SECTION V ALLOY DUCTILE IRONS SayFigure 5.1 Figure 5.2 Effect of silicon content on the eritical temperature in cast irons. INCREASE IN WEIGHT, gem Effect of silicon on the oxidation of ferrtic Ductile Iron in air at 650°C (120°).ALLOY DUCTILE IRONS Introduction SILICON- ‘MOLYBDENUM DUCTILE IRONS Effect of Silicon Three families of alloy Ductile Irons ~ austenitic (high nickel ~ Ni ~ Resist), bainitic and ferritic (high silicon-molybdenum) ~ have been developed either to provide special properties or to meet the demands of service conditions that are too severe for conventional or austem- pered Ductile Irons. While conventional and austempered Ductile Irons contain limited percentages of alloying elements primarily to provide the desired microstructure, alloy Ductile Irons contain sub- stantially higher levels of alloy in order to provide improved or special properties. The high silicon levels, combined with molybdenum, give the ferritic Ductile Irons superior mechanical propertios at high tem- peratures and improved resistance to high temperature oxidation. The high nickel content of the austenitic Ductile Irons, in conjunction with chromium in certain grades, provides improved corrosion resistance, superior mechanical properties at both elevated and low temperatures and controlled expansion, magnetic and electrical properties. Bainitic. irons are used where high strength and good wear resistance are obtain- able in either the as cast state or heat treated using from 1-3% alloy (Ni and Mo). The bainitic irons are not as widely used as the austenitic or Si-Mo Ductile Irons, so they will not be covered in this chapter. The reader is encouraged to contact us for more information or consult other publications such as the “Iron Castings Handbook” available through the ‘American Foundrymen’s Society. Alloy Ductile Irons containing 4-6% silicon and/or 0.4-2% molybdenum were developed to meet the increasing demands for high strength Ductile Irons capable of operating at high temperatures in applications such as exhaust manifolds or turbocharger casings. The primary prop- erties required for such applications are oxidation resistance, structural stability, strength, and resistance to thermal cycling. ‘These unalloyed grades retain their strength to moderate temperatures (Figures 3.21-23), perform well under low to moderate severity thermal cycling (Figure 3.37) and exhibit resistance to growth and oxidation that is superior to that of unalloyed Gray Iron (Table 3.1). Ferritic, Ductile Irons exhibit less growth at high temperatures due to the sta- bility of the microstructure. Alloying with silicon and molybdenum significantly improves the high temperature performance of ferritic. Ductile Irons while maintaining many of the production and cost advan- tages of conventional Ductile Irons. Silicon enhances the performance of Ductile Iron at elevated tempera- tures by stabilizing the ferritic matrix and forming a silicon-rich sur. face layer which inhibits oxidation. Stabilization of the ferrite phase reduces high temperature growth in two ways. First, silicon raises the critical temperature at which ferrite transforms to austenite (Figure 5.1). The critical temperature is considered to be the upper limit of the Saat) AyMPs 100 Seal Tense 0 seo a # : seo} 7 Figure 5.3 5 é 1 0 g 0 oot Souls 27 soo fs 40 te aol a suicon conten, % Influence of siicon on the room temperature mechanical propertis offerte Duc en. > = S = 3 “Tensile Strength Stress Rupture 3 st Pal il (Ma) a00-F | 000-F | 1200 | 1000n @ 1000-F wave | sarc | esorc sore fn ay ron amass) | 7a) | 2060 saan 0040-18 DI ance7oy_| 250373) [12000 2207 | | E a Si seisee) | a6ese) | 1300) 10060) WS MODE] err) | 40H | soHsN | 10 fax Si-am Moi] estas) | oii) | 20198) 07) Gray iron: Uralloyed, seseralieved Ductile Ions: Sub-Critialy annened t 1480°F 788°C) "Effect of silicon and molybdenum on the high tomporature tensile and creep rupture strengths of ferrtic Ductile Iron.Figure 5.4 useful temperature range for erritic Ductile Irons. Above this tempera- ture tho expansion and contraction associated with the transformation of ferrite to austenite can cause distortion of the casting and cracking of the surface oxide layer, reducing