ADI DAYS - Franco Bonollo
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Advanced Cast Irons: a Solution for Lightweight and Materials Efficiency
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ADI DAYS - Franco Bonollo
- 1. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe Advanced Cast Irons: a Solution for Lightweight and Materials Efficiency Prof. Franco BONOLLO Dipart. di Tecnica e Gestione dei Sistemi Industriali Università di Padova, sede di Vicenza
- 2. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe Contents Introduction Advanced Cast Iron The Lightweight perspective Advanced Cast Iron as a Lightweight solution The Materials Efficiency perspective Advanced Cast Iron as a Materials efficiency solution The Raw Materials Sustainability perspective Advanced Cast Iron as a Raw Materials Sustainability solution Concluding Remarks References & Contacts 2
- 3. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 3 Advanced Cast Iron Introduction
- 4. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 4 Mn Mg Al alloysNa Sr Te Ni* Cu Mn Si P Tical V Zr Ag Mo La Co Cr BeLa Fe Modification Solid solution strengthening Grain refining Eutectic Silicon homogeneisation Silicon refining Elements for slag control Die Extraction Advanced Cast Iron Design of Material Modern High Performance materials (Superalloys, HSLA steels, Primary Al alloys, etc) are DESIGNED
- 5. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 5 Advanced Cast Iron Advanced Cast Irons are Designed Materials Diameter & Roundness of Graphite nodules Size of Ferrite needles %C in Austenite Size of Austenite grains Number of Graphite nodules per mm2
- 6. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 6 Advanced Cast Iron Advanced Cast Irons are Designed Materials Diameter & Roundness of Graphite nodules Size of Ferrite needles %C in Austenite Number of Graphite nodules per mm2 Size of Austenite grains As Cast Conven onal Perlite Promoters As Cast Low Alloyed IDI Si 2.0% ADI 800 ISO Specifica ons ADI 800 ISO Specifica ons 0 40 80 120 160 200 240 280 320 360 0 100 200 300 400 500 600 700 800 900 0 2 4 6 8 10 CharpyImpactEnergyUnnotchedK[J] Rm,Rp0.2[MPa] A5 [1/100]
- 7. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Weight in Automotive 7
- 8. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe steel / iron light metals thermoplastics other metals elastomers glass / ceramics thermosets paint, undersealing textiles, other compounds electric/electronics thermoplastic elastomers other materials consumables (incl. fuel) Total weight: 1935 kg Source: BMW The Lightweight perspective Weight in Automotive 8
- 9. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Weight in Automotive Safety Comfort Performance 9
- 10. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Reducing CO2 Emissions 10 Eco-sustainability
- 11. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Weight & CO2 Emissions 11
- 12. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Weight & Fuel Consumption 12
- 13. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Effects of Lightweight Design 13
- 14. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Materials in Competition 14
- 15. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Materials in Competition - spaceframe 15
- 16. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Materials in Competition - spaceframe 16
- 17. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Materials in Competition - spaceframe 17
- 18. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Materials in Competition - spaceframe 18
- 19. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Materials in Competition - spaceframe 19
- 20. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Materials in Competition - spaceframe 20
- 21. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Road vs Rail vehicles 21
- 22. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Road vs Rail vehicles 22
- 23. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Road vs Rail vehicles 23
- 24. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Road vs Rail vehicles 24
