ANALYTICAL STUDY ON THE EFFECT OF COPPER AND NICKEL IN AUSTEMPERED DUCTILE IRON USING ANALYSIS OF VARIANCE

Transcription

1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 9, Issue 8, August 2018, pp , Article ID: IJMET_09_08_031 Available online at ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed ANALYTICAL STUDY ON THE EFFECT OF COPPER AND NICKEL IN AUSTEMPERED DUCTILE IRON USING ANALYSIS OF VARIANCE Jamaluddin Hindi and Gurumurthy B.M* *Corresponding author Assistant Professor Sr. Scale, Mechanical & Manufacturing Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal, India Sathyashankara Sharma Profeesor, Mechanical & Manufacturing Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal, India Gowrishankar M.C Associate Professor, Mechanical & Manufacturing Engineering, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal, India Novakar Jain and Madhukar Muralidhar B. Tech student, Mechanical & Manufacturing Engineering Department, Manipal Institute of Technology, Manipal Academy of Higher Education, Manipal, India ABSTRACT Present research work intended to study the effect of Cu and Ni effect on austempered ductile iron. By using design of experiment is used to analyzes the mechanical characterization of tensile and parameters. Temperature and time varying are two parameters which describes the effects on Austempered Ductile Iron (ADI). ANOVA is used to investigate the individual effect a d combined effects of alloying elements on and tensile. For a constant period of austempering, strength (both UTS & YS) and decrease and ductility increases with the increase in temperature. Keywords: Austempered Ductile Iron, analysis of variance, Factorial Design editor@iaeme.com

2 Analytical Study on the Effect of Copper and Nickel in Austempered Ductile Iron using analysis of variance Cite this Article: Jamaluddin Hindi, Gurumurthy B.M, Sathyashankara Sharma, Gowrishankar M.C, Novakar Jain and Madhukar Muralidhar, Analytical Study on the Effect of Copper and Nickel in Austempered Ductile Iron using analysis of variance, International Journal of Mechanical Engineering and Technology, 9(8), 2018, pp INTRODUCTION Production of different variety of material to the required customer specification plays a major role in industry. Investigation of materials for different application research intend in society. Especially durable Strength to weight ratio, low cost materials having more demand, in such conditions ductile cast iron also one of the material to investigating the researcher to meet the organization need. The present work is to improving the by conducting the heat treatment for different grade of alloyed ductile cast iron through Anova. There is a great demand for the materials which have high strength to weight ratio along with the lesser cost. Ductile Iron is one such material which offers all the favorable properties when subjected to a heat treatment called as Austempering. As of late, ADI usages for heavy area castings have been expanding essentially [7]. An expanded casting segment size brings about a diminished cooling rate and thus builds the trouble of getting the required microstructures. The nodule tally additionally diminishes with bigger segment thicknesses [8]. Defects, as smaller scale shrinkage, voids, graphite disintegration, carbide advancement and alloy components isolation additionally shape [9]. Thus, in this manner, to stay away from or lessen the natural isolation, it is important to screen casting variables, for example, hot metal treatment, immunization, tapping and the pouring temperatures, gating and feeding system. In such factors, warm treatment parameters of austenitizing time and temperature and austempering time and temperature have a noteworthy impact in choosing the last microstructure. ADI has been acquired through heat treatment that comprises of quenching also isothermal holding at a temperature scope of around C. Such blend of the cast iron properties, makes this element a correct substitute for steel components and alloys of aluminum. Weariness quality of ADI is higher than aluminum and is impervious to abrasive as well as adhesive wear [5, 6], however most importantly, its utilization will essentially lessen creation costs by approx. 20 % contrasted and wrought steel and 50 % contrasted and aluminum. Another imperative element is the lower heat treatment costs than, for instance, the carburizing expenses. Moreover, the insignificant procedure of making iron castings is less expensive than the steel castings cost (bring down vitality utilization), on account of which the generation costs is furthermore expanded by the plastic framing activity. Warm treatment deprived ADI has better machinability, which builds instrument life. Then again, completed elements have the same mechanical properties like various steel grades, though, are approx. 10 % less heavy. 2. MATERIALS AND METHODOLOGY In this research work, three different alloying elements (Copper, Nickel and unalloyed) have been added to the ADI. The ductile sample s different grades chemical composition mixture is shown below in the Table 1. The samples being utilized in the given examination were delivered by the business foundry of Larsen & Toubro, Kansbahal. The contrast between these three evaluations is: editor@iaeme.com