oxidation resistance. Second, the strong ferritizing tendency of silicon stabilizes the matrix against the formation of carbides and pearlite, thus reducing the growth associated with the decomposition of these phases at high temperatures, ‘The oxidation protection offered by silicon increases with increasing silicon content (Figure 5.2). Silicon levels above 4% aro suificient to prevent any significant weight gain after the formation of an initial oxide layer. Silicon influences the room temperature mechanical properties of Duc tile Iron through solid solution hardening of the ferrite matrix. Figure 5.3 shows that increasing the silicon content increases the yield and ten sile strengths and reduces elongation. For silicon levels above 6%, the material may become too brittle for engineering applications requiring any degree of toughness. Thus, the best combination of heat resistance and mechanical properties are provided by silicon contents in the range 4-6%. The solid solution strengthening effect of silicon persists to tem- peratures as high as 1000°F (540°C) but above that temperature the ten- je strength of high-silicon alloys is reduced as well (Table 5.1). Figures 54 and 5.5 illustrate the high temperature creep and stress-rupture strengths obtained in ferritic Ductile Irons containing 4% silicon. 1200 F (650 C) 4% Si + 2% Mo ake TENSILE STRESS, MPa TENSILE STRESS, 1000 psi 0.007 aor OF 70 70 MINIMUM CREEP RATE, PERCENT PER HOUR Influence of molybdenum on the minimum creep rate of ferritc Ductile Iron. SECTION VSECTION V Figure 5.5 Figure 5.6 roof 20h 100 80 60 40 wo 1200 F (650.6) 20 10 TENSILE STRESS, MPa TENSILE STRESS, 1000 psi 1500 F (815 C) TIME TO RUPTURE, HOURS Effect of molybdenum on the stress-rupture behaviour of feritic Ductile Ira. Unaloye fer kon 05% Mo terreiron 0.5% Mo tee eon 400°e oe Cunsteoe STRESS, MPa Unaoyed fete kon 407 ase ON 17248, esczs cont stele tas" © 700 700 To000 Ta0 000 THE, h 1% creep strain data for feritic Ductile Irom and C-Mn steels at 400°C (750°F) and 450°C (840°F),Figure 5.7 Effect of Molybdenum High Silicon with Molybdenum Applications STRESS, MPa TIME, h Creep rupture data for ferritic Ductile Iron and C-Mn steels ‘at 00°C (750°F) and 450°C (40°F) Molybdenum, whose beneficial effect on the croop and stress-rupture properties of steels is well known, also has a similar influence on Duc- tile Irons, Figures 5.6 and 5.7 show that the addition of 0.5% molybd num to ferritic Ductile Iron produces significant increases in creep and stress rupture strengths, resulting in high temperature properties that are comparable to those of a cast steel containing 0.2% carbon and 0.6% manganese. ‘The addition of up to 2% molybdenum to 4% silicon Ductile Irons produces significant increases in high temperature tensile strength (Ta- ble 5.1), stress-rupture strength (Tables 5.1 and 5.2 and Figure 5.5 and creep strength (Figure 5.4). Molybdenum additions in the range 0-1% to high-silicon Ductile Irons have been found to be very effective in in- creasing resistance to thermal fatigue (Table 5.3 and Figure 3.37). High silicon-molybdenum Ductile Irons offer the designer and end user @ combination of low cost, good high temperature strength, superior resistance to oxidation and growth, and good performance under ther- ‘mal cycling conditions. As a result these materials have been very cost- effective in applications with service temperatures in the range 1200-1500°F (650-820°C) and where low to moderate severity thermal cycling may occur. Ductile Irons with 4% silicon and 0.6-0.8% molybde- ‘num are presently specified for numerous automotive manifolds and tur- bocharger casings. High silicon irons containing 1% molybdenum are ‘used for special high temperature exhaust manifolds and heat treating racks. SantaStree to rupture Type of iron | Temperature, | MPa (kat) *c 100k | 1000 22% Si 650] 40 5.6) | 20 2.9) Table 5.2 4% Si 650 28 (4.1) 33 SL 1% Mo sso__| 43 (6.3) 4% Si 705 fwen| aan 3% Si 1% Mo jos__| 33 6) | 25 83} 4% St ais 7 (1.0) 33 Si 196 Mo ais | St) ‘fect of silicon and molybdenum on sree opture strength of fer- file Ducile rons Temperature cycling, [Gycles to “Type of iron peaecuanenel tances 21% Si 200 = 650 20 Table 