1. The document describes an investigation into the effect of temperature preheating on the chill plate to characterize the surface of ductile iron castings. 2. Samples of ductile iron were cast against chill plates that were preheated to different temperatures (500°C, 700°C, 900°C, and unheated) to study the microhardness, surface layer thickness, and elemental composition on the casting surface. 3. Preliminary results found that higher preheat temperatures produced a carbide structure on the casting surface, while no preheating resulted in a fully ferritic microstructure with uniform carbide formation and a pearlite-ferrite microstructure.

1. INTERNATIONAL CONFERENCE ON ENGINEERING MATERIALS AND
MANUFACTURE (ICEMM), MAY 2021
Paper ID: 174
Investigate Temperature Preheating on the Chill Plate to
Identify Surface Characteristic on the Ductile Iron by Sand
Casting
Department of Mechanical Engineering, Faculty of Engineering Diponegoro
University, Prof. Soedharto Street, Tembalang, Semarang 50275, Indonesia
AUTHOR
Natalino Fonseca. D. S. Guterres
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2. OUTLINE
INTRUDUCTION
EXPERIMENTAL
PROCEDURE
RESULTS
CONCLUSION REFERENCES
International Conference on Engineering Materials and Manufacture (ICEMM), MAY
2021
2

3. INTRUDUCTION
3
in the casting process, there are many methods used to harden
the components. One of them is chilled casting method is used to
harden the specimen surface hence it is resistant to high wear.
Reff. Richard B. Gundlach and Lyle R. Jenkins, ASM Handbook, Vol 1, 1993.
Molding sand modification to inprove surface quality, R. Danko 2013
I. Ovali et al. 2015
Its use also increases productivity level, improves product
defects in the surface area, and enhances the casted product's
mechanical properties
Chill is a high thermal conductivity material or component
used to accelerate the cooling of metal in the mold.
International Conference on Engineering Materials and Manufacture (ICEMM), MAY
2021
In the world of casting, ductile iron is very much needed for the
manufacture of machine components by means of casting.

4. 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
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INTRUDUCTION
Duplex Coated DLC
Nitriding and Carbonitriding
Plasma Transferred Arc (PTA)
Horizontal Continuous Casting Machine
(HCCM)
Manually Tig Welding
Tungsten Inert Gas Welding Process
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).
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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 area and
150 HRC for
speroidal graphite
area.
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.
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Surface coating using chill as a faster cooling distribution
system to the specimen surface during the final of
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
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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
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Some partially melted areas were also noticed in HAZ
near the interface, with ledeburitic structure
Theformation of different microstructures in alloyed
region:
This can be attributed to high solidification rate in TIG
Process that can avoid transformation of austenite to ferrite
and 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.
(1) alloyed zone
(2) fine hyper-eutectic
structure,
(3) eutectic structure
(4) unalloyed region’s
structure.
RESEARCH RELEVANT
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Surface melting of nodular cast iron by
TIG operated at 120A and 50V produced a
maximum melt depth of 1.68mm
and 750HV.
RESEARCH RELEVANT
International Conference on Engineering Materials and Manufacture (ICEMM), MAY
2021
The microstructure was dendritic
consisting of transformed austenite in a
matrix of austenite and cementite Fe3C.

11. BACKGROUND
Based on some of the
studies discussed, the
authors tried to do the
surface hardening of the
martensitic ductile cast iron
material using the chilled
casting method. The
application of chilled cast
iron focuses on the diffusion
system between the chill
material and the object
surface.
HIPOTESIS
The atomic structure's (Cr)
attachment in material chill
will be diffused to the
surface of the material
ductile iron is influenced by
the temperature in the area
of interaction between the
chill and the object surface.
Thus giving rise to the
formation of chromium-
carbide with very high
hardness.
OBJECTIVE
The purpose of this study is
to determine the
microhardness, surface layer
thickness, and the element
contained on the surface
with the difference in
preheating temperature
parameters that are
distributed to the chill plate
before the pouring process
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Materials and Sample Preparation
The melting materials used to form martensitic ductile iron are scrap steel and iron. The ductile iron
utilized in this study has a grade of 120-90-02 according to ASTM A536 standards, which is
recommended for users to make wear-resistant components such as gears, crankshafts, bearings and
others.
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 has according to standard ASTM A240
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Temperature preheating parameter to the identification of the different sample groups
The chill manufacturing process is SS 304 plate cut into
rectangles with a length and width of 270mm and 25mm and
bent according to the specimen shape. The number of chill
plate according to the variation of the preheating temperature
Code of
Sample
The thickness of the SS 304
plats
Preheating to surface of chill
plate (OC)
S1 0.2 mm 500OC
S2 0.2 mm 700OC
S3 0.2 mm 900OC
S4 0.2 mm Not Preheating
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Mold design and pattern position
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S4 sample, not
preheating
LPG and
Oxygen
cylinders
Preheating technique
Thermocouple
thermometer
Oxy acetylene torch
holder
S3 sample
S2 sample
S1 sample

