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EN-GJS-400-18-LT Castings for
Cold Climate
Technical Feasibility Assessment
A T Ansari
Business Case
• Current specification different for standard temperature EN-GJS-400-18-LT
& low temperature versions EN-GJ...
Background – GL note for cold climate
3
Define
Project Name Assessment of STV castings for LTV suitability
Objective Develop estimation tool for impact.
Analysis ...
Define : Test Program
• Planned Actions
– Identify casting manufactured for STV grade with normal process
control
– Conduc...
Measure: Test Data
• Select supplier
• Test data collected
– Tested 85 castings
– 35 castings tested impact at -20 as well...
Analyze: Relationship
• Regression analysis
– 160 results analyzed in 3 steps
– After removing 18 unusual reading, regress...
Improve : Factor Analysis
8
Main Effect by Impact testing temperature
Other 3 are interaction effects between 0.2% proof, ...
Control : Calculate Impact at -40
• Filtered data of 80 castings which are tested at -20
• Estimate impact value at -40 te...
Control : Impact estimation at -40
10
Technical Feasibility Assessment - Remarks
• Feasibility comments
– EN-GJS-400-18-LT to pass for impact 10J Avg at -40 deg...
Impact data distribution
12
-20 Calculated -40
Define – Close loop
Project Name Assessment of STV castings for LTV suitability
Objective
Develop estimation tool for impa...
Thank You
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Assessment of for Suitability of Ductile Iron Castings for cold climates

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Technical feasibility and risk assessment to use EN-GJS-400-18-LT in cold climates of -40 deg C

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Assessment of for Suitability of Ductile Iron Castings for cold climates

  1. 1. EN-GJS-400-18-LT Castings for Cold Climate Technical Feasibility Assessment A T Ansari
  2. 2. Business Case • Current specification different for standard temperature EN-GJS-400-18-LT & low temperature versions EN-GJS-350-22-LT • Two different specification take out flexibility from SCM and create a bottle neck for casting supply when sudden change in market demand • Easiest way is to have EN-GJS-350-22-LT castings common for both climates – This comes with side effects as tensile is less & castings have to be designed with more weight. – Thread engagements need to designed with bigger lengths – Fastener lengths increases • Another option is to have EN-GJS-400-18-LT material common for both version with mandatory test of LTV qualifying – This technical acceptable to certification – From EN-1563 Casting standard point of view looks difficult – Technical feasibility assessment with available data will help to conclude
  3. 3. Background – GL note for cold climate 3
  4. 4. Define Project Name Assessment of STV castings for LTV suitability Objective Develop estimation tool for impact. Analysis of Impact data for tested castings of EN-GJS-400-LT Benefits Flexibility to SCM Can cater to fluctuating market demand Reduced casting weight Less chances of thread rip-off in casting Fastener length can decrease Project Team Abdullah Ansari Mr. Seenivasa Ragavan Schedule Measure Analyze Improve Control Jan-2014 Feb-2014 Apr-2014 Apr-2014
  5. 5. Define : Test Program • Planned Actions – Identify casting manufactured for STV grade with normal process control – Conduct normal testing for STV – Conduct additional impact test for LTV – Wherever possible test impact at various temperatures • 25, 0, -10, -20, -30 & -40 – Record the data for analysis.
  6. 6. Measure: Test Data • Select supplier • Test data collected – Tested 85 castings – 35 castings tested impact at -20 as well as -40 – 42 Castings tested at -20 – 8 Castings Tested at 25, 0, -10, -20, -30, & -40 • Results compiled for – Tensile strength – 0.2% proof strength – Elongation – Impact
  7. 7. Analyze: Relationship • Regression analysis – 160 results analyzed in 3 steps – After removing 18 unusual reading, regression equation concluded • Impact Avg = 50.5 + 0.220 Impact temp - 0.0661 0.2% YS(N/mm²) - 0.0422 TS(N/mm²) - 0.0646 % EL • S = 1.36798 R-Sq = 83.5% R-Sq(adj) = 83.1% • Analysis shows impac testing temperature & 0.2% proof strength are most significant predictor for impact value • R-Sq suggests that about 83% variation is captured • Conduct Factor analysis for filtered data of 142 tests to find out contributing factors sequentially 7
  8. 8. Improve : Factor Analysis 8 Main Effect by Impact testing temperature Other 3 are interaction effects between 0.2% proof, Tensile, elongation & impact testing temperature
  9. 9. Control : Calculate Impact at -40 • Filtered data of 80 castings which are tested at -20 • Estimate impact value at -40 temperature for those 80 casting • Calculation results – As per calculation only 6 castings qualify for impact at -40 for Avg 10J – As per Calculation other 71 casting qualify for impact at -40 for indv 7J – As per calculation rest 3 castings failed for even individual 7J but the estimated value is more than 6J 9
  10. 10. Control : Impact estimation at -40 10
  11. 11. Technical Feasibility Assessment - Remarks • Feasibility comments – EN-GJS-400-18-LT to pass for impact 10J Avg at -40 deg C is difficult – EN-GJS-400-18-LT to pass for impact 7J Indv at -40 deg C is very much possible • Input to Design – Design assessment to be done with 7J & related factor of safety. – If 7J average is acceptable, then with material EN-GJS-400-18-LT we can move ahead – If 10J mandatory requirement then for material EN-GJS-350-22-LT we may need to go back – Though GL guideline gives us option to choose EN-GJS-400-18-LT based on pearlite content but it will be risky for fatigue life if required impact value not achieved. 11
  12. 12. Impact data distribution 12 -20 Calculated -40
  13. 13. Define – Close loop Project Name Assessment of STV castings for LTV suitability Objective Develop estimation tool for impact.  Analysis of Impact data for tested castings of EN-GJS-400-LT  Benefits Flexibility to SCM Can cater to fluctuating market demand Reduced casting weight Less chances of thread rip-off in casting Fastener length can decrease Project Team Abdullah Ansari Mr. Seenivasa Ragavan Schedule Measure Analyze Improve Control
  14. 14. Thank You

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