Cast Iron

This keynote address will provide a comprehensive overview of various lubrication aspects of a typical powertrain system including the engine, transmission, driveline, and other components, as well as the integration of these lubrication and surface engineering concepts into a unified automotive powertrain system. In addition, this presentation will focus on the current status and future trends in automotive lubricants including discussion of current and anticipated future requirements of automotive engine oils. This presentation will also review the current standard ASTM (American Society for Testing and Materials) test methods for engine lubricants and other compilations of automotive standards. In addition to engine oil test development, industrial researchers are developing light-weight materials such as non-ferrous materials (Al, Mg) for engine and drivetrain materials to replace the current heavy-weight cast iron blocks. Recent industrial developments include high strength and high density of composite materials, high volume liquid molding and hydroforming technology, structural adhesive boding, and the ability to mold large structural components. Industrial researchers have also developed processing improvements for forming more complex stamped aluminum parts or panels, more robust stamping, and improved casting techniques. In this paper, our insights and perspectives on future trends in light-weight tribological material and nonotribology will also be reviewed. #

This thesis focuses on fire resistance of 19th century cast iron framed structures.
Based on material property data obtained from a comprehensive literature review, upper and lower bound relationships of the thermal and mechanical properties of 19th century fireproof floor construction materials have been derived. Because these materials have large variability, a sensitivity analysis has been undertaken to investigate the most effective ways of representing such variability. The sensitivity analysis has indicated that the elevated mechanical properties of cast iron should be reliably quantified.  The thermal expansion of cast iron can be taken as equal to that of steel as in EN1993-1-2. Variabilities in other material properties have modest effects on fire resistance of cast iron structures and can be safely modeled according the Eurocode material models for similar modern materials (using thermal properties of modern steel for cast iron, using thermal properties of modern concrete for the insulation materials of cast iron structures).
In order to resolve some of the uncertainties in mechanical properties of cast iron at elevated temperatures, a total of 135 elevated temperature tests have been performed, including tension and compression tests, transient state and steady state tests, tests after cooling down and thermal expansion tests.  These test results have been used to establish the elevated temperature stress-strain-temperature relationships in tension and compression.
Afterwards, calculation methods are developed to calculate the bending resistance of cast iron beams and compression resistance of cast iron columns at elevated temperatures. For cast iron beams, a fibre model has been developed to calculate elevated temperature moment capacity of cast iron beams in jack arch construction, taking into consideration non-uniform temperature distributions in the cross-section. The fibre model divides the cross section into a large number of fine layers and for a given curvature and neutral axis position calculates the strain, the temperature, the stress and the force of each layer. It has been found that under historically applied load, the fire resistance of such beams can be 60 minutes or higher. The Monte Carlo simulation method has been used to take into account the variabilities of important mechanical properties of cast iron at elevated temperatures; Young’s modulus, 0.2% proof stress, ultimate strength, corresponding strain at ultimate strength and failure strain in tension and Young’s modulus, proportional limit and 0.2% proof stress in compression. This has enabled material safety factors of 1.50, 2.50, 4.50 and 5.50 to be proposed for target failure probabilities of 10-1, 10-2, 10-3 and 10-4 respectively.
For cast iron columns, a finite element model, built using the commercial software ABAQUS, has been used to examine the effects of changing different design parameters (column slenderness, member imperfection, cross section imperfection, degree of axial restraint, load factor and load eccentricity) on fire resistance of cast iron columns. Validation of the finite element model was by comparison of the simulation results against six fire resistance tests, three on unprotected and three on protected cast iron columns.  The results of this numerical parametric study indicate that the fire resistance of cast iron columns is generally higher than that of modern steel columns because the applied loads on cast iron columns are lower and cast iron columns have thicker sections than modern steel columns. Comparison of the numerical parametric study results with the calculation results using the steel column design method in EN1993-1-2 has found that the EN 1993-1-2 calculation results are generally on the safe side.

The paper discusses a recent stray find of a sword fragment with a possible stamp from Masuria in NE Poland. It was found close to a Roman Period cemetery of the Bogaczewo Culture. On typological grounds, the sword can be classified as a Roman Period weapon. However, the results of metallographic examinations suggest that the find may have been made either from very clean bloomery steel (or hypoeutectoid crucible steel) or from mass-made Industrial Age steel (Bessemer, Thomas, Siemens-Martin, etc.). On the other hand, the chemical composition of the sword would rather imply a pre-Industrial Period steel. In conclusion, it is carefully suggested that the weapon may be a genuine Ancient sword, although its final recognition as a Roman Period weapon could only be verified by finds made from similar metal in undoubted Roman Period contexts

Se comparan las propiedades mecánicas y el comportamiento a fractura de diversos componentes industriales, obtenidos con aleaciones de aluminio A356 y EN AC-46500, en estado bruto de colada y después de sometidos a tratamientos térmicos T5 y T6. Los componentes han sido fabricados mediante las nuevas técnicas de conformación en estado semisólido: Semi Solid Rheocasting® (SSR) y Sub Liquidus Casting® (SLC) Los resultados ponen de manifiesto la validez de estas tecnologías como alternativas a la fabricación de componentes de fundición esferoidal de matriz ferrítica.

