10 11648 J Ijmsa 20130203 14 PDF
10 11648 J Ijmsa 20130203 14 PDF
10 11648 J Ijmsa 20130203 14 PDF
Email address:
[email protected], [email protected](Adedayo, A.V.)
Abstract: Cast Irons are important engineering materials which possess a wide range of attractive properties. Their
properties are significantly dependent on the microstructure of the cast, cast iron components. A way of controlling the
microstructure of cast iron is through the control of cooling rates during solidification. To control cooling rate, the heat
storage capacity of the mould is important. This paper presents the report of a study on the characteristic effects of graphite
flake sizes on some mechanical properties of grey cast iron. Six mould materials with heat storage capacities ranging from
1.52 kJ.m-2.K-1.s-1/2 to 2.16 kJ.m-2.K-1.s-1/2 were prepared and used to cast some grey cast iron samples whose microstructures
were observed by optical microscopy. Mechanical properties of the grey iron were evaluated. The results show that the
properties increased with the heat storage capacity of the mould. Also, the microstructures show a dependence on heat storage
capacity of the mould.
Keywords: Graphite, Graphitization, Cementite, Grey Iron
With this composition of silica sand, other five different temperature of the specimen. The cutting speed was also
compositions of silica sand were prepared by addition of extremely low. These were to guide against any over heating
varying percentages of iron filings to the silica sand. This which may lead to change in microstructure of the samples.
serves to vary the Heat Storage Capacity (HSC) of the mould The produced samples were then tested for tensile strength,
material. The HSC is expressed as the root of the product of toughness and hardness. Metallographic samples were also
the thermal conductivity, the specific heat capacity and the prepared by a gentle grinding on abrasive silicon carbide
density of the mould materials. i.e: papers of successive finer grades 240, 320, 400 and 600
lubricated with water. Polishing of the specimens was
HSC = λ.c.ρ (1) carried out on a 150 mm rotating disc of a METASERV
universal polisher. 7µ and 15 µ diamond pastes were used,
where λ is the thermal conductivity, c the specific heat while kerosene was used as the solvent. Having obtained
capacity and ρ the density of the mould materials. For a mirror like surface, the polished samples were etched using
mould made of different materials, a simple proportion 2% Nital. The etched specimens were observed on the
formula was used to evaluate the resultant HSC i.e. Olympus metallurgical microscope with a minisee optical
viewing system connected to the USB port of a computer in
HSC multicomponet = Σf i λi .ci .ρ i (2) the department of materials science and engineering of the
Obafemi Awolowo University. Micro examination was
where fi is the fraction of component i in a multi-component carried out at a magnification of x100 and images captured
mould (see tables 1 and 2). A control sample, which had no for metallographic analysis. The graphite flakes in the
Fe content, was also prepared (see table 3). microstructure was characterized as inspired by AFS and
ASTM graphite flake type and size rating charts.
Table 1. Standard composition of the green moulding sand
Average 195
Heat storage capacity of Average
Mould hardness 190
the mould, HSC, graphite flake
Hardness (BHN)
material number
(kJ.m-2.K-1.s-1/2 ) sizes 185
(BHN)
180
A 1.52 0.075 168
175
A1 1.65 0.0375 172
170
A2 1.77 0.0375 175
165
A3 1.90 0.01875 182
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08
A4 2.03 0.009375 186 Graphite flake size (m)
A5 2.16 0.0046875 194 Figure 3. Variation of hardness number with graphite flake sizes
Table 6. Variation of elongation with graphite flake sizes Average elongation (%)
20
18
Heat storage capacity of Average Average
Mould 16
the mould, graphite elongation
material 14
Elongation (%)
Table 8. Variation of length of graphite flake with HSC Figure 5. Variation of toughness with graphite flake sizes
Heat storage capacity Length of Average Length of graphite flakes (m)
Mould
of the mould, HSC, graphite graphite flake 0.08
material
(kJ.m-2.K-1.s-1/2 ) flakes (m) sizes 0.07
Graphite flake sizes (m)
0.0125 to 0.03
A3 1.90 0.01875
0.025 0.02
0.00625 to 0.01
A4 2.03 0.009375
0.0125 0
0.003125 to 1.4 1.6 1.8 2 2.2
A5 2.16 0.0046875 HSC(kJ.m-2.K-1.s-1/2 )
0.00625
Figure 6. Variation of graphite flakes length with HSC
International Journal of Materials Science and Applications 2013; 2(3): 94-98 97
4. Conclusion
Figure 7. Microstructures (x100) of G.I. cast by mould material A, A1, A2, The research shows that the HSC of the mould has
A3, A4, and A5 respectively
significant effects on the graphite flakes sizes in the
microstructure of G.I. Graphite flakes sizes in turn affects
Generally, during solidification of G.I., primary austenite
the properties of G.I. This suggests that HSC of a mould
(γ) will separate out first until the eutectic temperature is
could be varied as required to effect changes in the
reached. At eutectic temperature, eutectic consisting of
microstructure, tensile strength, elongation, hardness and
austenite and graphite would form (Adedayo, 2010; Higgins,
toughness of G.I.
2004). This is due to the presence of sufficient silicon which
increases the instability of cementite. The eutectic develops
from nuclei and is in the form of approximately spherical Acknowledgements
particles known as eutectic cells. Graphite appears to be in
Nigerian Machine Tools Limited, Osogbo, Osun State,
the form of separate flakes, but in fact the eutectic cells are
Nigeria is acknowledged for assistance in mould preparation,
three dimensional and roughly spherical in shape (Higgins,
melting and casting of the grey cast iron samples.
2004). Rapid cooling, which produces a greater degree of
under cooling initiates the formation of a greater number of
eutectic cells and also more frequent branching in the
eutectic graphite “leaves”, giving much finer graphite flakes. References
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