Lightweight Design. Designing a lighter future with Advanced Cast Iron. Text Text. Enrico Veneri Business & Technology Development

Transcription

1 Lightweight Design Designing a lighter future with Advanced Cast Iron Enrico Veneri Business & Technology Development 1

2 Agenda Material Typical material properties Manufacturing processes Typical applications 2

3 Material Cast Iron: metallic Iron-Carbon alloy. Carbon >2% each type corresponds to several grades Grey Iron. Std EN 1561 Ductile Iron. Std EN 1563 Vermicular Iron. Std EN White Iron. Std ASTM A532 3

4 Material Cast Iron: metallic Iron-Carbon alloy. Carbon >2% each type corresponds to several grades Grey Iron. Std EN 1561 Ductile Iron. Std EN 1563 Vermicular Iron. Std EN White Iron. Std ASTM A532 depending on - Manufacturing process - Chemical composition 4

5 Cast Irons Manufacturing process: Mould casting Mould preparation Casting Iron preparation Cool down & Shake out Other: Fettling Heat treatment Machining 5

6 Cast Irons Manufacturing process: Continuous Casting Iron preparation Casting Cool down 6

7 Material Cast Iron: focus on conventional Ductile Iron Lightweight Design freedom Strength Durability Recyclability Noise absorbing 7

8 Material Cast Iron: focus on conventional Ductile Iron Ferritic Ductile Iron Std EN1563 Ferritic/Pearlitic Ductile Iron Std EN1563 Pearlitic Ductile Iron Std EN1563 Austempered Ductile Iron Std EN1564 8

9 Material Cast Iron: focus on conventional Ductile Iron Ferritic Ductile Iron Std EN1563 Ferritic/Pearlitic Ductile Iron Std EN1563 Pearlitic Ductile Iron Std EN1563 Austempered Ductile Iron Std EN1564 depending on - Manufacturing process - Chemical composition 9

10 Elongation at Fracture Material Ductile Iron: mechanical properties Lightweight?.we can have something better Ultimate Tensile Strenght 10

11 Elongation at Fracture Material Advanced Cast (Ductile) Iron Ultimate Tensile Strenght 11

12 Material Advanced Cast Iron: how they look like Solid Solution Strengthened Ferritic Ductile Iron Std EN1563 Ferritic/Perlitic Ductile Iron Std FIAT Isothermed Ductile Iron Patented Austempered Ductile Iron Std EN

13 Material Advanced Cast Iron: how they look like Addition of Silicon 3 to 4.5% Obtained as-cast Controlled alloying addition Controlled cooling Solid Solution Strengthened Ferritic Ductile Iron Std EN1563 Ferritic/Perlitic Ductile Iron Std FIAT Obtained by heat treatment (Austempering) Isothermed Ductile Iron Patented Austempered Ductile Iron Std EN

14 Elongation at Fracture Advanced Cast Irons Mechanical properties Ultimate Tensile Strenght 14

15 Ds0/2 [MPa] DK TH [MPa * m^0,5] Advanced Cast Irons Mechanical properties DI Machined test probes - Ø6,5 - Rotating Bending R= -1 - PS 50% Run Out 5 Million Cycles - Short Stair case DI y = 0,6985 HB + 207,3 R 2 = 0,9819 IDI DI 42CrMo4 QT ADI ADI DI Machined test probes - Rotating Bending R= -1 - PS 50% - Run Out 5 Million Cycles - Short Stair case DI IDI DI y = 0,0983HB - 11,929 R 2 = 0, CrMo4 QT ADI ADI HB HB 15

16 Advanced Cast Irons Mechanical properties To keep in mind: Plastic reserve (Rp/UTS) Fatigue properties Elastoplastic behavior Machinability 16

17 Advanced Cast Irons Manufacturing process: casting Mould preparation Casting Iron preparation Pattern tooling Core boxes Cool down & Shake out Other: Fettling Heat treatment Machining Inoculant Cooling time Spheroidizing alloy Good quality Pig Iron Good quality Steel Scrap Foundry returns 17

18 Performance Advanced Cast Irons Manufcaturing performance vs. Series size Manufacturing performance Continuous casting Vertical mould forming Horizontal mould forming Sand printing Hand moulding Units Series size Massive 18

19 Tooling cost Advanced Cast Irons Tooling cost vs. Series size Tooling cost Sand printing Vertical mould forming Hand moulding Horizontal mould forming Continuous casting Units Series size Massive 19

20 Manufacturing methods Selection To keep in mind: Component s geometry Annual volumes Foundry types Quality level Tooling costs Heat treatment Post casting process 20

21 Advanced Cast Irons Opportunities Lightweight Pay Load Net To Shape Durability Short Supply Chain 21

22 Advanced Cast Irons Challenges 22

23 Advanced Cast Irons Solutions 23

24 THANK YOU FOR YOUR ATTENTION! Zanardie Fonderie Enrico Veneri Tel.: