Icommet 2020

The 4th International Conference on Materials and Metallurgical
Engineering and Technology (ICOMMET) 2020
The Effect of Chills Thickness to Microstructure
and Surface Hardness Layer on Specimen Ductile
Cast Iron
Department of Mechanical Engineering, Faculty
of Engineering Diponegoro University, Prof.
Soedharto Street, Tembalang, Semarang 50275,
Indonesia
AUTHOR
Natalino Fonseca. D. S Guterres
1

OUTLINE
INTRUDUCTION
EXPERIMENTAL
PROCEDURE
RESULTS
CONCLUSION REFERENCES
The 4th International Conference on Materials and Metallurgical Engineering and
Technology (ICOMMET) 2020
2

INTRUDUCTION
Surface hardening in a
general sense involves
many processes that
improve the wear
resistance of parts
while utilizing the
tough interior
properties of the steel
or cast iron component
(J. R. Davis, 2001).
Some
components like
(Peter J. Blau, 2009)
Gears
valve seats
railroad rails
rolling-mill rolls
3

4
The 4th International Conference on Materials and Metallurgical Engineering and Technology
(ICOMMET) 2020
INTRUDUCTION
Duplex Coated DLC
Nitriding And Carbonitriding
Plasma Transferred Arc (PTA)
Horizontal Continuous Casting
Machine (HCCM)
Manually Tig Welding
Tungsten Inert Gas Welding
Process
MMC (Magnetic Moulding
Casting) system
Fine Particle Bombardment
(FPB) Treatment
Several processes have been used in
the surface hardening of Steel and
cast iron (J.R. Davis, 2005, C. M.
Allen and B. Boardman, 2005)
Induction hardening
Carburizing hardening
Flame hardening
Plasma hardening
Laser hardening
In recent years, ductile cast iron has
been widely used for surface
hardening by using many methods
as:
M. H. Sohi et.al., 2004; C. Hsu, J.
Lu, and R. Tsai, 2006; D. Myszka,
A. Z et al., 2009; H. T. Cao et al.,
2016; D. Zeng et al., 2017.

5
The 4th International Conference on Materials and Metallurgical Engineering and Technology
(ICOMMET) 2020
RESEARCH RELEVANT
Showing fine
grains of ferrite-
pearlite and
partially
transformed
martensite
R.George Sahaya Nixon and Dr. B. S.
Mohanty, 2013
The Hardness
values of other
trials vary in the
range of
210HRC for SS
side and 150
HRC for SG Iron
side
Friction stir welding methods
Their research use carbidic austempered ductile iron
(CADI), and they used copper and chromium chills to
investigate microstructure and hardness.
S. Laino et al., 2008
Carbides hardness of about 1100HV found in all sample
The carbides are of the type M3C, with chromium partially
substituting iron. leading to an increase in the Cr content found in
the carbides, 8.2 and 6.7% Cr for alloys 5,9% and 2,8%,
respectively.

6
Surface coating using chill as a faster cooling distribution
system to the specimen surface during the solidification step so
that the characterized areas become hard.
This casting method using chill has been widely applied to
steel and aluminium casting systems
Pavithra H S and M
G Anantha Prasada
(2018)
RESEARCH RELEVANT

7
Partially chilled ductile iron (PCDI)
in the as-cast condition during
solidification by means of a chill-in-
the-mold process.
Austempered Ductile Iron at different temperatures
R.C. Dommarco and J.D.
Salvande (2003)
ADI 300 ADI 280
ADI 260
ADI 240
RESEARCH RELEVANT

8
A copper chill and variation content of chromium was positioned at the end of the plate in
order to promote a chilling effect in its vicinity introducing a cooling rate gradient along the
plate.
S. Laino et al (2008)
to produce different variants of CADI, studying its microstructural
characteristics and evaluating some mechanical properties,
particularly the abrasion resistance and the impact toughness.
RESEARCH RELEVANT

9
Some partially melted areas were also noticed in
HAZ near the interface, with ledeboritic structure
Formation of different microstructures in alloyed region:
This can be attributed to high solidification rate in TIG
rocess that can avoid transformation of austenite to
ferrite and M7C3 carbides (α→ + M7C3).
In this study, ductile iron was surface melted and
chromium surface alloyed via pre-placing of
ferrochromium powder with different thicknesses and
subsequently surface melting by tungsten inert gas
(TIG) process. O
(1) alloyed zone
(2) fine hyper-eutectic
structure,
(3) eutectic structure
(4) unalloyed region’s
structure.
RESEARCH RELEVANT

10
Surface melting of nodular cast iron by
TIG operated at 120A and 50V produced a
maximum melt depth of 1.68mm
and 750HV.
The microstructure was dendritic
consisting of transformed austenite in a
matrix of austenite and cementite Fe3C.
RESEARCH RELEVANT