- 25. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Lightweight perspective Attributes & Impacts in Rail vehicles 25
- 26. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 26 The Lightweight perspective Cost saving in Lightweight
- 27. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 27 Advanced Cast Iron as a Lightweight solution Performance of Advanced Cast Iron
- 28. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 28 Advanced Cast Iron as a Lightweight solution Performance of Advanced Cast Iron As Cast Conven onal Perlite Promoters As Cast Low Alloyed IDI Si 2.0% ADI 800 ISO Specifica ons ADI 800 ISO Specifica ons 0 40 80 120 160 200 240 280 320 360 0 100 200 300 400 500 600 700 800 900 0 2 4 6 8 10 CharpyImpactEnergyUnnotchedK[J] Rm,Rp0.2[MPa] A5 [1/100]
- 29. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 29 Material Microstructure nod/ mm2 Es [GPa] R [MPa] p02 [MPa] A [%] HB DI 400 100% Ferrite 220 160 440 305 19 150 100% Ferrite 290 160 449 315 >30 168 DI 600 35% Ferrite-65% Pearlite 310 165 722 426 10 220 25% Ferrite-75% Pearlite 240 165 727 435 12 239 DI 700 5% Ferrite-95% Pearlite 244 161 805 487 8.0 244 5% Ferrite-95% Pearlite 310 161 862 500 8.8 275 IDI Pearl.-Ferr. Interconnected 220 170 758 455 10 240 Pearl.-Ferr. Interconnected 290 170 957 645 15 292 ADI 800 Ausferrite 244 170 858 551 15 270 Ausferrite 310 170 1084 757 17 321 ADI 1050 Ausferrite 244 163 1110 794 13 330 Ausferrite 244 163 1160 831 12 350 Ausferrite 310 163 1118 805 10 345 ADI 1200 Ausferrite 310 148 1355 1150 10 410 Ausferrite 310 148 1363 1046 11 410 Advanced Cast Iron as a Lightweight solution Performance of Advanced Cast Iron
- 30. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe Advanced Cast Iron as a Lightweight solution Properties ADI 800 ADI 1050 ADI 1200 IDI 30
- 31. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe Advanced Cast Iron as a Lightweight solution Specific Properties ADI 800 ADI 1050 ADI 1200 IDI 31
- 32. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 32 The Materials Efficiency perspective General strategies
- 33. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 33 The Materials Efficiency perspective Materials Properties in Design Process
- 34. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 34 The Materials Efficiency perspective Materials Properties in Design Process
- 35. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 35 The Materials Efficiency perspective Materials Properties in Design Process
- 36. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 36 The Materials Efficiency perspective Materials Properties in Design Process Cast Iron
- 37. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 37 The Materials Efficiency perspective Materials Properties + Process Characteristics in Design Process
- 38. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 38 The Materials Efficiency perspective Process as a variable for Design
- 39. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 39 The Materials Efficiency perspective Process as a variable for Design
- 40. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 40 A liquid metallic alloy is poured into a mould, then it solidifies, achieving the desired shape and finally is cooled up to room temperature. The key-stages of the process (melting – pouring – filling – solidification – cooling) may (?) generate defects & imperfections melting solidifyingfillingpouring cooling The Materials Efficiency perspective What is (basically) a Casting Process
- 41. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 41 Permanent Mold (Die) Disposable Mold Permanent Pattern Disposable Pattern • Investment casting • Lost Foam • Green sand • Shell molding • Plaster molding • Disamatic process • V-Process • Low Pressure Sand Casting • …… • Gravity Casting • Low Pressure Die Casting • High Pressure Die Casting • Vacuum HPDC • Semi-solid Casting • Squeeze Casting tooling tooling filling The Materials Efficiency perspective Classification of Casting Processes
