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EFFECT OF COPPER ON STRUCTURE - PROPERTIES OF CAST AND HEAT TREATED

DUCTILE IRON

NATIONAL INSTITUTE OF FOUNDRY AND FORGE TECHNOLOGY, RANCHI

Presented By: Under Guidance Of:

ARUN KUMAR Dr. K.K.SINGH
FF17M22 Professor
Department of Foundry
Technology

1
INTRODUCTION OF DUCTILE IRON:

 Ductile iron is a ferrous alloy consisting primarily of iron with carbon and silicon.

Ductile iron is also known as nodular iron, spheroidal graphite iron and spherulitic iron
in which graphite is present in tiny balls or spheroids

Magnesium and various Mg alloys are the most commonly used for spheroidisation of
ductile iron.

Silicon and other alloys are used to control the morphology of the precipitated graphite
and to control the amount of carbon that remains as a solid solution in the iron.

 Other elements are also present and controlled to produce the various grades and to
influence other mechanical properties like machinability and castability.
EFFECT OF COPPER ON DUCTILE IRON:

Copper is a strong pearlite promoter and act as a grain refiner. It increases the
proof stress with also the tensile strength and hardness with no embrittlement in
matrix.

It increase the wear resistance and corrosion resistance , good fatigue properties,
superior wear qualities, excellent toughness, and cost-effectiveness.

With the increase of copper content the tensile strength went on increasing up to
3 wt % of cu .

The tensile strength was almost doubled with the application of austempering
heat treatment process at 270˚C for one hour.
 HEAT TREATMENT:
Austempering

1.Heating of the castings in a molten salt bath up

to 815-927℃ .
2.Hold for 1 to 1.5 hr to dissolve carbon in
austenite.
3.Quench quickly in salt bath to avoid pearlite.
Fig.1 Austempering heat treatment

4 Hold at temperature (232-400℃) in molten salt

bath for isothermal transformation to
ausferrite(acicular ferrite in carbon enriched
austenite).
Advantages of Austempering

 ADI provides high strength and good fatigue properties.

 Superior wear qualities.
 Excellent toughness and cost-effectiveness.
APPLICATIONS:

Heavy Truck and Bus Components:jack stand gears, timing gears, wheel
hubs,suspension brackets etc.

Railway:track plats,friction wedges,nipper hooks etc.

Construction Equipment:bucket teeth and powertrain parts.

Agricultural:sprayers,harvester,plow points and seed boots etc.

Defense-track links and armors.

Gears,shafts, gear housing, sprockets etc.

Light Vehicle suspension system.

 LITERATURE REVIEW:
Author and Year Title Conclusion

J.O. Olawale et al. Processing Techniques and 1.Understanding the Processing Techniques and
(International Journal of Productions of Ductile Iron: A Productions of Ductile Iron that how to convert graphite
Scientific & Engineering Review flakes of GCI into spherical nodule shape of DI.
Research, Volume 7, Issue 9,
September-2016 ) 2.The mechanical properties of castings made with
spheroidal rather than flake graphite had high strength and
ductility, good fatigue life and impact properties .

Amar Kumar Das et al. Effect of Alloying Elements and 1.Alloying element (Cu) improves the mechanical
(Journal of Materials and Processing Parameters on properties of spheroidal graphite iron after austempering.
Metallurgical Engineering Mechanical Properties of
Volume 3,jan2013, Issue 1) Austempered Ductile Iron . 2.The properties are enhanced with austempering time but
with increasing austempering temperature it initially
increases and then gradually becomes constant.

M. Ashraf Shaikh et al. Effect of Heat Treatment

(International Journal of Processes on Ductile Cast Iron Sharp rise in the values of both strength and hardness with
Mechanical and Production Mechanical Properties :An the increase in austempering time.
Engineering, Volume- 6, Experimental Approach .
Issue-7, Jul.-2018)
Prabhukumar Sellamuthu et Austempered Ductile Iron (ADI):
al. Influence of Austempering
(Metals, Published: 12 January Temperature on Microstructure,
2018) Mechanical and Wear Properties and
Energy Consumption.
1.The wear resistance is increased slightly with
increasing of Mg%, nodularity% and pearlite %.
2. At elevated temperature, the wear resistance
decreased with increasing temperature in normal
atmosphere but when the Ar atmosphere was used
the wear resistance was increased at the same
elevated temperature, nodularity and pearlite %.

