Austempered Ductile Iron (ADI)

Kathy L. Hayrynen, PhD

Technical Director Applied Process Technologies Division

Class Outline
n What

is Austempering / Myths of Austempering n The Austempering Process n Properties of ADI n ADI Jeopardy

What Is the Austempering Process?

nA

high performance heat treatment that imparts superior properties to ferrous materials.

Dkme demirlerin Ostemperleme, Su verme ve Temperlenmesi

Osten it Perl it Fer rit Beyni t

Scaklk, C

Ausferr it Martens it Zaman, sn

Myths of Producing ADI

n Austempering

will make my low quality

iron better. n You need to make special ductile iron in order to austemper it.

ADI Starts With High Quality Ductile Iron

High Quality Ductile Cast Iron (A Necessary Requirement)

n

n n

Nodule Count in excess of 100 nodules per sq. mm Consistently High Nodularity (90%+) Maximum level of 0.5% carbides + nonmetallic inclusions Maximum allowable volume of 1% porosity and/or microshrinkage

High Quality Ductile Iron

n n n n

Consistent Pearlite Ferrite Ratio Consistent Chemistry

What are the alloy requirements to produce ADI?

n n

Alloying elements are added for hardenability or the ability to through harden. Most standard grades of ductile iron can be austempered to a section size thickness of 20 mm or inch. A knowledgeable Heat Treater will recommend the appropriate alloy content.

Class Outline
n What

is Austempering / Myths of Austempering n The Austempering Process n Properties of ADI n The ADI Market / Applications of ADI

The Austemper heat treat process for typical Cast Irons

Linear Dimensional Change

ADI Mikroyaplar

Grade 1 ADI

Grade 5 ADI

Class Outline
n What

is Austempering / Myths of Austempering n The Austempering Process n Properties of ADI n The ADI Market / Applications of ADI

OKGDD in 5 ASTM Standard

The properties of each grade are affected by the Austempering process NOT the chemistry of the iron
Grade 1 2 3 4 5 ekme
mukavemeti

Akma
mukavemeti

Uzama(%)
10 7 4 1 N/A

(MPa / Ksi)
850 / 125 1050 / 150 1200 / 175 1400 / 200 1600 / 230

(MPa / Ksi)
550 / 80 700 / 100 850 / 125 1100 / 155 1300 / 185

Darbe Sertlik (HB) Direnci (Joules / lb.100 / 75 269 321 ft.)

80 / 60 60 / 45 35 / 25 N/A 302 363 341 444 388 477 444 - 555

Typical Properties of ADI

Youngs Modulus
30 25 20 Msi 15 10 5 0 A lu m in u m ra y Iron A D I G D u ctile N i-H a rd Iro n C a st S te el F o rg e d S te e l

ADIs Wear Resistance

Relative Machinability of ADI

120 100 80 60 40 20 0 65-45-12 Ductile Iron AISI 1110 Free Machining Steel 100-70-03 Ductile Iron ASTM 897 125-80-10 AISI 4140 Steel at 30Rc

Comparison of Bending-Fatigue Strength of ADI with those of Conventional Ductile Iron and Steels

Comparison of Contact Fatigue Strengths of ADI with those of Conventional Ductile Iron and Steels

Effect of Different Shot Peening Schemes

Noise Reduction

Weight Per Unit of Yield Strength

Cost per Unit of Yield Strength

Gray Iron Ductile

Profit

Austempered Gray Iron Malleable Iron C Steel Forgings ADI Grades 14 ADI Grade 5 L.A. Steel Forgings H.T. C Steel Forgings C & L.A.Steel Castings H.T. L.A.Steel Forgings Carb.L.A. Steel Forgings Mn Steel Castings H.T. C & LA Steel Cast. Die Cast Aluminum Sand Cast Aluminum

0.00
Commission Material Cost Heat Treat & Transport

0.50

1.00

1.50

2.00

2.50

Relative Material Prices

How Does ADI Compare to Steel and As-cast Ductile Iron?

n n n n

Costs 20% less than steel 10% less dense than steel Improved Noise Damping Machinability

How Does ADI Compare to Aluminum?

n n n n n n

Minimum 30% cost savings 3 Times Stronger 2.3 Times Stiffer Fatigue strength Better Wear resistance

Limitations of ADI
n High

stiffness, part geometry fixed n Exposure to excessively high service temperatures n Coefficient of thermal expansion n Slight drop off in fatigue strength in the high cycle region

Questions ????

Its Time to Play . . . ADI Jeopardy

The Categories are:

n Medium

& Ar Vasta n Car & Light Truck n Demiryolu n Miscellaneous Industrial n Construction & Mining n Agricultural

Medium & Ar Vasta

Ar Vasta
Diesel Engine Timing Gears

Ar Vasta Steering Knuckle

Ar Vasta
Sway Bar Bushing

Ar Vasta Brake Spider

Ar Vasta Pintle Hook and Latches

Ar Vasta
ADI Duralite Hub

Ar Vasta AWD Clutch Collar and Diff Case

Otomobil ve Hafif Aralar

otomobil ve hafif aralar

Suspension Upper Control Arm

otomobil ve hafif aralar

Constant Velocity Joints

otomobil ve hafif aralar

Tow Hooks

Demiryolu

Demiryolu
Suspension Friction Wedges

Demiryolu
Suspension Housing

Rotary Railcar Dumper Gear

Miscellaneous Industrial and Consumer Products

Miscellaneous Industrial
Scissor Lift Gear Housing

Miscellaneous Industrial
Pipe Threading Components

Miscellaneous Industrial
Conveyor Chain Links

Miscellaneous Industrial Outrigger Forklift Axle Bracket

Miscellaneous Industrial
Lawnmower Gear and Axle

Miscellaneous Industrial
Power Conduit Bender Components

Miscellaneous Industrial Pump Impeller

Miscellaneous Industrial ADI Airport Runway Access Cover

naat / Maden

naat / Maden
Backhoe Digger Teeth

Snowplow Shoe

naat / Maden Pavement Breaker Housings

naat / Maden
Road Grader Control Arm

Tarm Aralar

Tarm Aralar
Farm Implement Hitches

Tarm Aralar
Plow Points

Tarm Aralar
Anhydrous Ammonia Knives

Tarm Aralar
Knotter Gear

Tarm Aralar
Brake Calipers

Tarm Aralar
Tractor Wheel Hubs

Tarm Aralar Mounting Bracket

Tarm Aralar
Combine Internal Elements

Where to Get More Information

www.appliedprocess.com www.ductile.org/didata www.matweb.com

Thank You!