- 42. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 42 Pouring in the die/mould Pouring in a pre-chamber Gravity pouring Pouring under pressure (i.e. injecting) Sand mould Ceramic mould Patterns Steel mould (i.e. die), permanent Sand cores Ceramic cores/Salt cores Metallic cores (i.e. inserts) Without air evacuation With air evacuation By gravity Under moderate (i.e. low) pressure Under high pressure Spontaneous heat transfer from alloy to mould/die Enhanced (cooling channels + air/gases) heat transfer Enhanced (cooling channels + water/oil) heat transfer solidifying cooling pouring filling tooling Sand Gravity Casting The Materials Efficiency perspective
- 43. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 43 Weight from few grams to tons Minimum Thickness 4 mm Maximun Thickness no limits Minimum diameter of holes (achieved with cores) 7 mm Degree of complexity - internal very high - external very high Tolerances + 2 on 250 Sand Gravity Casting The Materials Efficiency perspective Production rate 2 Equipment Cost 4 Time for prototyping 4 Metallurgical efficiency 0 (product weight/cast weight) Level of pressure tightness 2 Degree of automation 2-3 Possibility of heat treating 4 Net shape castings 2 Surface quality 1 4 3 2 1 0 Best Worst
- 44. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 44 • Molten metal flows into small sections in the molten cavity, hence any complex shape can be easily produced. • Practically any type of material can be cast. • Ideal method is by producing small quantities. • Any size of casting can be produced like up to 200 tons. • Casting is the often cheapest, most direct way of producing a shape with certain desired mechanical properties. • Certain metals and alloys such as highly creep resistant metal-based alloys for gas turbines cannot be worked mechanically and can be cast only. • Heavy equipment like machine leads, ship’s propeller etc. can be cast easily in the required size rather than fabricating them by joining several small pieces. • Casting is best suited for composite components requiring different properties in different direction. These are made by incorporating preferable inserts in a casting. The Materials Efficiency perspective The advantages of Casting Process
- 45. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 45 Casting Vs Other processes It is fact that in some cases, the casting process must give way to other methods of manufacture, where they may be more efficient. For example, forging helps developing fiber strength and toughness in steel, machining produces smooth surfaces and dimensional accuracy not obtainable otherwise, welding provides a easy way of fabricating wrought or cast products into complex structures while stamping produce lightweight sheet metal parts. Casting vs Forging: It should be recognized that castings and forgings start from very similar beginnings and castings can have some very distinct advantages over other product forms, including forgings. Some of the key Advantages of Casting over Forging can be with respect to the following: Design flexibility High production rate Large and complex parts Weakness of Casting Requires close process control and monitoring, Shrinkage porosity may occur, Metallic projections, Cracks, hot tearing, coldshuts, Laps, oxides, Misruns, insufficient volume, Inclusions The Materials Efficiency perspective The advantages of Casting Process
- 46. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 46 Process vs Microstructure (& Defects) vs Performance The Materials Efficiency perspective Role of Casting Geometry (e.g. thikhness) on microstructure and properties
- 47. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 47 • Defects • Poor Microstructure • Poor Mech. Propert. • Scraps • Few Imperfections • Good Microstructure • Good Mech. Propert. • Suitable for use Control of Process Path The Materials Efficiency perspective
- 48. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe Advanced Cast Iron as a Materials Efficiency solution Integrated Design 48