5.3 3.6% Si 200 - 650, 173 3.6% $1 0.4% Mo 200 = 680 a8 44% S10.2% Mo 200 - 650 209 44% Sogo Mo 200 = 650 333 Influence of silicon and molybdenum on the thermal cycling be- haviour of ferstc Ductile Ian ‘sme oor frail et heme trans | pict _ vane cee : cme | = (Pre DSSS] [| [| SI TD HTH Te ence emcee Hl ve am mor» Ms 818 on BRR ee ee re [saa a ie Ta a Ga en ae cH Eel 2 iba a 290 380 269 oon 3408 0s0 3 ae —_e Haw aH Enieei® la i 20 18 100 908 300 010 fis_Sunetige pa os ae eB wid @ Sameer” ewes Ho oi 2 RR GEE = Gt |= cone 6 nw EBSD Me F Semmes Table 5.4 ASTM and ASME specifications and typical applications for all types of Ductile Ni-Resist Irons.Production. Requirements AUSTENITIC DUCTILE IRONS High silicon-molybdenum Ductile Irons can be produced succesfully by any competent Ductile Iron foundry that has good process control, provided that the following precautions are taken. Carbon levels should be kept in the range 2.5-3.4%. Carbon content should be reduced as the silicon level and section size increase. sil yn may vary from 3.7 to 6% according to the application. Increas- ig the silicon content improves oxidation resistance and increases strength at low to intermediate temperatures but reduces toughness and machinability ‘Molybdenum contents up to 2% may be used. Increasing the molybdenum level enhances high temperature strength and improves machinability. Pearlite and carbide stabilizing elements should be kept as low as pos- sible to ensure a carbide-free ferritic matrix. Normal nodularizing and inoculation practices should be used but pour- ing temperatures should be higher than for normal Ductile Iron. In- creased dross levels require good gating and pouring practices, and increased shrinkage necessitates larger risers. Castings must be shaken out and handled carefully to avoid breakage, and all castings should be heat treated to improve toughness. Castings are commonly given a sub- critical anneal ~ 4h at 1450°F (790°C) and furnace cooled to 400°F (200°C) - but a full anneal is required if the matrix contains significant quantities of carbides and pearlite. Machinability is similar to normal pearlitic /fervitic Ductile Irons with hardness values in the range 200-230 BHN, A family of austenitic, high alloy Ductile Irons identified by the trade name “Ductile Ni-Resist” have been produced for many years to meet ‘a wide range of applications requiring special chemical, mechanical and physical properties combined with the economy and ease of production of Ductile ron. Ductile Ni-Resist irons containing 18-36% nickel and up to 6% chromium combine tensile strengths of 55-80 ksi (380-550 MPa) and elongations of 4-40% with the following special properties: # corrosion, erosion and wear resistance, ‘© good strength, ductility and oxidation resistance at high temperatures, © toughness and low temperature stability. © controlled thermal expansion, © controlled magnetic and electrical properties and © good castability and machinability, SECTION V‘Typical Mechanical Properties of Ductile NiResist Irons ‘Table 5.5 Typical room temperature mechanical properties of Ductile Ni-Reslst Irons. ‘SubZero Temperature Impact Properties ‘Charpy Vee Math eb) Table 5.6 Effect of temperature on impact properties of different types of Ductile Ni-Resist(IMLIDE « 1.8558 J), 35 Figure 5.8 Probable Average Curve 1 5 = ° a 00 300 200 100 0 100 Test Temperature, F Effect of temperature on the impact properties of type D-2M Ductile Ni-Resist (afetbe = 13858),Specifications and Recommendations Mechanical Properties Table 5.4 summarizes the ASTM and ASME specifications for Ductile \Ni-Resist Irons and lists typical applications for each grade. Section XII contains further information on international specifications for these materials. The applications listed for each grade take advantage of the following general characteristics. ‘Type D-2, the most commonly used grade, is recommended for service requiring resistance to corrosion, erosion and frictional wear up to tem- peratures of 1400°F (760°C). ‘Type D-2B provides higher resistance to erosion and oxidation than Type D-2 and is also recommended for use with neutral and reducing salts. ‘Type D-2C is recommended where resistance to corrosion