.0 3.8
7 11.8 8.0 -3.8
Appendices
209
Table H4
Begresslon Analysts lor 20-39% Chromlum
Regression Statlst¡cs:
MultipleR.... .0.990691769
RSquare .....0.981470182
AdjustedRSquare ......0.96911697
Standard Error .. ......1.957821908
Observations ".........16
ANOVA:
df SS MS F Significance F
Regression 6 1827.236775 304.5395 79.4506'f 2.78228E-07
Residual I 34.49759962 3.833067
Total 15 '1861.734375
I
t
I RES¡DUAL OUTPUT:
* Pred¡cted Aqtual
ü Observation (in.) !.€ngth (in.)
Length Diflercnc€
1 11 .4 10.0 -1 .4
2 7.4 6.0 -1.4
3 0.8 3.5 2.7
4 16.2 16.5 0.3
5 11.3 11.0 -{.3
6 32.3 30.0 -2.3
7 33.2 35.5 2.3
8 29.8 32.5 2.7
9 29.0 28.5 -{.5
10 23.0 22.5 4.5
11 19.2 17.5 -1.7
12 28.9 30.0 1.1
13 31.1 30.0 -1 .1
Teble H5
Relationshtps lor Flutdtty
I
20-390/" Cr alloys -84.3 -11.1 14.6 -17.4 6.90 -{.909 0.090
b
a
,,fur.Qff.+$k:gir"r
Glossary
Terms in Glossary
Cementire (Ch. 1) Metastable Phase Diagrams (No citing exactly) (see Ch. 5 under
Transformation Diagrams; only says'Metastable Phase")
Columnar or Equiaxed Growth (Ch. 2)
Oxidizing and Reducing Environments (Ch. 9)
Constituents andPhases (Ch. 1)
Pearhte (Ch. 1)
Corrosion (Ch. 1 and Ch. 9)
Peritecüc Reactions (Ch. 2)
Delta and Alpha Ferrite (Ch. 2, Ch. 3)
Phase Diagram (Ch. 2)
Differential Thermal Analysis (see: DTA Thermogram)
Plastic Strain (sae.' Dislocation Movement)
Dislocation Movement (Ch. 5)
Potentiostat (Ch. 9)
DTA Thermogram (Ch. 2)
Primary Carbides (see.' hoeutectic Austenite)
Elastic Strain (see.' Dislocation Movement)
hoeutectic Austenite and himary Carbides (Ch. 2)
Electron Microprobe (Ch. 2)
Scanning Electron Microscopy (Ch. 1)
Epsilon Carbide (Ch. 5)
Stainless Steels (Ch. 1, Ch. 5)
Equiaxed Growth(see: Columnar or Equiaxed Growth)
Stoichiometry (Ch. 2)
Equilibrium Phase Diagram (see Metastable Phase Diagram)
Superheat (Ch. 1)
Eutecüc (Ch. l)
Transformation Diagram (see.. Phase Diagram)
Eutectic Colony (Ch. 2)
,l
Tumbtng Mills (see.' Ball and Tumbling Mills) i!i
Gibbs Free Energy t:
tf,
ffi
ba¿iry phsé
*2.0
E
()
.g
q
E
ti6
()
.l¡is"c
oC
'I69S
-§.0
Iut. % of allsying ¿lémÉnt
Glossary
213
since they are of distinct morphology, crystal structure and compounds) melt and solidify. It is called dffirentialbecatse
chemistry. This is analogous to composite terminology, where temperatures are measured simultaneously from two small
the fiber reinforcement is considered a distinct constituent crucibles. One crucible will contain the alloy of interest and
from the epoxy matrix. This deñnition may seem a little üe other crucible will be empty or contain a material of known
pedantic, but it helps to clarify the importance of having thermophysical properties. Both crucibles are placed within a
distinct constituents versus distinct phases within your iron. programmable, radiant fumace and heated or cooled at a
controlled rate. The differential temperature between the two
Corrosion: Corrosion is t}te process of gradual wearing away of a crucibles is then plotted as the alloy undergoes melting or
material by chemical means. For ferrous-based materials, it is freezing. With some care, one can measure the heat of fusion
the disassociation of the metallic bonds between the Fe atoms, that is released during üe liquid <+ solid phase change. More
allowing the release of free Fe atoms into the chemical importantly, we can determine the exact start and stop tem-
solution. A by-product ofthis reaction is the chemical reaction peratures of all phase change reactions (cooling curve data,
of these free Fe atoms with O, to form rust. Rust is a complex which simply measures the temperature of the metal as it cools
compound of Fe*O, atoms in non-stoichiometric parts. from liquid + solid, does not typically yield such good
numbers). For example, using a DTA instrument we can
Delta (5) and Alpha (o) Ferrite: When pure iron solidifi es at I 5 39C
create a graphical record ofthe iron as it solidifies, pinpointing
(2802F), it forms as a ferrite body centered cubic (BCC)
the austenite start temperature and the start of the eutectic
crystalline structure. As the pure iron cools, it remains ferritic
reaction. Such data allows a quick determination of whether
down to 1400C (2552F). At this temperature, it transforms to
the iron is a short or long freezing alloy.