In this paper the thermo elastic phenomenon occurring in the disk brakes, the occupied heat conduction and elastic equations are solved with contact problems. The numerical simulation for the thermo elastic behavior of disk brake is obtained in the repeated brake condition.

Component failures due to the hydrogen embrittlement (HE) were observed in different industrial systems, including high-pressure hydrogen storage tanks, aircraft components, high-strength alloy components, and high-strength steel fasteners. The contemporary approach in studying the effects of hydrogen on the mechanical properties of steels and iron at different scales is based on the implementation of various multiscale (macro, micro-meso, and nano-atomic) modeling approaches and the applications of advanced experimental methods. A large number of contemporary studies confirmed the multiple effects and activity of different HE mechanisms in steels and iron. The coexistence and synergistic activity-concurrent action and effects in a cooperative manner of different HE mechanisms, including the hydrogen-enhanced localized plasticity (HELP) and the hydrogen-enhanced decohesion (HEDE), were recently detected and confirmed through computations-simulations, as well as experimentally in different grades of steel. However, the critical evaluation and quantification of synergy between the HELP and HEDE mechanisms, enhanced plasticity and decohesion, hydrogen-deformation/dislocation interactions and their simultaneous effect on the mechanical properties (hardening and softening), still do not exist. In this review paper, the multifaceted nature of the synergistic interplay of HE mechanisms is covered through extensive literature overview regarding the chronological development of ideas related to the HELP + HEDE concept and HELP mediated HEDE model. The particular emphasis is given to the proposal of the novel and unified HELP + HEDE model based on the specific microstructural mapping of the dominant HE mechanisms with implications on the fracture process and resulting hydrogen-assisted fracture modes. Most of up-to-date experimental and modeling approaches, current trends and future challenges in the investigation of the synergistic interplay of HE mechanisms in different grades of steel, including the most advanced, and iron, are also included and critically discussed.

Cast iron columns were used in many 19th century structures. Many such structures are still in use today and it is important that they fulfill the current requirements on fire resistance. This paper presents the results of a comprehensive study of the behavior and fire resistance of cast iron columns based on extensive numerical simulations using ABAQUS. The ABAQUS simulation model was validated against six fire tests performed in the USA in 1917. The validated model was then used to investigate the effects of several parameters (column slenderness, load factor, load eccentricity, imperfections of column and cross section, axial restraint) on the behaviour of cast iron columns in fire. The parametric study results indicate that the fire resistance is governed by the applied load and these columns are sensitive to load eccentricity. Based on a comparison between the numerical simulation results and predictions of the EN 1993-1-2 method which is for modern steel structures, it has been found that the EN 1993-1-2 method can give safe and reasonably accurate estimate of the strength and fire resistance of cast iron columns.

Abstract: India had overseas trade contacts from the 4th-3rd Millennium BC. The history of Portuguese shipwrecks in Goa waters began with the arrival of Vasco da Gama at Kapukad (Kappat) a few kilometers north of Calicut (Kozhikode) in Kerala, India on 17 May 1498. Since then there had been frequent sailing of ships between India and Portugal and to the other Portuguese colonies. The ships sailed from Southeast Asian countries to Portugal enroute Goa, Mombasa and other Portuguese colonies around the Indian Ocean and they ...

Direct solutions of pipe flow problems are not possible because of the implicit form of Colebrook-White equation, which is most commonly used for determining the friction factor of commercial pipes. New empirical equations for head loss, h , due to friction undergone by water flowing in the PVC, commercial steel, asphalted cast iron, galvanized iron, cast iron and concrete pipes