3 Jamaluddin Hindi, Gurumurthy B.M, Sathyashankara Sharma, Gowrishankar M.C, Novakar Jain and Madhukar Muralidhar initial one is unalloyed, next one is alloyed with Copper and the last one is alloyed with Nickel. Amount of tests of each review has been taken and been warmed to 900 o C for about minutes (austenisation) and after that exchanged rapidly to a salt bath (salt mix was 50 wt. % NaNO 3 and 50 wt. % KNO 3 ) kept up at various temperatures (250 o C, o C, o C) for 30 minutes initially with intervals of, 90 and 120 minutes accordingly. In Figure the demonstration of the examples when austempering takes place. Table 1: The Ductile Iron Specimens chemistry The product samples, hence, are furnace heated to austenization temperature of 8ºC along with the rate of heating maintained at 1ºC / hour and is taken into solution for a hour and a half. Thus, the samples are all of a sudden quenched into the salt bath assigned as his alt 1150 kept up at at temperature 345ºC and further, doused for 150 minutes. Finally, the elements are air cooled. Hence, the ADI prepared arranged possesses a 363 BHN value of. Figure 2.1 Methododology of problem soliving Fig 2.1 describes the type investigation used in the present paper. This problem is solved by using deductive method by using secondary data sampling techniques. Consideration and heating of the samples of each grade for minutes to 900 o C (austenisation) takes place and afterwards it is exchanged rapidly to a salt bath (salt mix has 50 wt. % NaNO3 and 50 wt. % KNO3) kept up at temperature of 2 o C, 310 o C, and 3 o C for 35 min, 65 min, 95 min respectively editor@iaeme.com

4 Analytical Study on the Effect of Copper and Nickel in Austempered Ductile Iron using analysis of variance 3. RESULT AND DISCUSSION 3.1. Multilevel Factorial Design

5 Jamaluddin Hindi, Gurumurthy B.M, Sathyashankara Sharma, Gowrishankar M.C, Novakar Jain and Madhukar Muralidhar 3.2. Hardness plots Figure 3.1 shows the interaction plot of with respect to time temperature and material. In the interaction plot, the intersection on the graph implied high interactions among the three variables. Thus the graph with an intersection coordinate was analyzed. As shown in Figure 1, the interactions between the three fixing variables had an influence over the. The interactions between the variables showed that the temperature and duration tend to affect the. As shown in Figure 1 increases as temperature and duration increase up to certain point. Further increase in the temperature and duration the decreases. Figure 3.1 Interaction plot for Figure 3.2 Main effects plot for Figure 3.3 Residual plots for. Figure 3.2 depicts the mean effect plot of factors that effect on of the different condition of material. The data mean value is used to analyses the each factor effect. The effect of time is shown that, decrease in the as time increases up to certain point. Further increase in the time the increases. The effect of temperature exhibited proportional to. Figure 3.3 shows the probability, fits, and histogram and observation order plots. The normal distribution plot has shown probability of distribution within -5 to 5 range. The output is distributed on above and below the line. Optimum values of time and temperature are analysed by using the contour plot. Figure 3.4 shows the contour plot for the response in terms of the process variables, temperature and time. It is relatively easy to identify on examining from Figure 3.4 that the optimum value is nearly 55 to 85 (mention the unit) and 230 (unit) and response is, maximum at this point. From the Figure 4., it can be inferred that the process may be slightly more sensitive to change in temperature than to change in time editor@iaeme.com

