Common Technical Specification for All our Castings

Transcription

1 Common Technical Specification for All our Castings Spheriodal Graphite Iron:- SG Iron Castings are manufactured in accordance with the European Standard EN1563:1997, and in the grades tabulated below: Mechanical Properties Tensile Strength (RM) 0.2% proof stress (Rp0.2) Elongation (A) % min. Grade EN-GJS LT1) N/mm2 min. 400 N/mm2 min EN-GJS RT2) EN-GJS EN-GJS EN-GJS EN-GJS EN-GJS EN-GJS EN-GJS EN-GJS ) LT for low temperature 1) RT for room temperature Minimum impact resistance values measured on V-notched test pieces machined from separately cast samples. Minimum impact resistance values (in J) Grade Mean value from 3 sets Individual Value Temperature EN-GJS LT1) /-2 C EN-GJS LT2) /-5 C

2 Ductile SiMo Iron:- By increasing the Silicon and Molybdenum content of SG Iron, the heat resistanceand strength at high temperatures is increased. Physical properties depend on temperatures; typical values are detailed in thetable below: C= %, Si= %,S < 0.02%, Mg= %, Mo= % Temperature oc Tensile Strength N/mm2 0.2% Proof Stress N/mm2 Modulus of Elasticity N/m x 104 Hardness BHN ( ) The main application for SiMo is in Automotive Exhaust and Turbocharger Systems,but it is suitable for any high temperature application where both strength andductility are required. Machineability is similar to that of EN-GJS Typical Microstructure Guideline Figures for Maximum Manifold and Exhaust Gas Temperatures Material Grade Max. Manifold Temperature C Max. Exhaust Gas Temperature C EN-GJS EN-GJS-SiMo (0.5% Mo) EN-GJS-SiMo (1.0% Mo) EN-GJV-SiMoNi Ni Resist D-5S

3 Ductile Ni-Resist Iron:- By alloying SG iron with Nickel, a stable austenitic nodular iron is produced, giving excellent resistance to growth and oxidation up to 925ºC. The main application for Ni-Resist is in Gas Turbines and Automotive Exhaust and Turbocharger Systems, where temperature fluctuates between 500 and 1050ºC. Ni-Resist is suitable in these applications because its ductility, hot strength and low coefficient of thermal expansion provide best resistance to such severe themal shocks. Physical properties depend on operating temperatures and the exact nickel composition of the SG iron alloy. However typical values for the austenitic Ni-Resist grade D5S are detailed below: Castings PLC Ni-Resist Ductile Iron conforms to: ASTM AS71:1984, grade D5S EN-GJSA-XNiSiCr BS 3468:1986 DIN 1694: GGG-NiSiCr Typical Chemical Composition:- C 2.0% max Si % Mn % Ni % Cr % P 0.08% max Cu 0.50% max Mechanical Properties:- Tensile Strength (Rm) N/mm2 Proof Stress (Rp0.2) N/mm2 Elongation (A) % Modulus of Elasticity (E) 130 to 150 kn/mm2 Brinell Hardness HB Ni Resist Microstructure Guideline figures for maximum Manifold temperatures Material Grade Max. Manifold Temp. C Max. Exhaust Gas Temp. C SG400/ SiMo 0.5% SiMo 1% SiMo Ni Ni Resist D5S

4 Grey Iron:- Grey Iron castings are manufactured in accordance with the European Standard EN 1561:1997 and in the grades tabulated below. Grade Tensile Strength in separately cast sample Rm N/mm² min EN-GJL EN-GJL EN-GJL Grey Iron Microstructure Casting Tolerances:- Castings tolerances are dependent on both the materials cast and the method of production used. General Tolerances for metal alloy castings are specified by the International Standards Orginization, in their Standard ISO 8062 for SG Iron castings, made in machine produced sand moulds. The appropriate grades are Castings Tolerance (CT) 8 to 12. The capability of our green sand plant senables us to offer castings conforming to Grade CT8. Castings produced in Hand will conform to grade CT9. These 2 grades are detailed in the table below: Closer Tolerances may be offered in specific instances.

5 Raw Casting Basic (mm) Total Tolerance(mm) Over Up to and Including CT8 CT Mismatch (not to be added to values above) Unless otherwise specified mismatch shall lie within the tolerance shown. Unless otherwise specified the taper shall be added to the nominal dimension. It is not part of the tolerance. Grey Iron Microstructure

6 Pattern Draft:- Minimum tapers required to achieve satisfactory mould separation

7 Design Service:- We can create an SG Iron casting to serve your purposes From initial meetings we can design and develop the casting concept, undertake virtual analysis and testing and offer 3D and 2D representations of the part. We can then produce real parts for test purposes and analyse the results so you can sign off the project, all with the objective of minimum component cost. To offer this service we have joined forces with Mira Creative Automotive Design, who will combine their extensive experience with our knowledge of cast components and build on the success we have already achieved together on leading automotive projects. Typical Design Project OEM Set Target: To re-design an existing part to reduce material mass by 10% without changes to the material specification, manufacturing process or key performance characteristics Delivered: Using CAE analysis and CAD tools MIRA was able to not only meet these targets but exceed them. Deploying our design know-how a new part was developed that exceeded the OEM target and delivered a weight saving of 18%