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Sample Testing and analysis
International Conference on Engineering Materials and Manufacture (ICEMM), MAY
2021
The microstructure analysis is based on the ASTM
247 procedure
the specimen is polished with sandpaper (400,
800, 1500, and 2000), then etched with nital 98mL
ethanol and 2mL nitric acid (HNO3) based on the
test guide on ASM Handbook Vol. 9
SEM-EDX is used to identify contaminated or
unknown particle interactions between two materials
from ductile cast iron and austenitic stainless steel
(SS 304).
The expected results are the percentage of element
content deposited in the surface area will be detected
by EDX, and the coating layer's thickness on the
surface measured by SEM cross-section.
Furthermore, the measurement process for the
diffusion thickness layer was processed by ImageJ,
then measurements were taken ten times to take the
average value

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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.
International Conference on Engineering Materials and Manufacture (ICEMM), MAY
2021
Uniformity of graphite nodules with
microscopic magnification 200x.
This graphite structure is under the
specifications of the nodular cast iron
material according to the ASTM A 536
standard.
RESULTS

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Sample S4 is not using preheating)
Sample S1 use preheating of
500OC
The microstructure formation on specimen S4 is
average and consists of a fully ferritic-matrix
microstructure. Therefore, with the rapid cooling process,
eutectic carbide formation and a microstructure containing
cementite, ferrite, and pearlite are very uniform and
compact on the surface area.
International Conference on Engineering Materials and Manufacture (ICEMM), MAY
2021
The coating area is found to be a primary
eutectic carbide or Cr-carbide structure and is
defined as (FeCr)3C.
RESULTS

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International Conference on Engineering Materials and Manufacture (ICEMM), MAY
2021
Sample S2, use preheating of 700OC)
That the average microstructure consists of ferrous carbide and acicular ferrite
near the diffusion zone with the small number of martensite phases.
The microstructure growth in the diffusion zone is a very large eutectic carbide
called (FeCr)7C3 because the element Cr diffuses too much to the surface.
The ledeburite layer so-called white cast iron layer which is dominant in the
surface area.
Sample S3, use preheating of 900OC)
RESULTS

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International Conference on Engineering Materials and Manufacture (ICEMM), MAY
2021
The results of SEM-EDX and SEM-Crossection
are taken from different temperature
parameters, then they will be compared
between the use of low and high temperatures
preheating.
RESULTS

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2021
Temperature
preheating
Carbon (C) Silicon (Si) Chromium (Cr) Nickel (Ni)
Weight
(%)
Atomic
(%)
Weight
(%)
Atomic
(%)
Weight
(%)
Atomic
(%)
Weight
(%)
Atomic
(%)
Not using
preheating 18.67 47.53 1.98 2.16 0.13 0.08 0.11 0.06
500°C 26.01 57.93 1.65 1.57 3.93 2.04 0.56 0.26
700°C 14.77 40.83 1.79 2.11 5.06 3.23 1.72 0.97
900°C 27.88 46.58 0.78 0.87 11.85 7.13 0.40 0.21
RESULTS SEM-EDX calculation results show that the higher the preheating temperature is used, the thicker the
diffusion of Chromium elements onto the surface

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CONCLUSIONS
International Conference on Engineering Materials and Manufacture (ICEMM), MAY
2021
Based on some of the results above then, the following conclusions were drawn:
1. By using the preheating method for the chill plate before the pouring process, it has resulted in a different
surface layer by not using preheating.
2. Compared with do not use preheating proses on the chill plate, the formation of a carbide eutectic
structure on the surface of Y-Block specimens with a thickness of 0.012mm to 0.020mm, increases the
hardness up to 900HV. Furthermore, by preheating, it can diffuse Chromium elements onto the ductile iron
surface to form (FeCr)3 C and (FeCr)7C3 structures called ledeburite structures, which are categorized as
white cast iron with a high hardness.
3. High preheating temperatures increase the thickness of the hardness layer on the ductile iron surface and
raise the high hardness value on the surface. The higher preheating temperature used, the greater the
chromium element's ability that diffuses to the ductile iron surface to reach 7.13%.
4. The results obtained, this method can be applied to surface hardening of components that require high
wear resistance such as gears, hot rolling mills, crankshafts, bearings, cylinder blocks, and others.

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