IRONMAKING MINERALS AND ANCIENT SIDERURGY. SOME CLARIFICATION. 
Speaking about ancient siderurgy, in very many archaeological and historical publications “iron mineral” is quoted as  a generic and lone ironmaking materials; moreover, magnetite, pyrite and some iron silicates, are quoted as ironmaking in ancient, medieval and modern times.  To clarify errors and contradictions, it is necessary to subdivide the long siderurgy history, and tecnology, in four periods, partially overlapping: 
1) the historical direct reduction (low fire and shaft furnace) producing direct ductile iron from the Iron Age beginning to the second half of the XIX century; 
2) the historical indirect reduction (blast furnace) producing indirect hard iron from about X-XI centuries to the half of the XIX century; 
3) the current siderurgy (foundery/steelworking complexes) producing indirect iron and steel from the XVIII century to theese days;
4) the “new” direct reduction (for sponge iron) producing direct ductile iron from the beginning of the XX century to the future (we hope).
So we can to assert, on the basis of the single iromaking minerals technical properties, but also from the literature and old documents, that limonite and hematite were the lone iromaking minerals in the first direct reduction;  the same, toogheter with magnetite and siderite, were used in the historic indirect reduction;  all theese, and other (iron sulphides and silicates), are used in the current siderurgy. 
Regarding the true magnetite, we can see it late ironmaking possibilities, with the indirect  reduction (second half of the XVI century), due its compact structures and harmfull sulphide presences;  regarding the sandy magnetite, due its  grittiness and hight content in titanium, we only can see some proofs starting to the XVIII century end.  Sandy magnetite also was used in one of the first “new” direct reduction processes for producing, during the Second Mondial War, the autarkic “ferrital” (= Italian iron), that seams to have been the first true used metal from “sponge” iron.

The best way to reduce the weight of the mechanical Components is employing the composite material. Gears are
the most effective component in mechanical power transmission system. Conventional material Spur gears like
make cast steel can be replaced by Spur gears made of composite materials. This results in light weight Spur gears,
which add to the existing list of advantages of Spur gears, such as smooth and silent operation and larger load
carrying capacity, while at the same time maintaining higher strengths, which is an important requirement in
applications like spacecraft, aircraft and Robotics. The composite materials not only reduce the weight and also
possess excellent characteristics of corrosion and fatigue resistant. Further, on Selecting large series production of
these gears, large cost saving seem also feasible. In this paper Polyoxymethylene spur gears are designed and
analysed to check whether it is capable to replace the cast iron spur gears used in sugarcane juice machine.
Keywords: Cast Iron Spur Gears, Sugarcane Juice Machine, Polyoxymethylene Spur Gear.

Pine tar samples from each out of six, successively filled barrels from a traditionally accomplished, yet temperature monitored, kiln production have been characterised by combined gas chromatography mass spectrometry (GC-MS). The relative abundance of resin-and fatty acids correlated in a distinctive way to the temperature development within the kiln, which made it possible to identify from which barrel each sample originated. The pine tar samples were according to an at least 300 years old tarring practice of Medieval Stave churches, subsequently seethed in a cast iron pan and again characterised by GC-MS. The characteristics of the initial samples were still evident after heating to 180-190°C.

Das Siegerland im südöstlichen Teil Nordrhein-Westfalens beherbergt eine der größten Siderit-Lagerstätten Deutschlands, dessen Bergbau-Geschichte bis in die Kelten-Zeit zurückreicht . Bereits in der Latène-Zeit wurde im Siegerland Eisenerz abgebaut und im Rennfeuerverfahren verhüttet. Anhand von Ausgrabungen zahlreicher Verhüttungsplätze im Siegerland lässt sich ein großes Produktionszentrum für Eisen nachweisen, das in der späten Latènezeit aktiv war. Da anzunehmen ist, dass die Menge an produziertem Eisen den Eigenbedarf übertraf, kann eine Distribution der Produktion in angrenzende Regionen angenommen werden. Das Deutsche Bergbau-Museum Bochum führt bereits seit 12 Jahren umfangreiche Forschungen über die latènezeitliche Eisenwirtschaft im Siegerland durch. Aus zahlreichen Prospektionen und Ausgrabungen von Verhüttungsplätzen im Siegerland stammt ein umfangreiches Fundmaterial. An zahlreichen Proben konnten Blei-Isotopen-Analysen durchgeführt werden, um die Lagerstätte des Siegerlandes zu charakterisieren. Auf diese Weise entstand eine große Datengrundlage, die zu einem Vergleich für Provenienzstudien herangezogen werden kann. Zu der Datenbasis gehören nicht nur Zwischenprodukte der Produktionskette, wie etwa Rösterze, Schlacken, Luppen, Ofenwände, sondern auch Eisenerze, die aus den Oberflächenbegehungen und aufgelassenen Pingen des Siegerlandes stammen. Bei den Erzen handelt es sich um zahlreiche Goethit-Erze, wie auch um Hämatit und Siderit. Für Provenienzstudien an Eisen hat sich bislang kein gängiges Verfahren etablieren können, obgleich dazu bereits einige Studien existieren. Da mittels Blei-Isotopen-Analysen bei archäologischem Kupfer Provenienzstudien erfolgreich durchgeführt werden konnten, wurde versucht, dieses Verfahren auch auf Eisen anzuwenden. Jedoch steht eine ausreichend große Datenbank von Blei-Isotopen-Analysen an Eisenerzen verschiedener Lagerstätten bisher aus. Für die Durchführung von Provenienzstudien wurden insgesamt 34 eiserne Artefakte aus einem gesicherten latènezeitlichen Kontext ausgewählt. Die Artefakte stammen aus den Regionen angrenzend an das Siegerland in Nordrhein-Westfalen und Hessen. Bei den Fundorten handelt es sich überwiegend um Wallburgen (z. B. Milseburg, Kr. Fulda, Altenburg bei Niedenstein, Schwalm-Eder-Kreis und Heidetränke, Hochtaunuskreis), jedoch befinden sich ebenfalls Nekropolen, ein Waffenopferplatz (Wilzenberg, Hochsauerlandkreis) und eine Siedlung mit gewerblichem Charakter