BACKGROUND
Based on some of the studies
discussed, the authors tried to
do surface hardening using the
chill casting method. The author
tries to use SS 304 stainless
steel plate.
HIPOTESIS
Chill as a fast cooling process,
through a very fast compaction
process, the Cr and Ni
composition elements contained
in the stainless steel will diffuse
to the surface of the ductile iron
specimen and cause a white
cast iron structure on the
substrate.
OBJECTIVE
The purpose of this study was
surface hardening using chill
casting to determine the
microstructure, hardness value,
and surface hardness layer
thickness on the specimen
ductile iron.
11

12
Materials and Sample Preparation
The ductile iron material used in this study where are taken from steel scrap and to process
as tensile strength is 120 Ksi, yield strength 90 Ksi and 2% elongation.
Elements TC (a) Mn Si Cr Ni Mo Cu P S Ce Mg
% 3.89 0.45 1.90 0.04 0.17 0.07 0.15 0.03max 0.002max 0.15 0.06
C Si Mn Ni Cr Fe
0.025 0.9 0,7 12 24 Balance
Chemical composition of SS 304

13
Code of
Sample
The thickness of the SS 304
plats
Preheating the chill plate
(Gas LPG )
Cooling With Argon and O2
Spray (10 Ksi)
B1 0.2 mm (700OC) Cooling
B4 0.2 mm Not heating Not Cooling
Chill thickness parameter to the identification of the different sample groups
Length = 335 mm; 25 mm in width and 3
parameters of the thickness: 0.2mm, 0.5mm,
and 1.0mm

14
Chill plate placed into the
mold to position on the
surface of the pattern.
Patern and
chill palte
Construction of
molding
Reff. M. Qian et al (1996)

15
This is a drawing of the detail of the mold
construction. which shows the principles and
techniques of preheating and techniques of cooling.

16
Microstructure and Mechanical Properties Examination
Samples for the microstructure test and Rockwell hardness test can be tested at the same location
Microstructure observation points and Rockwell test points were carried out in the area where the chill plate will
attach. The test was carried out starting with the microstructure test and then testing for Rockwell.

17
The microstructure
formed in the ductile
iron specimen process,
especially in the middle
area for all samples, is
a very round and
uniform nodularization
structure and the dark
graphite nodules
surrounded by α-ferrite
matrix not etched.
The microstructure that is formed on the surface of the B1
sample using a plate chill thickness of 0.2mm is ferrite and
perlite which are contained in the very fine matrix structure
so that at a fast cooling rate the granular transformation of
the perlite structure into a ledeburite structure is called the
“cementite” phase.
This cementite structure is
formed due to the
composition of the Fe-Cr-
Ni system, which is
stabilized at austenizing
temperature in the final of
the solidification step and
then followed by cooling,
giving rise to eutectic
carbide M7C3. This phase
can be categorized as
white cast iron which is
very hard, brittle, and
wear-resistant.

18
Sample B2 and B5
(thickness of plate
0,5mm)
Sample B3 and B6
(thickness of plate
1,0mm)
The microstructure that arises on the
surface of the specimen using a plate chill
thickness of 0,5mm (samples B2 and B5)
is cementite as well but the area affected
by the cementite structure is very large
compared to samples B1 and B4.
In addition, for samples B3 and
samples B6. Where the area formed by
the cementite structure is wider than the
sample using plate chill thickness of
0.2mm (B1 and B4) and 0.5mm (B3 and
B6).

19
The hardness value on the
surface is high because the
particles contained on the
surface are dominated by
chromium structure, so the
combination of Cr and
carbon values above 3.5%
will produce high carbide
iron M7C3 or categorized as
white cast iron structure
Areas that experience
low hardness on
irregular surfaces due
to uneven and
unfocused spraying of
the argon gas cooling
liquid

20
CONCLUSION
Based on the results obtained after casting with a chill casting method to surface
hardening ductile iron, the researchers drew the following conclusions:
1. Casting using 304 stainless steel plate chill with high pouring temperature
successfully diffuses the Cr and Ni structure into the ductile cast iron surface.
2. Cr content above 15% reacts with a carbon value above 3.5% at austenizing
temperature then quenched will produce a ledeburite structure so that it
transforms the ferrite and perlite phases into cementite.
3. The thickness of the plate chill greatly affects the thickness of the hardness
layer on the surface of the ductile iron; the thinner the plate chill is used as a
coating, the thinner the hardness on the surface.
4. The hardness value on the surface of the ductile iron specimen to hard
compared to the middle area because the surface structure is white cast iron.

21
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(Continue)
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