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Simulating Porosity in Ductile Iron e-Tips

Castings Nr. 17

c) Micro shrinkage occurs late during


Ductile, or nodular, cast iron solidification and is formed between the
components have many solidifying dendrites. Usually the amount
advantageous characteristics of micro shrinkage is influenced by the
cooling rate, pressure and alloy freezing
which combine high toughness,
range.
increased ductility, high strength,
fatigue and wear resistance. The casting of nodular iron is interesting
Nodular cast iron is created because the formation of the graphite
Figure 1: Illustrated images showing the
nodules during solidification can lead to
through an alloying process different forms of shrinkage porosity.
a total net volume expansion, as shown
(usually with Mg) where in Figure 2. However, contrary to what
nucleation favors the formation of Introduction to Porosity might be expected, micro-porosity can
graphite nodules instead of flakes nevertheless form. The expansion of the
Shrinkage porosity, as shown in Figure 1, solid skeleton during solidification
of grey iron, thereby giving the
can be characterised by the following: should be taken into account to explain
material increased ductility and
this phenomenon. Similar to a sponge
superior elongation properties. a) Pipe shrinkage, including surface sinks, when it expands in water, a suction of the
Some typical automotive ductile occurs early during solidification when liquid occurs in between the interstices of
the liquid metal on the surface of the the sponge leading to a pressure drop,
iron parts include steering
casting, exposed to the atmosphere, is which in the case of solidification is
knuckles, exhaust manifolds, brake under a depression due to the responsible for micro-porosity.
calipers, camshafts, clutch drums, contraction of the solidifying metal on
brake cylinders, connecting rods the inside. The metal is then pushed However, if the outer surfaces of the
downwards (or inwards) by atmospheric casting are prevented from expanding
etc.
pressure forming a pipe, or sink, which is then an increasing pressure on the inside
visible on the surface of the casting. can help to feed this micro-shrinkage.
During casting, unlike most cast Good gating design can help to take
alloys, ductile iron does not simply b) Macro shrinkage occurs when the advantage of this phenomenon.
contract as the metal cools and liquid is surrounded by enough solid
material which is strong enough to resist
solidifies. In the liquid state the
the depression of the contracting liquid.
volume change is quite linear and Usually the size of the pores is greater
predictable but as the metal than 3mm. These defects are internal and
begins to solidify, ductile irons can generally be prevented by optimal
pouring temperature, riser positioning
show a considerable amount of
and size.
expansion due to graphite
precipitation. This effect can allow During solidification the expansion of the
experienced foundrymen to make metal due to graphite expansion can
cause liquid to be pushed back into the
use of riserless methods.
gating system resulting in problems with
Figure 2: Volume change during solidification
porosity during subsequent solidification.
for hyper-eutectic, hypo-eutectic ductile and
grey cast iron. Ref. http://www.ductile.org/
magazine/2001_3/elidavid.htm
Simulating porosity Conclusion

Predicting the behaviour of the metal Simulating ductile iron castings using
during solidification is not trivial as one ProCAST can help to understand the
needs to consider the different modes of solidification behaviour and determine
shrinkage as well as trace the evolution of the effect of graphite expansion on
the liquid metal free surface. One has to porosity.
distinguish between how much volume
change is used for macro shrinkage and Optimal gating design can then be
how much is used for micro shrinkage. determined to help take advantage of
this expansion effect in ductile iron
The amount of shrinkage will depend on castings.
the following:

- thermal cooling conditions Figure 3: Geometry of casting indicating the


- the alloy content risers, down sprue and blue line indicating the
- the casting temperature cross-sectional cuts in Figure 5 & 6.
- the amount of graphite expansion
occurring during solidification.

Example

The example shown in Figures 3 of a


casting without riser sleeves was
simulated to illustrate the influence of
graphite expansion on the porosity
results.

The porosity results are shown in Figure 4


& 5. When taking graphite expansion
into account, as shown in Figure 4, the
porosity is considerably lower than when
not considering expansion, as shown in
Figure 5. In the later results there is also
the presence of pipe shrinkage.

Figure 4: Cross-section contour plot of porosity Figure 5: Cross-section contour plot of porosity
where red indicates macro porosity. Ductile where red indicates macro porosity and yellow
cast iron simulation when considering the indicates 100% vacant region. Ductile cast iron
graphite expansion. Results performed using simulation when not considering the graphite
ProCAST expansion. Results performed using ProCAST.

Calcom SA
Parc Scientifique EPFL, CH-1015 Lausanne, Switzerland
phone: +41 21 693 2918 / fax: +41 21 693 4740
mail@calcom.ch / www.calcom.ch

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