In this experimental study some statistical calculations have been made to eliminate quality problems such as undesirable tolerance limits and out of circularity of spherodial cast iron parts during machining. X-R control charts have been constructed on the data obtained from this manufacturing to discover and correct assignable causes, so that the machine capability (Cp) and the process capability (Cpk) can be determined.

The corrosion behavior of cast iron in different aqueous salt solutions has been studied. Samples of cast iron were exposed in the salt solutions media for 40 days and corrosion rates evaluated, using total immersion test and Tafel extrapolation curves. The concentration of salts taken is 5 g/liter. The total immersion test parameters vise weight loss; corrosion rate as well as Tafel extrapolation parameters, I corr., corrosion potential , corrosion rate have been calculated. Besides these terms, the pH and electrical conductivity have been calculated by standard methods.

Although there have been great advances in the development of cutting tool materials which have significantly improved the machinability of a large number of metallic materials, including cast irons, steels and some high temperature alloys such as nickel-based alloys, no equivalent development has been made for cutting titanium alloys due primarily to their peculiar characteristics. This paper reviews the main problems associated with the machining of titanium as well as tool wear and the mechanisms responsible for tool failure. It was found that the straight tungsten carbide (WC/Co) cutting tools continue to maintain their superiority in almost all machining processes of titanium alloys, whilst CVD coated carbides and ceramics have not replaced cemented carbides due to their reactivity with titanium and their relatively low fracture toughness as well as the poor thermal conductivity of most ceramics. This paper also discusses special machining methods, such as rotary cutting and the use of ledge tools, which have shown some success in the machining of titanium alloys. © 1997 Elsevier Science S.A.

A B S T R A C T Cast iron beams were extensively used in many 19th century structures, especially in fireproof flooring systems (such as jack arch). Many such structures are still in use today and it is important that they fulfil the current requirements of fire resistance when there is a change of use. These structures are out of scope of modern design codes and old design codes do not provide guidance for fire resistance design. Furthermore, cast iron is a brittle material weak in tension, and there are many uncertainties in its mechanical properties at ambient and elevated temperatures due to material flaws. It is necessary to quantify the probability of structural failure and to introduce safety factors to reduce the probability of structural failure in fire to an acceptable level. This paper presents the results of a detailed study whose purpose is to derive appropriate safety factors to achieve different levels of reliability, for fire safety design of cast iron beams. In this study, a fibre analysis method has been used to calculate the moment capacity of four different types of cast iron cross section. Using randomized stress-strain-temperature relationships, based on variability of the different governing parameters (under tension: maximum stress, 0.2% proof stress, corresponding strains at maximum stress (strength) and failure; under compression: Young's modulus, proportional limit, 0.2% proof stress and the maximum stress), the probability distribution of moment capacity has been calculated. Based on the criterion of cast iron beam failure not exceeding probabilities of 10 −1 , 10 −2 and 10 −3 , material safety factors of 1.5, 3.0 and 5.0 respectively have been obtained.

The effect of austempering on the microstructure and toughness of nodular cast iron (designated as CuNiMoSG) alloyed with molybdenum, copper, nickel, and manganese has been studied. Light microscopy (LM), scanning electron microscopy (SEM), and X-ray diffraction technique were performed for microstructural characterization, whereas impact energy test was applied for toughness measurement. Specimens were austenitised at 860 °C, then austempered for various times at 320 and 400 °C, followed by ice-water quenching. Austempering at 320 °C produces a microstructure consisting of a mixture of acicular bainitic ferrite and the stable carbon-enriched austenite. In this microstructure ε-carbides are also identified after austempering up to 5 h. Fracture mode is changed from ductile to brittle with the prolonged time of austempering at 320 °C. The highest impact energy (115 kJ) corresponds not only to ductile fracture, but also to the maximum value of the volume fraction of retained austenite. Only martensitic structure was observed during austempering at 400 °C, inducing brittle fracture and significantly low-impact energy (10–12 kJ).