- 49. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe Advanced Cast Iron as a Materials Efficiency solution Tailoring Properties and their Distribution 49
- 50. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Raw Materials Sustainability perspective Criticality of Raw Materials 50
- 51. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Raw Materials Sustainability perspective Iron Group Criticality Assessment (Global) 51
- 52. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Raw Materials Sustainability perspective Criticality Assessment for EU (2013) 52
- 53. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe The Raw Materials Sustainability perspective Criticality Assessment for EU (2013) 53
- 54. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe Advanced Cast Iron as a Raw Materials Sustainability solution The Competitors for Cast Iron 54
- 55. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 16CrNi4 Carbon, C 0.13 - 0.18 % Manganese, Mn 0.70 - 1 % Phosphorous, P 0.035 Sulfur, S 0.035 Silicon, Si 0.15 - 0.40 % Chromium, Cr 0.80 - 1.10 % Molybdenum, Mo - Nickel, Ni 0.80 - 1.10 % 18NiCrMo5 Boron, B 0.0010 - 0.0050 % Carbon, C 0.12 - 0.21 % Chromium, Cr 0.85 - 1.2 % Iron, Fe 96% Manganese, Mn 0.45 - 0.70 % Molybdenum, Mo 0.45 - 0.60 % Nickel, Ni 1.2 - 1.5 % Phosphorous, P <= 0.035 % Silicon, Si 0.20 - 0.35 % Sulfur, S <= 0.040 % Domex 700 Carbon, C 0.12 % Manganese, Mn 2.10 % Phosphorous, P 0.025 % Sulfur, S 0.010 % Silicon, Si 0.10 % Alluminium, Al 0,015% Niobium, Nb 0,09% Vanadium, V 0,20% Titanium, Ti 0,15% Class I Type D Ni-Hi-Cr Martensitic White Cast Iron Carbon, C 2.5 - 3.6 % Chromium, Cr 7.0 - 11 % Iron, Fe 78% Manganese, Mn <= 1.3 % Molybdenum, Mo <= 1.0 % Nickel, Ni 5.0 - 7.0 % Phosphorous, P <= 0.10 % Silicon, Si 1.0 - 2.2 % Sulfur, S <= 0.15 % Advanced Cast Iron as a Raw Materials Sustainability solution The Competitors for Cast Iron 55
- 56. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe Class II Type C 15% Cr-Mo-HC Martensitic White Cast Iron Carbon, C 2.8 - 3.6 % Chromium, Cr 14 - 18 % Copper, Cu <= 1.2 % Iron, Fe 74% Manganese, Mn 0.50 - 1.5 % Molybdenum, Mo 2.3 - 3.5 % Nickel, Ni <= 0.50 % Phosphorous, P <= 0.10 % Silicon, Si <= 1.0 % Sulfur, S <= 0.060 % Class III Type E 25% Cr Martensitic White Cast Iron Carbon, C 2.3 - 3.0 % Chromium, Cr 23 - 28 % Copper, Cu <= 1.2 % Iron, Fe 65% Manganese, Mn 0.50 - 1.5 % Molybdenum, Mo <= 1.5 % Nickel, Ni <= 1.5 % Phosphorous, P <= 0.10 % Silicon, Si <= 1.0 % Sulfur, S <= 0.060 % Crucible Steel CPM® 10V® (AISI A11) Tool Steel Carbon, C 2.45 % Chromium, Cr 5.25 % Iron, Fe 81.25 % Molybdenum, Mo 1.3 % Vanadium, V 9.75 % HARDOX 500 Carbon, C 0.30 % Silicon, Si 0.70 % Manganese, Mn 1.60 % Phosphorous, P 0.025 % Sulfur, S 0.0.10 % Chromium, Cr 1.50 % Nichel, Ni 1.50 % Molybdenum, Mo 0.60 % Boron, B 0.004 % Advanced Cast Iron as a Raw Materials Sustainability solution The Competitors for Cast Iron 56
- 57. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe Critical materials: List of materials considered as critical to the EU due to supply risk of the raw materials from which they are derived. Critical materials are mostly defined in terms of elements. Advanced Cast Iron as a Raw Materials Sustainability solution The Competitors for Cast Iron “Stand by” elements 57
- 58. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 58 Advanced Cast Iron as a Raw Materials Sustainability solution The typical Composition of ADI
- 59. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe Concluding Remarks 59 Advanced Cast Irons Designed Materials Microstructure controlled by the Process Solution for Lightweight Absolute & Specific Properties Solution for Materials Efficiency Advantages of Casting Process Solution for Raw Materials Sustainability Good for Substitution
- 60. Austempering, A Technology for Substitution ADI DAYS 2016 6th – 7th October Minerbe 60 Contacts Prof. Franco BONOLLO Dipart. di Tecnica e Gestione dei Sistemi Industriali Università di Padova, sede di Vicenza Str. S. Nicola, 3 – 36100 Vicenza (Italy) e-mail: bonollo@gest.unipd.it tel.: +39 0444 998743 fax: +39 0444 998889 www.gest.unipd.it/metallurgia