Abhishek Singh et al. Effect of Copper on Austempering The ductile iron alloyed with copper is showing
(International Journal of Behavior of Ductile Iron. little bit high tensile strength and hardness but
Science and Research (IJSR) , lower elongation compared with unalloyed ductile
2017) iron.

A.M. Omran et al. Effect of Cu and Mn on the 1. % increase in strength by copper is larger
(International Journal of Mechanical Properties and compared to Mn addition.
Engineering Research and Microstructure of Ductile Cast Iron. 2. Good metallurgical quality will be obtained as
Applications,Vol.4, Issue 6, the post inoculation increased.
Version 1, June 2014, pp.90-96) 3. The tensile strength and hardness is increased by
increasing Mg% .
OBJECTIVES:
To study the effect of copper on structure-properties of cast and heat
treated ductile iron
To check the tensile strength.
To check the Hardness.
To check the characterization of microstructure the specimen and
compare the results.
 WORK METHODOLOGY
Ductile iron (TC 3.7%,Si 2.5%,Mn 0.3%, S 0.01%, P 0.01%)

Adding cu as an alloying element

As-Cast,0%wt cu 1%wt cu 2% wt cu 3% wt cu

Check the properties, which one alloying shows better

Austempering heat treatment with varying time and temp.

Check the tensile strength, microstructure and hardness

Analyse the results and make final conclusion

 EXPERIMENTAL PROCEDURE
Step1. mould preparation
• Synthetic sand system consisting of high silica sand, Bentonite
and coal dust from the Foundry work shop of the institute was Fig.2: Pattern dimension

used.
• 1% Dextrine,3% bentonite and 4% water were added during
mulling.
• Mulling was carried out in a Muller of 150 Kg capacity in the
foundry work shop
Step2.Casting
•Pig iron and metal scrap melting in induction furnace. Mg
treatment was done in laddle.
•Copper added in the ladle by 1%, 2% and 3% during pouring of
molten metal in the mold and prepare the tensile bar. Fig.3: Casting of the sample
Step3. preparation of tensile test specimen.
Specimen for the tensile strength are prepared as per ASTM standards having
Gauge length: 60 mm
Gauge diameter: 12 mm
Total length: 120 mm
Grip diameter: 18 mm

Fig.4: tensile test specimen

Step4. heat treatment of tensile sample.
. Stage 1-sample(1%wt Cu) were heated at 900°C and
hold for 60 mins for austenitising and then
transfered quickly to a salt bath ( 50 wt % NaNO3
and 50 wt % KNO3) maintained at 250°C,300°C and
350°C respectively for 1 hour and after that allow it Stage 1
for air cooling.

Stage 2- Again samples(1%Wt Cu) were heated at

900°C and hold for 1 hr for austenitising and then
transfered quickly to a salt bath for 30 mins and 90
mins at 250°C and cooled in still air

Stage 2
Fig .5: isothermal cycle for austempering heat treatment.
STEP 5. Tensile Testing using UTM

Procedure-
• The specimen’s dimensions (diameter/gauge
length/total length in mm etc.) were measured
accurately with vernier calliper.

•The specimen was inserted into the machine and gripped

by the jaws.

•Maximum load was set and loading was done till the
specimen failed.

•The corresponding readings tensile strength reading was

noted.
Fig .6:Tensile testing
Step 6. Preparation of Metallographic specimens
• The metallographic bars of 20mm×10mm round specimens are cut from the
tensile bar and process of making metallographic specimens done.

• The specimen preparation consists of following steps:-

• In intermediate polishing 180,220,320,400,600,800,1000 and 1200 grades

emery paper was used.