The choice of friction material can have a direct influence on the wear life of the brake block or wheel, which is typically much more expensive to replace. The classical cast iron brake block is gradually replaced by organic composite or sintered composite brake blocks. Nowadays, attention is devoted to solving problems connected with using modern brake materials and their impact on thermal and mechanical loading of railway wheels. In this paper, the investigated subjects are the gray cast iron brake shoes, with lamellar graphite and with high content of phosphorus (0.8–1.1%), according to requirements for the brake shoes

Microstructures and hardness of aluminum alloy ductile iron were investigated by SEM, XRD, EPMA and hardness measurement techniques. The results show, increasing the Al-alloying element leads to decrease of free ferrite and carbide, as well as increase in the pearlite volume fraction. It is also has been found that in the higher values of Al, about 85% of the matrix would be pearlite. It is indicated that an increase in the aluminum content also leads to a decrease in the spacing between pearlite layers. XRD results show, in the presence of Al, intermetallic compounds such as Al 6 Fe, AlFe 3 C 0.5 , Fe 3 Al and FeAl were produced. Furthermore the hardness measurements illustrate that by increasing the Al content, the microhardness of ferrite and pearlite and specimens hardness have been significantly increased.

The study of wear mechanisms represents a very important task for the development of roll materials, with improved hot tribological properties. In the present paper the wear behaviour of different materials, i.e., high alloy steels (high speed steels (HSS)) and cast irons (high chromium irons (HiCr) and indefinite chill irons (IC)), produced by centrifugal casting, has been comparatively evaluated by means of a rolling sliding hot wear test. A disc specimen of C40 plain carbon steel, induction heated up to 700 • C, is allowed to rotate against a high alloy steel/iron at 200 rpm, corresponding to a slip rate of 28%, for a total period of time comprised between 1 and 3 h. A maximum contact hertzian stress of 300 MPa was imposed. The wear rates have been evaluated by weight measurements of the specimen, before and after each test period. The surface roughness was also determined as representative for the roll profile retention during service. The friction was continuously monitored. The wear mechanism is given by the combination of abrasion and oxidation. High speed steels show remarkable lower wear rates than high chromium and indefinite chill irons, because of their higher hot hardness. The retention of high hardness at elevated temperature is very important to reduce abrasive wear and also to support the protective oxide layer which develops on the surface of the roll material. As a general rule the roughness at the end of test tends to increase with increasing wear rate, as demonstrated by the relatively soft indefinite chill iron. However, the oxidation resistance also influences the final roughness, higher roughness values being observed for poorly oxidized materials. A simplified model explaining this experimental evidence is proposed.

Titanium alloys and their composites have the potential to reduce truck disc brake component weight and improve their resistance to road-salt corrosion. A titanium alloy rotor can weigh approximately 37% less than a conventional cast iron rotor with the same dimensions, while offering good high-temperature strength and much better resistance to corrosion from road-deicing salts. Friction coefficients and temperature rise

The tribological behaviour of the monolayer PVD-titanium aluminium nitride (TiAlN) coated carbide inserts in unidirectional dry sliding against steel and cast iron counterparts was investigated using the pin-on-disc standard test with varying sliding speeds and normal loads. Three different materials of various machinability rates were used as the counterparts, namely the normalised medium carbon steel C45 equivalent to AISI 1045, austenitic stainless steel 1H18N9T equivalent to AISI 304 and gray cast iron EN-GJL-300 with flake-shaped graphite. A pin-on-disc device with round tool inserts was used to conduct friction and wear tests in which both the friction coefficient and the linear wear of the tribo-pairs were continuously recorded versus sliding distance. For the quantitative comparison of the wear resistance of the tribo-pairs tested the volumetric wear rate was selected. Light microscopy (LM), scanning electron microscopy (SEM) and X-ray microanalyses by EDAX were applied for observations of wear scars and wear products, and the identification of the predominant wear mechanisms which occurred. Some specific frictional behaviours and relevant wear mechanisms observed for both steels and cast iron sliding over thin TiAlN layer are highlighted and quantified. Moreover, the contact conditions, under which the TiAlN film can protect the carbide substrate are specified. It is concluded that for sliding materials with dominating severe adhesive wear, as for example for the couple TiAlN/stainless steel, the protective function of the TiAlN coating is not sufficient.