austenite (y) (i.e., 6Fe + yFe), which remains stable down to
910C (1670F), whereittransformsbackto ferrite (i.e., yFe + Elastic Strain (see.' Dislocation Movement)
aFe). Historically, when these transformations where de-
tected, it was not known that the crystalline structure between
Electron Microprobe: This is another very useful form ofelectron
1539 and 1400C was the same as the one below 910C. Hence,
microscopy that is similar to SEM but with enhanced capabili-
they got two different names: 6Fe for the high temperature ties. The electron microprobe allows the direct chemical
form (liquid =+ 6Fe) and qFe for the low temperature form analysis of micron-sized phases with extremely good accu-
(Tfe + oFe). When the composition of the alloy is such that racy. The electron beam is focused through a series of electro-
the initial solidification reaction of liquid =+ 6Fe is all that magnetic lenses (ust like the SEM) onto the phase under
analysis. X-rays then cascade from the bombarded phase and
occurs as the alloy cools to room temperature, üen üe correct
name for the ferrite phase is delta (6Fe) and not alpha (oFe) are filtered and measured via wavelength dispersive spec-
ferrite. trometers (WDS). Hence, electron microprobe analysis is also
known as WDS analysis. Quantitative work is performed by
Differential Thermal Analysis (see.' DTA Thermogram) analyzing known standards (e.9., CrzC: carbide or NBS
standards) and then hitüng your unknown phase with the
Dislocation Movement: There are many fine metallurgy books that
electron probe.
provide extensive information about dislocations and disloca-
tion movement (e.g., R.E. Reed-Hill, 1973). In üe meantime, Epsilon (e) Carbide: This carbideis extremely small and onlyforms
thfuk of dislocations as small movements within the crystal during the tempering (below 200C/392Í) of medium- to high-
lattice that allow the accommodaüon of plastic strain. For C martensite (C content in excess of 0.27o).It has an unusual
example, when a load or force is applied to a material, the carbide structure of hexagonal close-packed and an unusual
material can behave elastical$ or plastically. Ifloaded elas- chemistry of Fez.¿C (it is not cementite). It can only be seen by
tically, themateial will rebound or revert to its original shape using very high-resolution electron microscopy. In fact, for
after the load is applied. If loadedplastically, the material will many years there existed some controversy over its structure
"plastically" flow and will not revert to its original shape. This and chemical composition. As mentioned, during martensitic
mechanism ofplastic flow is seen in every hardness measure- decomposition at low temperatures, epsilon carbide will form.
ment. For plastic flow to occur, there must be dislocation This process allows the body-centered tetragonal (BCT) crys-
movement. Dislocations can be defined in many üfferent tal lattice to relax or become less distorted. The end result of
ways. One way to view a dislocation is to think of one atom this process is thatmedium- andhigh-C martensite is replaced
slipping over another atom within the crystal lattice. That is, with amixture of epsilon carbide and lowercarbonmartensite
there is no such thing as a dislocation; it is only a name given that is of lower hardness but much tougher.
to the physical process of one atom slipping past another atom.
Equiaxed Growth (see.' Columnar or F,quiaxed Growth)
Naturally enough, depending on the crystal structure of the
material, it is easier for an atom to slip in some directions than Equilibrium Phase Diagram (see.' Metastable Phase Diagram)
in others. How easily atoms slip past each otherdetermines the
yield strength and, of course, the hardness of the material. If Eutectic Colony: One deñnition of a colony is a group of things
having a common characteristic. In this case, a coÍrmon
the crystal lattice is highly strained, as it is in high-C marten-
characteristic of aeutectic colonyis its growthdirection. Once
site, it becomes exceedingly difficult for dislocation move-
solidi{ication has started (whether near the wall of the mold or
ment (i.e., for atoms to slip). Since the crystal structure is more
resistant to plastic flow, the indenter will create a smaller
on some small fragment of solid) growth will occur in a
preferred direction, determined, in part, by the üermal gradi-
crater for any given load and a higher hardness will be
ent and, in part, by the nature of the carbide crystal. All carbide
measured. For more detailed information on hardness mea-
crystals grow faster along some directions than along other
surements, see Appendix D.
directions. In the case of a eutectic colony, we have coopera-
DTA Thermogram: Differential thermal analysis (DTA) is a very tive or coupled growth between the austenite and the carbide
effective tool for understanding how metals (and organic phase in one preferred direction. Each colony originates from
Glossary
215
simple oxidizing chemicals and, since free O is readily avail- tell us what phase the iron is in at any temperature or at any
able in most environments, a protective Cr2O3 film can easily composition. The diagrams are constructed on thebasis of the
form. With reducing acids such as HC1 or H2SOa, metallic (Fe, metallurgical analysis of dozens arid dozens of alloys. For
Cr, etc.) atoms are still disassociated from the matrix, but example, to determine the various phases that are present in
without the oxygen component, the protective film never the iron as a function of temperature, one procedure is to melt
forms, and the phase or constituent continues to dissolve a small sample and cool it very slowly to the desired tempera-
away. ture and üen quench it in water. The sample is then metallur-
gically examined to determine the phases present and their
Pearlite: A eutectoid mixture of alpha ferrite (cx,Fe) and M3C. relative volume fractions. This procedure is repeated for
Pearlite is a decomposition product of iron that has been different temperatures and many compositions until enough
alloyed with some fraction of carbon. After solidification, as data is gathered to construct the phase diagram. So why guess?