6 material material time Analytical Study on the Effect of Copper and Nickel in Austempered Ductile Iron using analysis of variance Contour Plot of vs time, temperature 90 < > temperature 325 Figure 3.4 Contour plot for v/s time, temperature Figure 3.5 shows the contour plot for the response in terms of the process variables, material and time. The material 2 has shown more wide range of properties with respect to time. The material 1 and 3 has shown less sensitivity to time Contour Plot of vs material, time Contour Plot of vs material, temperature < > < > time temperature 325 Figure 3.5 Contour plot for v/s time, material Figure 3.6 Contour plot for v/s material, temperature Figures show the 3d surface plot of and input process parameters of temperature, time and material. Figure 3.7 exhibited increase in the at lower temperature and moderate time. Figure 3.8 shows effect of temperature and time on. It is clear that the is depended on material and temperature. Figure 3.9 shows effect of material and time on. It is clear that the is depended on material and time. Surface Plot of vs temperature, time S urface Plot of vs temperature, material time 250 temperatur e material 3 temperature Figure 3.7 surface plot for v/s time, temperature Figure 3.8 Contour plot for v/s temperature, material editor@iaeme.com

7 Jamaluddin Hindi, Gurumurthy B.M, Sathyashankara Sharma, Gowrishankar M.C, Novakar Jain and Madhukar Muralidhar Surface Plot of vs time, material material 3 time Figure 3.9 surface plot for v/s time, material. The above Figures demonstrate the variety of concerning the austempering time at temperatures of 250 o C, o C, and 0 o C, for every one of the evaluations.. Hardness expands from 30 min- min austempering time, from min to 90 min it diminishes and again, from 90 min once in a while expands. At the end, it is concluded that is expanding from 30 minutes to one hour and for one hour demonstrating essentialness distinction for both the evaluations. Austempered ductile iron alloyed with copper indicates smidgen higher than the unalloyed counterpart test Figure 3.10 shows the interaction plot of tensile strength. In the interaction plot, the intersection on the graph implied high interactions among the three variables. Thus the graph with an intersection coordinate was analyzed. As shown in Figure 1, the interactions between the three fixing variables had an influence over the tensile strength. The interactions between the variables showed that the temperature and tensile, tend to affect the. As shown in Figure tensile increases as temperature and duration increase up to certain point. Further increase in the temperature and duration the tensile decreases. Figure 3.10 Interaction plot for tensile Figure 3.11 depicts the mean effect plot of factors that effect on tensile strength of the material. The data mean value is used to analyses the each factor effect. The effect of time is shown that, decrease in the tensile strength as time increases up to certain point. Further increase in the time the tensile strength increases (give reason). The effect of temperature exhibited proportional to tensile strength editor@iaeme.com

8 Mat Temp Mat Analytical Study on the Effect of Copper and Nickel in Austempered Ductile Iron using analysis of variance Figure 3.11 Main effects for tensile Figure 3.12 shows the probability, fits, and histogram and observation order plots. The normal distribution plot has shown probability of distribution within -5 to 5 range. The output is distributed on above and below the line. Contour Plot of vs Mat, Temp < > Temp Figure 3.12 Residual plot for tensile Figure 3.13 Contour plot for tensile v/s material, temp Optimum values of time and temperature are analysed by using the contour plot. Figure 3.13 shows the contour plot for the tensile strength response in terms of the process variables, temperature and time. It is relatively easy to identify on examining from Figure 3.4 that the optimum value is nearly 55 to 85 (mention the unit) and 230 (unit) and response is, maximum at this point. From the Figure 4., it can be inferred that the process may be slightly more sensitive to change in temperature than to change in time.figure 3.14 shows the contour plot for the tensile strength response in terms of the process variables, material and time. The material 2 has shown more wide range of properties with respect to time. The material 1 and 3 has shown less sensitivity to time. Contour Plot of vs Mat, Time Contour Plot of vs Temp, Time < > < > Time Time 90 Figure 3.14 Contour plot for tensile v/s material, time Figure 3.15 Contour plot for tensile v/s temp, time editor@iaeme.com

