Case Studies from Element experts

Failure Analysis of a Fractured Ductile Cast Iron Bracket

Conducted by: Element New Berlin, 3200 S. 166th Street, New Berlin, WI 53151

WHAT WENT WRONG A prototype grade 65-45-12 ductile iron bracket fractured while it was being dynamically tested. It was requested that the nature and cause of fracture be identified, and that the additional casting defects along the fracture faces be characterized. INSPECTION AND TESTING Fracture initiated at the radii at the edges of the component, and within a cast-in hole. In addition, the fracture surfaces exhibit light colored regions in the areas of fracture initiation, darker surfaces further along the fracture, and exposed dark colored porous regions. The radii at the edges of the part are likely regions of higher stress concentration. The measured tensile and yield strengths of 90.5 ksi and 72 ksi for the component significantly exceed the values required for this grade of ductile iron, while the 2% elongation is significantly below specification. The core hardness of 207 HBW 3000/10/10 is typical for this material. The fracture faces as shown in Figure 1 were further characterized via scanning electron microscopy (SEM). An initiation site at a radius is shown in Figure 2, and exhibits brittle cleavage fracture and exposed graphite nodules. The darker fracture surface exhibits dimples which are indicative of ductile rupture. The surface within the dark porous region exhibits primarily a dendritic structure and a morphology indicative of shrinkage porosity within a casting. Metallographic evaluation of a cross section that was excised through the region at which fracture initiated revealed significant amounts of massive carbides, which are undesirable in a ductile iron due to their brittle nature, as shown in Figure 3. The microstructure of the material adjacent to the ductile rupture region is composed of pearlite and ferrite, with exposed graphite nodules shown in profile at the fracture surface. CONCLUSION The brittle cleavage features in the region of fracture initiation coincided with the presence of the massive carbides in the microstructure, while the ductile features coincided with the pearlite and ferrite. In addition, the tensile sample was excised from a region in which the carbides occurred, and the elevated tensile and yield strengths, with extremely low percent elongation, were consistent with that which would be expected for a ductile iron containing an elevated carbide level. The presence of concentrated carbides at the fracture initiation sites reduced the ductility of the material, which cracked when bending loads were applied. The presence of the carbides in the ductile iron matrix is likely a result of excessive chill, or rapid solidification, in the casting process. Excessive shrinkage porosity was observed in the casting wall as well, although this was not directly responsible for the failure. The selective yellowing of the silicone-based elastomer cannot be explained. The silicone seal is pressed into a channel in the nylon housing. The channels examined did not exhibit any discoloration. REFERENCES 1. ASM International, ASM Handbook, Vol. 15, Casting, Ohio, 1988.

This document contains general information, no rights can be derived. Failure Analysis of a Fractured Ductile Cast Iron Bracket, Element New Berlin, www.element.com Page 1 of 2

This document contains general information, no rights can be derived. Failure Analysis of a Fractured Ductile Cast Iron Bracket, Element New Berlin, www.element.com Page 1 of 2