is less severe and high ductility is required, ‘Type D-2M (2 classes) is recommended for cryogenic applications requir- ing structural stability and toughness. Type D-3 exhibits excellent elevated temperature properties and resistance to erosion. It is recommended for applications involving ther- ‘mal shock and thermal expansion properties similar to ferritic stainless steels. ‘Type D-3A provides good resistance to galling and wear, and intermedi- ate thermal expansion. ‘Type D-4 provides resistance to corrosion, erosion and oxidation that is superior to Types D-2 and D-3. ‘Type D-5 is recommended for applications requiring minimum thermal expansion. ‘Type D-5B should be used in applications requiring minimum thermal stresses, and good mechanical properties and resistance to oxidation at high temperatures. ‘Type D-5S provides excellent resistance to oxidation when exposed to air at temperatures up to 1800°F (980°C) and is also recommended for applications involving thermal cycling at temperatures up to 1600°F (870°C) ‘The room temperature mechanical properties of Ductile Ni-Resist Irons are described in Tables 5.4 and 5.5. The data shown in Table 5.5 are from either 1 inch (25 mm) keel blocks or castings tested in the as-cast condition. Castings should be ordered according to ASTM A439 or other specifications, but for special applications specific properties may be defined in more detail by agreement between the customer and the foundry, SECTION VSECTION V Elevated Temperature Properties of Ductile NiResist Alloys ; two. | tyeo2 | tye02e | tye03 | tops | treo Tape 0-58 tr | tro oes | a ah eer ge | | ge | | em | om | om | oom | om wget Fag | om | sup | om | om | ce | caw | con | ane ca BR) 2) 8 |e) |) 8) & iter Gi | aio | GSB | zie | ioe | am sae | i B 2/2 \e| 8/8) 2 2|s i! ee | | | UE | i | iS “eo | ae | age | me | = | ae ae | oe a [SS |) oo oS) eR commen | | oe = |e - vio | IP Be) = | = | & vo | Fostete: Values in parentheses are extapoated or ntmpoaied. + Type D-28 reo, — | Table 5.7 Elevated temperature properties of Ductile Ni-Resist Irons. 5-10Elastic Properties Strength and Elongation Low ‘Temperature Properties Figure 5.9 Ductile Ni-Resist Irons have elastic moduli in the range 13-19 x 108 psi (0-130 GPa). These values are significantly lower than those of con- ventional Ductile Irons and are very similar to Ni-Resist irons with flake graphite. The proportional limit of as-cast Ductile Ni-Resists varies from 10 to 19 ksi (70-130 MPa), reflecting the influence of the austenite matrix and chromium content on initial yielding. With the exception of Type D-2M, the 0.2% yield strength and tensile strength are similar for all Types because of their common austenitic matrix. Unlike strength, elongation and toughness vary significantly be- tween Types, depending upon the chromium, molybdenum, and sili- con contents. In the low-chromium Types D-2C and D-5, as-cast clongations vary from 25 to 40%, with correspondingly good toughness. Types D-2, D-2B, D-3 and D-5B, all containing nominally 2 to 3% chro- mium, have as-cast elongations the range of 5 to 20% and lower tough ness. Due to the stability of the austenite matrix, the mechanical properties of Ductile Ni-Resists are not strongly affected by heat treat- ments. High temperature treatments to disperse carbides can increase the yield and tensile strengths of Type D-2 by 10-15 ksi (70-105 MPa) while retaining good elongation. Annealing treatments may improve elongation values through the reduction of the carbide content and the spheroidization of any remaining carbides, Ductile Ni-Resist Irons, due to their austenitic matrices, retain their toughness and ductility to very low temperatures (Table 5.6). Type D-2M, with slightly higher nickel and manganese contents to extend the sta- bility of the austenite phase to extremely low temperatures, improves on the already superior low temperature properties demonstrated by the other Types of Ni-Resist. Figure 5.8 shows that the Charpy v-notch impact energy of Type D-2M increases with decreasing temperature, peaking at - 275°F (- 170°C) and retaining room temperature tough- ness to temperatures as low as - 320°F (- 195°C). Comparison of cree strengths of several