An efficient and modular numerical prediction model is presented to predict vibrations and re-radiated noise in buildings due to metro trains. The approach comprises of three weakly coupled problems: the dynamic vehicle-track-tunnel-soil interaction problem, the dynamic soil-structure inte raction problem and the cal- culation of the acoustic response inside the rooms. The three-dimensional dynamic tunnel-soil interaction problem is solved with

Heat treating the ductile cast iron produced austempered ductile iron (ADI), which has outstanding mechanical properties that can be varied over a wide range by varying the heat treatment parameters. In the present work a series of test were conducted and the effects of austempering temperature and times onto the material properties was investigated. The machinability of ADI was evaluated by comparing tool life, tool wear rate, cutting forces, and surface finish produced on a job as general criteria. Machinability tests were carried out following ISO 3685: 1993 (E) standard "Tool Life Testing with Single Point Turning Tools". The cutting force data used in the analyses were gathered by a tool breakage detection system that detects the variations of the cutting forces measured by a three-dimensional force dynamometer. Six pairs of ductile iron specimens, austempered at 300, 350 and 400 • C for 1 and 2 h were tested. The cutting tools used in the tests were coated carbide inserts, ISO SNMG 120408 (K10), clamped on tool holders CSBNR 2525 M12. No cutting fluid was used during the turning operations. During the experiments cutting forces, flank wear and surface roughness values were measured throughout the tool life and the machining performance of ADI having different structures were compared.

A new process of making iron, using a blast furnace and a forge, both powered by water, was introduced into the Weald in the 1490s, and spread to other parts of England and Wales from the 1550s. This book provides a history of every ironworks of the charcoal blast furnace period, except the Weald. It also covers early coke ironworks (built before 1815) and water-powered bloomeries (of the previous technology). After introductory material on the industry generally, each chapter deals with the ironworks of one district, including also other water-powered mills processing iron, steel furnaces, early ironworks powered by steam engines, and a few other works. Blade mills (and cutlers wheels), which provided the initial cutting edge for tools are not included in those areas where they are ubiquitous. The period covered is an era in the technology of an important industry in Great Britain.

A previously unattributed outdoor sculpture at the Rienzi House museum of European decorative arts in Houston required treatment for corrosion and lead paint mitigation. The sculpture was extremely corroded, with the base partially buried in soil, causing large pustules of iron corrosion and extensive failure of the oil-based top coats and red lead primer.

Scope of the present article is to review the current state of the art with respect to simulation of microstructure evolution based on the multiphase-field approach in technical alloy grades. Starting from a short overview about computational thermodynamics and kinetics and respective databases for technical alloys, an engineering approach to phase-field and multiphase-field models will be depicted in order to allow for a basic explanation of these methods-in general being developed by physicists and mathematicians-for materials scientists and metallurgists. These explanations are followed by examples of applications of the multiphase-field method to solidification and solid state transformations in steels, cast iron, superalloys, Al-and Mg-alloys, solders and other alloys and compounds. The article is concluded by a short description of present and future trends.

This paper analyses a catastrophic cylinder failure of a four stroke 14 V diesel engine of an electrical power plant when running to nominal speed of 600 rpm. The rated power of the engine was 7.5 MW and before failure had accumulated 80,000 h in service operating mainly at full load. As a result, the piston and liner of cylinder 4 were broken; the crankcase and main crankshaft bearings next to this cylinder were also damaged. The mechanical properties of the liner (grey cast iron) and piston body (aluminium alloy) including tensile properties and Brinell hardness were evaluated. No signs of fatigue failure were identified in liner and piston. A finite element model of the liner has shown that the most heavily loaded areas match the fractured zones.

AbstrAct Purpose: In this work, it is pretended to make a comparison of different pearlite contents in pieces with similar shape and dimensions and to analyze the variation of mechanical properties as pearlite content increases. The three pieces used had form of stair made of ductile cast iron. Design/methodology/approach: The present study was based on an adequate balance of alloying elements. None heat treatment was used to obtain different pearlite contents in the microstructures. Many specimens taken from the cast were mechanized to be polished and swabbed with nital to analyze the microstructure. To study the mechanical properties these casts present many tests were done such as Charpy impact test, done at different temperatures. Fracture toughness and tensile strength tests were done, as well. Findings: This study gave evidences that heat treatments are not necessary to obtain different pearlite content in the microstructure. Good mechanical properties are obtained by an appropriate balance of alloying elements. Research limitations/implications: They are that of natural sources. Besides, high and precision technology must be applied to get the present results better. Practical implications: Cast iron productions are focussed straight on machine building and automotive industries and constructions. The low cost production of ductile cast iron, its mechanical properties and low cost transformations are the tempting for application. Originality/value: The whole experimental work and the appropriate results obtained as consequences of the analysis carried out are novel, although applied methods are well known. Values presented in tables are given as new results of our experiments. This work is of great importance for the development of new economical methods for ductile iron production. This study is directed to researchers and metallurgy centres.

In this study, Cr white iron of 18.23 wt.% was subjected to a series of subcritical heat treatments. At both temperatures of 350 and 450 °C, no precipitation of secondary carbides was observed, and the overall microstructure resembles to that of the as-cast condition. At 550 °C, hardness values increased slightly compared to the as-cast values. No evidence of secondary carbide formation was observed. At 650 and 750 °C, extensive-to-complete transformation to pearlite-ferrite structures has occurred. Some evidence of secondary carbide precipitation especially for prolonged treatment periods was not adequate to obstruct the hardness decrease due to the dominating effect of pearlitic-ferritic formation. At 850 °C, secondary carbide precipitation and martensite formation lead to high hardness values.