9 Jamaluddin Hindi, Gurumurthy B.M, Sathyashankara Sharma, Gowrishankar M.C, Novakar Jain and Madhukar Muralidhar Figures show the 3d surface plot of tensile strength and input process parameters of temperature, time and material. Figure 3.16 exhibited increase in the tensile strength at lower temperature and moderate time. Figure 3.17 shows effect of temperature and time on tensile strength. It is clear that the tensile strength is depended on material and temperature. Figure 3.18 shows effect of material and time on. It is clear that the tensile strength is depended on material and time. Surface Plot of vs Mat, Temp Surface Plot of vs Mat, Time Temp 2 Mat Time Mat Figure 3.16 Surface plot for tensile v/s material, temp Figure 3.17 Surface plot for tensile v/s material, time Surface Plot of vs Temp, Time Temp Time Figure 3.18 Surface plot for tensile v/s temp, time The above Figures demonstrate the variety of tensile strength concerning the austempering time at temperatures of 250 o C, o C, and 0 o C, for every one of the evaluations. strength expands from 30 min- min austempering time, from min to 90 min it diminishes and again, from 90 min once in a while expands. At the end, it is concluded that tensile strength is expanding from 30 minutes to one hour and for one hour demonstrating essentialness distinction for both the evaluations. Austempered ductile iron alloyed with copper indicates smidgen higher tensile strength than the unalloyed counterpart. 4. CONCLUSION ANOVA has shown that, austempering temperature is the major contributing factor on with a relative contribution of % followed by austempering time with 15 % relative contribution. Regression equations were fit to predict the of the material involving all the factors considered for this study. High R squared value give the good fit and this equation can be used to predict the for the material for the factors with the range of values considered for this study. 1. For a period of time austempering, ductility increase with decrease in ultimate strength and with the increase in temperature. 2. For a particular temperature UTS and changes in to higher version with respect to increase in heat treatment austempering time editor@iaeme.com

10 Analytical Study on the Effect of Copper and Nickel in Austempered Ductile Iron using analysis of variance 3. Ductility improved with respect to austempering time and also increases in strength observed in Cu and Ni alloy ADI but it is up to 1 hour 30 minutes maximum time period. 4. Nickel and copper alloys having significant influence in improving the mechanical properties ADI compared to un alloyed ADI material. REFERENCES [1] Franetovic, V.; Shea, M.M.; Ryntz, E.F. Transmission electron microscopy study of austempered nodular iron: Influence of silicon content, austenitizing time and austempering temperature. Mater. Sci. Eng. 1987, 96, [2] Panneerselvam, S.; Martis, C.J.; Putatunda, S.K.; Boileau, J.M. An investigation on the stability of austenite in austempered ductile cast iron (ADI). Mater. Sci. Eng. A 2015, 626, [3] Putatunda, S.K. Development of austempered ductile cast iron (ADI) with simultaneous high yield strength and fracture toughness by a novel two-step austempering process. Mater. Sci. Eng. A 2001, 315,. [4] Zhang, N.; Zhang, J.; Lu, L.; Zhang, M.; Zeng, D.; Song, Q. Wear and friction behavior of austempered ductile iron as railway wheel material. Mater. Des. 2016, 89, [5] Hemanth, J. Effect of cooling rate on dendrite arm spacing (DAS), eutectic cell count (ECC) and ultimate tensile strength (UTS) of austempered chilled ductile iron. Mater. Des. 1999, 21, 1 8. [6] Cast Metals Development Ltd. Austempered ductile-iron castings Advantages, production, properties and specifications. Mater. Des. 1992, 13, [7] Trudel, A.; Gagne, M. Effect of Composition and Heat Treatment Parameters on the Characteristics of Austempered Ductile Irons. Can. Metall. Q. 1997, 36, [8] Putatunda, S.K.; Gadicherla, P.K. Influence of austenitizing temperature on fracture toughness of a low manganese austempered ductile iron (ADI) with ferritic as cast structure. Mater. Sci. Eng. A 1999, 268, [9] M.F. Ashby, J. Abulawi, H.S. Kong, On surface Temperatures at Dry Sliding Surfaces, Cambridge University Press, Cambridge, [10] J. Zhang, A.T. Alpas, Transition between mild and severe wear in aluminium alloys, Acta Mater. 45 (1997) [11] A.S.M.A. Haseeb, Md. Aminul Islam, Md. Mohar Ali Bepari, Tribological behaviour of quenched and tempered, and austempered ductile iron at the same level, Wear 244 (2000) [12] Rajendra M. Galagali, Dr. R. G. Tikotkar Experimental investigations on wear process parameters optimization of Austempered Ductile Iron using Taguchi technique International Journal of Innovative Research in Science, Engineering and Technology (IJIRSET) eissn: , pissn: , Volume4 Issue 4, April [13] Montgomery, D.C. and Runger, G.C., Applied Statistics and Probability for Engineers, John Wiley & Sons, New York, NY, editor@iaeme.com