Du NiResiet trons and CF-4 stainless steel “1 SECTION V: 2 soona i ? » ” soow|— 6 “ Rr, 2 «000 g Figure 5.10 i ve ° ‘ oom § Yau See |. ee 2 0010 00 fm a00 —v000 00 Tepe Shortterm tensile properties of type D-2 Ductile Ni-Resist at elevated temperatures, Oxidation Resistance Inches Peetaton Per Yar Table 5.8 Bac on 5 30, Bite Nest pe D2 Dist Ne eset pe Bo Date Wifes Type D4 East Reet Tape 2 ‘ped Sante St Test }—Fumae atesphere—ai. 400. a 300 Tat 2—uimae strgephare—2i 60 3 ED.1700 F600, between 60 ‘0 and 66D 00 F600 9810900 5, NiResist, conventional ines see Oxidation resistance of Ductile Ni-Resi and high silicon Ductile Irons and type 309 5-12High Temperature Properties Thermal Cycling Resistance Oxidation Resistance Wear and Galling Table 5.7 summarizes the high temperature mechanical properties of the various Types of Ductile Ni-Resist Irons. Creep data for these materi- als are shown in Figure 5.9, with those of CF- stainless steel included for reference. The addition of 1% molybdenum to Duetile Ni-Resist in- creases the high temperature creep and rupture strengths of Types D-2, D-3 and D-5B to the extent that their creep and rupture propert equal o superior to those of cast stainless steels HF and CF-4 5.10 shows the short-term, tensile properties of Type D-2 from room tem- perature to 1400°F (760°C). It is interesting to note that there is no tem- perature range in which embrittlement occurs, and that yield strength does not decrease appreciably until temperatures exceed 1200°F (650°C), ‘When cycled to temperatures of 1250°F (675°C) and above, conventional ferritic Ductile rons and steels pass through a “‘critical range” in which phase changes produce volume changes resulting in warping, cracking and loss of oxidation resistance. Ductile Ni-Resist Irons, because they are austenitic at all temperatures, do not undergo such phase changes and thus possess superior resistance to high temperature thermal cycling ‘Table 5.8 compares oxidation data for certain Types of Ductile Ni-Resist with conventional and high-silicon Ductile Irons, conventional Ni-Resist, and type 309 stainless steel. The chromium-containing Ductile Ni-Resists D-2, D-2B, D-3, D-4 and D-5B provide good resistance to oxidation and maintain satisfactory mechanical properties at temperatures as high as, 1400°F (760°C). These properties make these grades highly suitable for applications such as furnace parts, exhaust lines and valve guides. For service temperatures exceeding 1300°F (700°C), Types D-2B, D-3, and D-4 are preferable. Type D-5S, with its superior dimensional stability and oxidation resistance, should be used when these properties are re- Quired for service temperatures as high as 1600°F (870°C). Ductile Ni-Resists and Ni-Resist with flake-type graphite exhibit corro- sion resistance which is intermediate between those of unalloyed Duc- tile Iron and chromium-nickel stainless steels. Table 5.9 summarizes the corrosion resistance of Types D-2 and D-2C Ductile Ni-Resist in a num- ber of corrosive environments. It is generally desirable to have chromium ‘contents in excess of 2% for materials exposed to corrosive media, There- fore, Types D-2, D-2B, D-3, D-4, D-5B and D-5S are recommended for applications where a high level of corrosion resistance is desired. There are exceptions to these general comments and the reader is advised to consult the International Nickel Company bulletin ‘Engineering Proper- ties and Applications of Ni-Resists and Ductile Ni-Resists."” for infor- ‘mation on the corrosion behaviour of Ductile Ni-Resist Irons in over 400 environments, The presence of dispersed graphite, as well as the work-hardening character of Ductile Ni-Resist alloys, provide a high level of resistance to frictional wear and galling. Types D-2, D-2C, D-3A and D-4 offer good aa aySU Corrosion Resistance of Ni-Resist Austenitic Nickel Irons Expressed in inches penetration per year i T ores Maia Twanae | Teo? “Renae sts out: 105; UO) NSIS 13 dys DE GEH) 625A mi ‘oars | oni Arm sate on 10% (MAS, 937,13 dys at 9 EF, 82311 mn ort tee vagus leh 385 ever iy $07: etyene yea 4352 0, 455 MS, 27% NC, 08% Nas | "fee Rade etwas atas af sree | eons nts eee cmmereat 5105, dm, 29 days at abosphve temp. S