• Cloth polishing- alumina powder of 0.05micron with water was used

• Etching- Kellers Etch was used as etchant for revealing the microstructure
Step 7.Hardness testing
• The polished surface is subjected to a load of 1000 Kgf with 10 mm
steel ball diameter. The load is applied for 25 Sec.

• After the removal of load, the resultant round impression is measured

in millimetre using an eye piece.
• BHN was calculated using formula

Where,
P = Load applied = 3000 Kgf ,
D = Diameter of ball =10 mm Fig .7: Hardness Test
Di = Diameter of indentation in mm
Fig.7 :hardness testing of (a) as- cast Sample (b) sample with heat treatment for 1hr

(c) sample with heat treatment at 250˚C for 30

min,60 min and 90min
 Results and Discussion
• Effect of copper in as- cast condition
Characterization of microstructure
•The microstructure of ductile iron in as
cast condition is mostly pearlitic . These
cause changes in the mechanical
properties of ductile iron.

(a) (b)
•The gray area in the microstructure
represent pearlite while white area
represents ferritic phase present in the
matrix.

•This structure has a non-homogeneous

matrix due to presence of varying amount (c) (d)
Fig.8 : Microstructure of as-cast ductile iron (a
of ferrite and pearlite 0%wt Cu (b) 1%wt Cu (c) 2%wt Cu (d) 3%wt Cu
 Table 1 : Mechanical properties of as- cast Base and alloyed Ductile
Iron.
Metal UTS(MPa) % Elongation Hardness (BHN)

Base 480 4.1 155

1%Cu 570 3.7 173

2%Cu 750 3.5 191

3%Cu 840 3.3 208

H a r d n e ss (B H N )
900 4.5
800 4
700 3.5

% Elongation
600 3
UTS (MPa)

250
500 2.5
400 200 2
300 150
1.5
200 1
100
100 0.5
0 50 0
Base 1% Cu 2%Cu 3%Cu Base 1%Cu 2%Cu 3%Cu
0
Base 1% Cu 2%Cu 3%Cu % Cu
%Cu % Cu
Effect of heat treatment on Base and alloyed ductile iron.
• The Base and alloyed samples were austenitized in a Resistance furnace at a temperature of
900°C for one hour and austempered in a Resistance oven at 3000C for one hour.

• The hardness test was performed. It is obserbed that addition of Cu in the Ductile Iron
increases the hardness of the Ductile Iron. This is because of-

1. the grain refinement takes place due to the addition of Cu.

2.And retained austenite -ferrite matrix around the graphite nodules increases the tensile
stength and hardness very high. But it is limited up to 1% of Cu,after that it decrease in the
amount of retained austenite phase.
So further 1wt% of Cu addition is selected and the effect of austempering variable was studied.
 • Microstructure of 1% copper alloyed ADI at different temperature for 60 min.

•As the austempering temperature

increases, the morphology of bainite is
changed from acicular to plate like
structures.
(a) (b)
•The percentage of retained austenite bainite
increases at higher austempering
temperatures and the tensile strength
decreases.

•The fine structure of the bainite plates and

low amount of retained austenite results in (c)
high strength at low austempering Fig 9: Microstructure of austempered ductile iron
temperature. a) 1%wt Cu at 250 0C (b)1% wt Cu at 300 0C(c) 1%wt Cu at
350 0C.
 Table 2: Mechanical properties of ADI with 1% copper austempered at 60 min

Temp(°C) for 60 min UTS(MPa) % Elongation Hardness (BHN)

250 1170 2.1 493

300 1005 3.2 326

350 918 3.5 295

H a r d n e ss(B H N )
1400 4
1200 3.5
3

% Elongation
1000
UTS(MPa)

600 2.5
800 500 2
600 400 1.5
400 300
1
200 200
0.5
100
0 0
250 300 350 0 250 300 350
200 220 240 260 280 300 320 340 360
Temp(°C) Temp(°C) Temp(°C )
•Tensile strength and Hardness decreases with increase in
austempering temperature . Elongation increases with increase in
austempering temperature.

•the tensile strength and harness is more when 1%wt Cu alloying

sample austepered at 250 0C for 60 min due to fine structure of the
bainite plates and low amount of retained austenite.

