solution strengthened ferritic iron dis survey - …greetings ductile iron society members: subject:...

SOLUTION STRENGTHENED FERRITIC IRON DIS SURVEY

Rob Logan/Cathrine Hartung Elkem Metal Inc.

DIS Annual Meeting, June 1-3, 2016 Hilton Garden Inn, Perrysburg, OH

CONTENT


• Review of SSF

• DIS Survey and Results

• Summary of Survey

• Post Summary

1998

Solution strengthened

ferritic ductile iron – SSF

A new material….

SSF vs “Normal” Pearlitic ductile iron

• Higher Silicon - 3.2 to 4.3% vs. approximately 2.5%

• 30% higher yield strength for the same tensile strength

• 100% higher elongation for same tensile strength

• 50% easier to machine compared to GJS 500 - 700

3

vs

SSF – 1563 Standard Comparison

Key Reference

«EN 1563 - New Generation Ductile Irons» Seyfi Değirmenci

Bülent Şirin Bert Duit

(Componenta Döküm. Tic. San. A.Ş)

https://ankirosfoundrycongresstr.files.wordpress.com/2014/09/yeni-nesil-

dc3b6kme-demirler_tc3bcdoksad-kongresi_12sep14.pdf

SSF Survey Background

• An SSF survey was proposed in January 2016.

– Intent was to collect information from DIS members on current status of SSF,

determine interest and potential ideas for research projects.

• Survey concept and most questions were approved at the DIS January R&D.

• Survey sub-committee formed (JW, BR, JMc, DW, RL) to refine and finalize.

– A total of 9 questions were identified to be included in the survey

– Comments at each question are taken

• Susan created an on-line version of the survey in early Feb.

• Survey Introductory page and link were sent out in mid Feb.

• Those surveyed include 59 Foundry individuals from 59 different domestic and

overseas foundries and research patrons. A total of 51 Associate individuals from

51 different domestic and overseas associates were also surveyed.

• A reminder was sent out in early April for survey completion.

6

Greetings Ductile Iron Society Members:

Subject: SSF (Solution Strengthened Ferritic Ductile Iron)

You have been selected to complete a survey by the DIS on the topic of Solid

Solution Ductile Iron, also known as SSF. This material referred to in standard

ISO EN 1563, for iron containing higher than 3% Si.

Note that once you start the survey, it should only take five or ten minutes to fill out

depending on answers. There is no back button to go back a screen so make

sure your answers are what you want before hitting Continue on each page.

"This info will be kept confidential and only reported back to DIS as

consolidated“

Thank you for participating

Jim Wood

Ductile Iron Society


Survey Title Page

Survey Results


1. Do you currently produce SSF (Solution Strengthened Ferritic Ductile Iron) to Standard 1563,(EN-GJS-450-18, EN-GJS-500-14, EN-GJS-600-10)?

Number of Response(s) Response Ratio

EN-GJS-450-18 0 0.0%

EN-GJS-500-14 0 0.0%

EN-GJS-600-10 0 0.0%

None 24 96.0%

Other 1 4.0%

Total 25 100%

4 comments

One foundry able to make 600-10 properties from regular ductile

Another foundry producing Hi Si Ductile for reasons other than strength

Survey Results


2. If you answered none to question 1, have you been asked to quote/produce this material?

Number of Response(s) Response Ratio

EN-GJS-450-18 3 12.0%

EN-GJS-500-14 4 16.0%

EN-GJS-600-10 3 12.0%

None 18 72.0%

Other 1 4.0%

Total 25 100%

3 Comment(s) One response was for Sibodur others are more general in nature

Survey Results


3. What general applications, markets for 1 and 2?

Number of

Response(s) Response Ratio

Automotive 4 57.1%

Oil and Gas 2 28.5%

Agriculture 3 42.8%

Engineering 1 14.2%

Other 0 0.0%

Total 7 100%

Survey Results


4. What technical problems have you experienced making these materials?

5 Comment(s) Chemical Measurement, refinement and control.

Meeting Impact Properties

Melting Logistics

Survey Results


5. Did you overcome some problems? Which ones?

Number of


Yes 0 0.0%

No 5 20.0%

No Responses 20 80.0%

Total 25 100%

1 Comment(s) n/a

Survey Results


6. How did you overcome the problem?

1 Comment(s) Chemistry Control

Survey Results


7. Do you believe DIS should study SSF further? If Yes, what specifically about SSF should DIS Study?

Number of


Yes 21 84.0%

No 2 8.0%

No Responses 2 8.0%

Total 25 100%

16 Comment(s)

Summary to Comments from Question # 7


What specifically about SSF should DIS Study ?

Themes of the Comments

• Fatigue and other Properties.

• Dealing with increased propensity towards Porosity

• Graphite Structure Control

Survey Results


8. Do you envision growth in this material over the next several years? If yes, please provide comments.

Number of


Yes 17 68.0%

No 3 12.0%


Total 25 100%

18 Comment(s)


Please provide comments about growth of SSF?

Comments range from

• Not sure and do not totally understand the material

to

• Yes, This material has many advantages, weight reduction,

consistency, many potential applications.

to

• It can only go up


Survey Results


9. Do you believe the DIS should be promoting this material in the marketplace?

Number of


Yes 14 56.0%

No 8 32.0%


Total 25 100%

15 Comment(s)


Do you believe the DIS should be promoting this material in the

marketplace?