üe iron cools through the eutectoid temperature, pearlite is If you really want to know what your iron is doing, during
formed via the following reaction: yFe + aFe and M¡C. Its solidification or heat treating, consult a phase diagram. You
morphology is often characterized as a lamina¡ structure of will avoid doing a lot of work that others have already done.
alternating plates offerrite and carbide. Optically it has the (See also: Equilibrium and Metastable Phase Diagrams)
appearance of mother-of-Pear1.
Plastic Strain (see.' Dislocation Movement)
Peritectic Reactions: The Fe-Cr-C system has two peritectic reac-
liquid and a solid phase combine
tions . In peritectic reactions a Potentiostat: This is an electrical deüce used to determine the
to solidify as two solid phases. A method to locate these corrosion characteristics of metals. A schematic of a simple
peritectic reactions is to look for the meeting point of three potentiostat is shown in Fig. 3. By maintaining an electrical
liquidus surfaces. One such intersection is formed by the 6, 1, bridge to a neutral potential, the electrometer can then mea-
and MzC¡ liquidus surfaces. This peritectic point (fixed in sure anychanges inthe flow of electrons, fromthe sampleinto
composition and temperature) is reached by ferritic irons, for the liquid or vice versa. More advanced units can vary the
example, corrosion-resistant irons having a base composition potential between the sample and the neutral cell, while
of 2Vo C,307o Cr. As this iron solidifies, initially 6 forms. The measuring the current flow. In such a fashion, the onset of
remaining liquid then moves toward the peritectic point at passivation can be measured. That is, once the material has
2.87o C and 327o Cr at 1289C (2352F). Since this is the passivated the curent flow will drop appreciably due to the
intersection of three liquidus surfaces, all three phases will formation of the protective and insulating passive film. The
ii coexist in the solid form. The actual reaction is: L + cr6Fe + potential at which this film forms determines whether the
yFe + M7C3. At the other end of the phase diagram, we find a material will passivate or corrode under oxidation conditions.
tl
low-Cr peritectic point being the intersection of the g, MrC¡, Data from such experiments are plotted as potential (mV)
and M3C liquidus surfaces. If the iron is a Ni-Hard 4 contain- versus current density (nA/cm2) and are known as
ing3%o C,9Vo Cr, and anSi <1.57o, then it will undergo the potentiodynamic plots. More general information can be
peritectic reaction located at 4.27o C,9.77o Cr at 1183C found in corrosion textbooks or in ASTM G-3, Conventions
(2161F), where L + M7C3 + yFe + MrC. Peritectic reactions Applicable to Electrochemical Measurements in Corrosion
are often incomplete because a solid phase must transform Testing.
into another solid phase via a diffusion-dependent route. Primary Carbides (see.' Proeutectic Austenite)
Typically, as the iron conúnues to cool, it drops through the
peritectic point into the eutectic valley. Proeutectic Austenite and Primary Carbides: Metallurgical ter-
minology is sometimes not as straightforward as it may
Phase Diagram: Understanding phase diagrams is not that difficult.
appear. In hyp oeutectic irons, p roe uf e cti c au ste¡oire is the flrst
Think of phase diagrams as simple maps to describe the iron phase to solidify and it occurs before üe eutectic, hence the
or alloy behavior in terms of temperature and composition' prefrx pro. ln hypercutectic irons, primary carbides arc the
We generally check anÜor measure the properties of an iron
first phase to solidify and their formation occurs before the
at room-temperature properties; phase diagrams, however,
eutectic. It would seem logical that primary carbides might
also be known as proeutectic carbides. However, the terminol-
ogy proeutectic austenite and primary carbides prevails.
ELECfRO[IETEE
Reducing Enüronment (s¿¿r Oridizing and Éeducing Environ-
ments)
composed of seven metal atoms to three carbon atoms, yield_ Reed-Hill, R.8., Physical Metallurgy Principles,2¡d p. van Nostrand
ed.,
ing a stoichiometry of M7C3. Hence, the use of the word Co., New York, NY (1973).
"stoichiometry" to help us describe the chemical composition
Rivlin, V.G., Critical Review of Constitution of Carbon-Chromium-I¡on and
of the various carbides found in AR irons is accurate and Carbon-kon Manganese Systems, International Metals Review, vol.29,
illuminating. pp.299-327 11984y.
Glossary