•So further austempering time(30,60min)variation on that sample

was analysed.
 • Effect of different austempering time on microstructure-properties of
ADI at 250 0C .
Effect on Microstructure
•At 60 min austempering time, the high strength and high
hardness value can be attributed to the presence of acicular
bainite, some martensite and retained austenite .

•The fine structure of the bainite plates and low amount of (a)
retained austenite results in high strength at low austempering
temperature.

• As the austempering time increases the acicular ferrite

transforms to coarse ferrite and the elongation increases after 60
min austempering time.
(b)

Fig.10 : Microstructure of ductile iron with heat treatment at

(a) 250 0C for 30 min (b) 250 0C for 90 min.
 Effect on the mechanical properties

Table 3 : Mechanical properties of ADI with 1% copper at 250 0C

Time(min) for 250°C UTS(MPa) % Elongation Hardness (BHN)

30 1101 2.8 361

60 1170 2.1 493

90 1120 2.4 400

H a r d n e s s (B H N )
1180

1160 3
2.5
1140

% Elongation
UTS(MPa)

600 2
1120 500 1.5
400
1100 1
300
200 0.5
1080
100 0
1060 0 30 60 90
20 30 40Time(min)
50 60 70 80 90 100
20 30 40 50 60 70 80 90 100 Time(min)
Time(min)
 CONCLUSION
1) The ductile iron alloyed with copper shows little bit high strength and hardness
but lower elongation compared with unalloyed ductile iron.
2) As the austempering temperature increases hardness and tensile strength
decreases and percentage elongation increases in the copper alloyed ductile
iron.
3) As the austempering time at 250 0C increases, tensile strength, hardness first
increases and then decreases and elongation first decreases and then increases.
4) In microstructure the austenite increases with increasing austempering
temperature.
5)At higher temperatures upper bainitic structure and the at lower temperatures
lower bainitic structure was found.
6)The hardness and strength found higher in ADI comparatively to DI.
 FUTURE SCOPE
•Engineering applications of ductile iron in as cast and different heat treated conditions
are growing day by day. Austempered Ductile Iron’s application has increased
tremendously in many industrial areas.

• Austempered Ductile Iron is increasingly the material of choice of designers and

engineers because of their cost effective performance. It has started to replace steel in
some structural applications. It has also found it’s tremendous applications in
automobile sector which includes crankshafts, disc-brake calipers, axle housings, etc.

•It is also used to manufacture pipes, pump bodies, rock drillers, etc. For all these
applications, we need to take into consideration many other mechanical properties
like, wear and erosion resistance, impact resistance, fracture toughness, creep
resistance, noise reduction and energy saving properties, etc.

•So in future, we can measure the above mentioned mechanical properties to optimally
select a material for its specific application.
 REFERENCES
1)Overseas Foundry Vol.12 No.1 January 2015,Effect of alloying elements on austempered
ductile iron (ADI) properties and its process:Review.
2) Nofal A.A., jakova L., Journal of the university of chemical technology and
metallurgy,44,3, 209, 213-228, review.
3) A guide to the mechanical properties of ductile iron, mid Atlantic casing service.
4)Ductile Iron Data for Design Engineers, and International Journal of Advanced Technology
in Engineering and Science Volume No.02, Issue No. 12, December 2014.
5) Ashraf Sheikh Muhammad, Effect of heat treatment and alloying elements on characteristics
of austempered ductile iron, Ph.D thesis, 2008.
6) Chandler Harry , Heat treaters guide: practices and procedures for irons and steels, ASM
International; 2 Sub edition (December 1995).
7) Nili Ahmadabadi M., Ghasemi H.M. and Osia M., effects of successive austempering on the
tribological behavior of ductile cast iron, Wear, Vol 231(1999) PP 293-300.
8) Batra Uma, Ray S. and Prabhakar S.R., Tensile properties of copper alloyed austempered
ductile iron: Effect of austempering parameters, JMEPEG (2004) Vol 13, PP 537-541.
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