QUEIROZ, José Francisco Ferreira - A Companhia de Artefactos de Metais, estabelecida no Porto (1837-1852). Para o estudo monográfico de uma fundição pioneira. Famalicão, 2005 (separata de "Arqueologia Industrial", IV série, Vol. 1, n.º 1-2, p. 15-72).

In the present work, the transformation characteristics of ductile iron austempered from intercritical austenitization temperature ranges were investigated. For this purpose, an unalloyed ductile cast iron containing 3.50 wt% C, 2.63 wt% Si and 0.318 wt% Mn were intercritically austenitized (partially austenitized) at various temperatures and then rapidly transformed to a salt bath held at the 365°C for austempering for various times to produce dual matrix structure with different ausferrite volume fractions in ferrite matrix. A microstructure map was created to illustrate the transformation of products quantitatively as a function of austempering time for a particular intercritical and austempering heat treatment temperature and time. It was demonstrated that the total volume fraction of transformed phases was approximately constant for all austempering times after rapidly transforming samples from a particular intercritical temperature to austempering temperature. It was found out that the new ferrite (It is also called epitaxial ferrite) introduced into the intercritically austenitized structure during austempering and its content was dependent on the intercritical austenitizing temperature and austempering time.

Pre-disturbance measurements of the in-situ corrosion properties of iron fittings on the snow brig James Matthews (1841) have been used as conservation management tools for the site. The wreck of the former slave trader is historically significant and the potential impact of continued industrial activities associated with nearby dredging activities necessitated in-situ cathodic protection of exposed iron fittings. A laboratory simulation study of the impact of pH and chloride content on the corrosion of cast iron and mild steel was conducted. There was a linear relationship between the corrosion rate of cast iron and the log of chloride ion concentration in the pH range 7.8< pH >5.5 with only a small pH effect noted for the given range of conditions. Studies on a 19th century mild steel sample indicated that the corrosion rate was linearly dependent on the square root of the chloride ion concentration and the corrosion rate fell in a linear fashion as the pH was increased to s...

Ductile cast irons (DCIs) are characterized by a wide range of mechanical properties, mainly depending on microstructural factors, as matrix microstructure (characterized by phases volume fraction, grains size and grains distribution), graphite nodules (characterized by size, shape, density and distribution) and defects presence (e.g., porosity, inclusions, etc.). Considering ferritic DCIs, ferritic matrix -graphite nodule debonding is only seldom observed and the main ferritic DCI damaging micromechanism consists in cracks nucleation and propagation in the graphite external shell coming from the reduced carbon solubility in phase during cooling process ("onion-like" mechanism). A second damaging micromechanism is sometimes observed together with the "onion-like" mechanism and consists in cracks nucleation and propagation corresponding to the graphite nodule center ("disgregation" mechanism). The importance of this damaging mechanism is dependent on the loading conditions and is probably influenced by the graphite nodule nucleation mechanism during solidification. In this work, the damaging micromechanisms in a pearlitic DCI have been investigated by means of the Scanning Electron Microscope (SEM) observation of the specimen lateral surface during the tensile tests ("in situ" tests). Damaging micromechanisms development has been analyzed, focusing both the role of the graphite nodules and the cracks initiation and propagation in the pearlitic matrix.

A research was done to investigate the effect of 0.05…0.25wt.% addition rate of Ca, Zr ,Al - FeSi alloy, in ladle and in-mould inoculation of grey cast irons. In the present paper, the conclusions drawn are based on thermal analysis. For solidification pattern, some specific cooling curves characteristics, such as undercooling degree at the beginning of eutectic solidification and at

Thickness quantification of conductive ferromagnetic materials has become a common necessity in present-day structural health monitoring and infrastructure maintenance. Recent research has found Pulsed Eddy Current (PEC) sensing, especially the detector-coil-based PEC sensor architecture, to effectively serve as a nondestructive sensing technique for this purpose. As a result, several methods of varying complexity have been proposed in recent years to extract PEC signal features, against which conductive ferromagnetic material thickness behaves as a function, in return enabling thickness quantification owing to functional behaviours. It can be seen that almost all features specifically proposed in the literature for the purpose of conductive ferromagnetic material-thickness quantification are in some way related to the diffusion time constant of eddy currents. This paper examines the relevant feature-extraction methods through a controlled experiment in which the methods are applied to a single set of experimentally captured PEC signals, and provides a review by discussing the quality of the extractable features, and their functional behaviours for thickness quantification, along with computational time taken for feature extraction. Along with this paper, the set of PEC signals and some MATLAB codes for feature extraction are provided as supplementary materials for interested readers.