nai Neal conde wlan. 185 hp 53.7 ap at 06 625, 008 oot Phage ac 85%, pried 213066 A Velo LET pt min 2 day om 23s og ttm nde ig SD fl of es, 27 C3008 gi MAD, aes of WH SpE, day at aR 2 oe eons coz So wt st 208601), ety 2 Here ye oo oo Sha Hine 15555 MaEL 9035 MOK, 107, MgSO 2 day oF coms oats ‘Stun batate on 205 MSD, ph L313 ys at 50 CF, 25 min, cous, oon Sodium side solution: 5% NaCl, p58 7 cay at 300 E825. mis ows cots Sean haronte: 07 Hh + hey ono sspnées NC 13 as € 3 Agel min soma eae £07; NaOH oom oma suason 10 ones aoe 5 we mon | some ous aE nD 9K oon mse Siu sate saben: 10% Na,S0, 9H 40,7 days a 30 GE F825 mm, nis amt Sauna 9%, 0130 C7) seid, Vey 14 pw mn, das on une 7 NED, Sry pl 00 HL, 0 gg NHC, 80 os ome ous S30, Vey 6 pe mn, 28 ys cons anes igo toe arn is 0°. Nt, 3; CO, 315 10,108 day at 85. C HS ow vey oan 028 echidna ph 825,19 days at 0), 52518 me aus ones Canis 1% vem. Table 5.9 Corrosion resistance of Ductile Ni-Resist Irons. Types D-2 and D-2C, Physical Properties of Ductile NiResist eet eee | ese | tee pce te ny [tee | toc | “te Table 5.10 Physical properties of Ductile Ni-ResistErosion Resistance Physical Properties Thermal Conductivity ‘Thermal Expansion Electrical and Magnetic Properties wear properties when used with a wide variety of other metals at tem- peratures from sub-zero to 1500°F (815°C). Tests performed from room temperature to 1000°F (540°C) have shown that ‘Types D-2 and D-2G have lower wear rates than bronze, unalloyed Ductile Iron, and INCONEL 600. The improved wear resistance is attributed to the spheroidal graphite and the formation of a nickel oxide film at higher temperatures. Types D-2B and D- provide inferior wear resistance compared to other Ductile Ni-Resists because they contain massive carbides which might abrade a mating material. Ductile Ni-Resist castings, particularly those containing higher chromi- um levels, provide excellent service where resistance to erosion and cor- rosion are required, such as in the handling of wet steam, salt slurries and relatively high velocity corrosive liquids. Steam turbine components, such as diaphragms, shaft seals and control valves are proven examples of the excellent resistance of Types D-2 and D-3 to steam erosion at high temperatures. Resistance to cavitation erosion makes Ductile Ni-Resist suitable for pump impellers and small-boat propellers. Higher-chromium Types D-2B, D-3, and D-4 are recommended when cavitation erosion is severe, Service results show that Type D-2 is superiorto straight chro- mium stainless steels or bronzes in resisting cavitation for applications such as boat propellers and pump impellers. Table 5.10 summarizes the general physical properties of Ductile Ni- Resist Irons. The thermal conductivities of Type D-2 Ductile Ni-Resist, Ni-Resist, Gray Iron and several steels are listed in Table 5.11. The spheroidal graphite shape and austenitic matrix are responsible for the relatively low con- ductivity of Ductile Ni-Resists. Figures 5.11 and 5.12 illustrate the wide range of thermal expansion exhibited by the different Types of Ductile Ni-Resist and the influence of nickel content on the thermal expansion behaviour of Type D-3. High expansion Types D-2 and D-4 are used to match the expansion of materi- als such as aluminium, copper, bronze and austenitic stainless steels. ‘Type D-3, with different nickel levels, is used to obtain the controlled. intermediate thermal expansion required to match the thermal expan- sions of a wide variety of steels and cast irons. Types D-5 and D-5B are recommended for applications requiring maximum dimensional stabil- ity, such as machine tool parts, glass molds and gas turbine housings. Table 5.12 compares the electrical resistivity of Type D-2 Ductile Ni- Resist with that of Ni-Resist, Gray Iron and various steels. Table 5.13 ‘compares the magnetic permeability of all Types of non-magnetic Duc tile Ni-Resist with that of Ni-Resist, Gray Iron, bronzes and a variety of steels. Values for Types D-3, D-3A, D-5 and D-5B are not shown because they are ferromagnetic. The non-magnetic character of Types D-2 and 5-15 Na‘Thermal Conductivity Mate Slee marino ives RS Sib oe | sd ys Table 5.11 Therm: igure 5.11 7 Mean coefficient of