Comments range from

• I say no because all I can see is standard DI being replaced by high Si

DI. If High Si DI can be used advantageously over another type of metal

(e.g. steel, Al), then it would make sense to "promote" this material.

to

• Not until the advantages and drawbacks of the material are well

understood

to

• Possibly if there are specific applications where it would advance the use

of Ductile Iron.


Overall Survey Summary • None of the respondents, with may one exception, are selling SSF but

several are trialing/testing out the material and quoting it.

• There are some technical issues with producing this material and a strong

interest from the respondents for DIS to study SSF. But, only about 34%

of foundries responded to the Survey.

• Some respondents are looking for more information on SSF and do not

yet think DIS should be promoting SSF. For this reason we have included

several additional slides, after this one, with more Information on the

subject of SSF.

• Results of Survey were shared with the Ad-hoc team in late April for

general feedback and summary of comments. Moving forward, these

members are also key to influencing the projects that the R&D committee

focus on.


Comparison of properties

2

3

“Normal” SSF “Normal” SSF “Normal” SSF “Normal”

Property GJS

450-10

GJS

450-18

GJS

500-7

GJS

500-14

GJS

600-3

GJS

600-10

GJS

700-2

0.2% Yield

strength

[MPa] 310 350

+13

% 320 400 +25% 370 470

+27% 420

+12%

Tensile

strength

[MPa]

450 450 = 500 500 = 600 600 =

700 -14%

Elongation

[%] 10 18 +80

% 7 14 +100% 3 10

+230% 2

+400%

Hardness

HB 30 160-210 170-200 -

40% 170-230 185-215 -50% 190-270 200-230

-63% 225-305

-63%

KIC 72 75 +4% 63 72 +14% 38 65

+72% 30

+54%

Data for relative wall thickness of t<30 mm

* Hardness data is for relative wall thickness t ≤ 60 mm

Minimum requirements as given by standard EN 1563

Comparison of properties

2

4

“Normal” SSF “Normal” SSF “Normal” SSF “Normal”

Property GJS

450-10

GJS

450-18

GJS

500-7

GJS

500-14

GJS

600-3

GJS

600-10

GJS

700-2

E-modulus [GN/m2]

169 170 169 170 174 170 176

Poisson’s ratio

0.275 0.28-0.29 0.275 0.28-0.29 0.275 0.28-0.29 0.275

Fatigue limite (rotation

bending) notched 10.6

mm diameter [MPa]

128 130 134 140 149 165 168

Fatigue limite (rotation

bending) unnotched 10.6

mm diameter [MPa]

210 210 224 225 248 274 280

Mass density [kg/dm3] 7.1 7.1 7.1 7.0 7.2 7.0 7.2

Fatigue Properties of SSF

2

5

Source: Richard Lärker

SSF maintain properties throughout the entire casting section from

surface to centre. Properties of SSF are not depending on surface

quality the same way as for ferritic-pearlitic GJS.

Fatigue strength – machined surface

2

6

•No difference in fatique limit for SSF compared to normal pearlitic cast iron, ADI has best fatique properties for machined specimens.

Charpy Impact Testing – Room Temperature


«EN 1563 - New Generation Ductile Irons» Seyfi Değirmenci

Bülent Şirin Bert Duit

(Componenta Döküm. Tic. San. A.Ş)

Doug White DIS Paper - Avoiding Shrinkage Defects and Maximizing Yield in Ductile Iron

• Coordinate %C with: % Si, section size, and pouring temperature - while optimizing C and minimizing Si

• Avoid producing a very high nodule count with a constant nodule size such as generated from over-inoculation or Bi additions.

• Keep base S at a uniform level

• Use thermal analysis to monitor shrinkage propensity

• Avoid long holding periods of base iron. Add 100% crystalline graphite to replace lost carbon during holding while recovering some nucleation effect.

• Avoid long holding periods of treated iron.

• Use appropriate MgFeSi and inoculants.

• Maintain mold strength as uniformly high as possible.

• Use Flow and solidification simulation software. Consider the use of chilling techniques to manipulate freezing rates at required parts of the casting to minimize the need for risers while optimizing structures.


Advantages of SSF

• Combination of higher strength together with high ductility.

• A tougher material than ferritic-pearlitic ductile iron (higher KIC ).

• Similar, perhaps better, impact behavior as ferritic-pearlitic (GJS 500-7)

for GJS 500-14 at Room Temperature

• No carbon depleted surface rim gives no reduction of strength in surface

rim – positive for fatigue life.

• Reduced variation in hardness gives less and more even tool wear and

reduced surface roughness.

• Stronger Ferritic matrix means less negative influence from poor

graphite on mechanical properties

• Lower Density and Lighter castings

• Improved weldability ??

3

2

Disadvantages of SSF

• Greater tendency towards Shrinkage

• Great tendency towards Chunky Graphite

• Lower low temperature Impact properties than pearlitic grades.

• Another iron type to add to your shop complexity.

3

3

For information or assistance with SSF, contact:

• Contact Rob Logan or your Local Elkem Rep

https://www.elkem.com/




solution strengthened ferritic iron dis survey - …greetings ductile iron society members: subject:...

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