thermal expansion for various types of . Ductile NEResist Figure 5.12 ffoct of nickel onthe ther- ‘mal expansion oftype D-3 Ductile Ni-ResistProduction Requirements Machinability Heat Treatment Table 5.12 D-2C has been applied in several industrial applications where magnet- ic permeability must be kept at a minimum in order to prevent exces- sive heat generation and power loses from eddy currents Special Ductile Iron foundry practices, some of which affect casting de- sign, are required for the production of Ductile Ni-Resist castings. To obtain maximum casting performance and minimum production cost, the design engineer should initiate consultations, at an early stage in the design process, with a Ductile Iron foundry experienced in the production of Ductile Ni-Resist castings. ‘The machinability of Ductile Ni-Resists falls between that of pearlitic Gray Iron with a hardness of about 240 BHIN and mild steel when machin- ing practices follow those recommended in the Inco publication A242, “Machining and Grinding Ni-Resist and Ductile Ni-Resist.”” Large and complex Ductile Ni-Resist castings should be mold-cooled to 600°F (315°C) before shakeout to relieve stresses. When required, stress-reliof should be performed at 1150-1250°F (620-675°C). Anneal- ing, which softens and improves ductility primarily by the decomposi- tion and spheroidization of carbides, should be conducted at 1750-1900°F (960-1035°C) for 1 to 5 hours, depending on section size and the degree of decomposition and spheroidization desired. Anneal- ing should be followed by air cooling or furnace cooling if minimum hardness and maximum elongation are required. When Ductile Ni-Resist is to be used at temperatures of 900°F (480°C) and above, the casting can be stabilized to minimize growth and war- page by holding at 1600°F (870°C) for two hours, followed by furnace cooling to 1000°F (540°C), followed by air cooling to room tempera- ture. To assure dimensional stability for all Types of Ductile Ni-Resist the following heat treatment should be performed: hold at 1600" (670°C) for 2 hours plus 1 hour per inch of section size; furnace cool to 1000°F (540°C); hold for 1 hour per inch of section size, and slowly cool to room temperature. After rough machining, reheat to 850-900°F {450-480°C) and hold for 1 hour per inch of section size to relieve machining stresses. Furnace cool to below 500°F (260°C). ectrical Resistance eve Reasons ate ‘oe Electrical resistivity of Ductile Ni-Reslst, N-Resist, Gray Iron and different steels, SECTION VStH ey Table 5.13 Magnetic Permeability eta Permesiy “Magnetic permeability of different types of Ductile Ni- Resist, Ni-Resst, Gray Iron, various steels and bronzes. REFERENCES S. 1, Karsay, Ductile ron il, Quebec tron and Titanium Corporation, 1972, ‘Annual Book of ASTM Standards, Volume 01.02, Ferrous Castings, 1987, Engineering Properties and Applications of the Ni-Resists and Ductile NiResiats, The In- temational Company, New York, NY, 1976. ‘The Iron Castings Handbook, Ion Castings Society, Ine., 1981 Metals Handbook, American Society for Metals, Vol. 1. sth edition, 1961 E, Soohnchen and O. Bernhofen, ‘The Thermal Expansion Coefficient of Cast Iron,” Ar chive fur das Fisenhattenwesen, Vol. 8, 199, HT. Angus, Cast Iron: Physical and Engineering Properties, 2nd ed., Butterworths Inc, 1967, E, Piwowarsky, Hochueertiges Gusseisen, Springer-Verlag, Berlin, 1942, G.N. J. Gilbort. Engineering Data on Nodular Cast Irons, British Cast sociation, 1968 High Strength trons. Ductile fron, International Nickel Company. New York, NY, 1956. “Ductile ron” Alloy Digest Data Shoot, Engincering Alloys Digest. Inc.. Upper Mont: lar, NJ, 1956. “Ductalloy." Alloy Digest Data Sheet Engine NJ 1956. ‘BE. Nolmark, etal. "Thormophysical Properties of Cas rons," Russian Castings Produc: tion, September, 1967. ‘A Design Engineer's Digest of Ductile Iron, sthedition, 1983, QIT-Fer et Titane Ine, Mo ‘weal, Quobec. Canada Ductile ron, Metals Handbook, American Society for Metals, 9th edition, Vol 15, 1988 |W, Paishurst and K. Robri 29, 1979, pp. 657-681 19 Research As- 1 York imax Molybdenum Company. 1g Alloys Digest ne. Upper Montclair ‘High-slicon Nodular Irons.” Foundry Trade Journal, March