Biodiesel is currently in regular use as an alternative fuel over conventional petroleum diesel. However, corrosion of automotive materials is one of the concerns related to biodiesel compatibility issues. In addition, auto-oxidation of biodiesel can also enhance the corrosiveness of biodiesel. The present study aims to investigate inhibition effect of ethylenediamine (EDA), n-butylamine (nBA), tert-butylamine (TBA) against corrosion of cast iron. Static immersion tests in biodiesel in the presence (100 ppm) and absence of different corrosion inhibitors were carried out at room temperature for 1200 hours. At the end of the test, corrosion characteristic was investigated by weight loss measurements and changes on the exposed metal surface. Fuels were analyzed by using TAN (total acid number) analyzer and FTIR in order to investigate the acid concentration and compositional characteristics respectively. Surface morphology was examined by digital photography and scanning electron microscope (SEM). Oxide layers were investigated by X-ray diffraction. Results showed that TBA was more effective corrosion inhibitor in reducing corrosion than others. © 2011 Elsevier B.V. All rights reserved.

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An ionic liquid (IL) trihexyltetradecylphosphonium bis(2-ethylhexyl) phosphate has been investigated as a potential antiwear lubricant additive. Unlike most other ILs that have very low solubility in nonpolar fluids, this IL is fully miscible with various hydrocarbon oils. In addition, it is thermally stable up to 347°C, showed no corrosive attack to cast iron in an ambient environment, and has excellent wettability on solid surfaces (e.g., contact angle on cast iron <8°). Most importantly, this phosphonium-based IL has demonstrated effective antiscuffing and antiwear characteristics when blended with lubricating oils. For example, a 5 wt % addition into a synthetic base oil eliminated the scuffing failure experienced in neat oil and, as a result, reduced the friction coefficient by 60% and the wear rate by 3 orders of magnitude. A synergistic effect on wear protection was observed with the current antiwear additive when added into a fully formulated engine oil. Nanostructure examination and composition analysis revealed a triboboundary film and subsurface plastic deformation zone for the metallic surface lubricated by the IL-containing lubricants. This protective boundary film is believed to be responsible for the IL's antiscuffing and antiwear functionality.

Maritime archaeological explorations have been initiated in Goa waters since 1997 for locating port installations and shipwrecks both in coastal waters and riverbanks. Exploration off Sunchi reef in 3 to 6 m water depth brought to light a barrel of a hand gun, guns, Chinese ceramics, sherds of Martaban pottery (stone ware), elephant tusks and hippopotamus teeth, a number of dressed granite blocks, a cast iron cannon ball, lead pieces, copper vessel and strip, stone and clay bricks, pieces of glass bottles, etc. These findings suggest that the ship might have arrived from Portugal via African countries to Goa and grounded due to lack of knowledge of the topography of the area. Thermo-luminescence dating of Martaban pottery (stone ware), the radiocarbon dating of ivory and comparative study of the 'Admiralty Pattern Long Shanked' type of iron anchor indicate that the wreck could be dated to the early 17th century AD. The findings of Sunchi Reef show the evidence of the Indo-Portuguese maritime trade and are the oldest wreck observed so far in the nautical archaeology of India.

This work focuses on the corrosion of cast iron in a drinking water network. The study is performed in water and in a sandy soil saturated with the same water. In the presence of corrosion products, the inner wall surface shows a lower corrosion rate than the external wall. In the two media, impedance diagrams are described by a high-frequency loop characteristic of a protective corrosion layer and a diffusion impedance loop at low frequencies associated with oxygen diffusion. Different models involving mass transfer through a porous layer are suggested for the inner and the external corrosion layers.

For older water pipeline materials such as cast iron and asbestos cement, future pipe failure rates can be extrapolated from large volumes of existing historical failure data held by water utilities. However, for newer pipeline materials such as polyvinyl chloride (PVC), only limited failure data exists and confident forecasts of future pipe failures cannot be made from historical data alone. To solve this problem, this paper presents a physical probabilistic model, which has been developed to estimate failure rates in buried PVC pipelines as they age. The model assumes that under in-service operating conditions, crack initiation can occur from inherent defects located in the pipe wall. Linear elastic fracture mechanics theory is used to predict the time to brittle fracture for pipes with internal defects subjected to combined internal pressure and soil deflection loading together with through-wall residual stress. To include uncertainty in the failure process, inherent defect size is treated as a stochastic variable, and modelled with an appropriate probability distribution. Microscopic examination of fracture surfaces from field failures in Australian PVC pipes suggests that the 2-parameter Weibull distribution can be applied. Monte Carlo simulation is then used to estimate lifetime probability distributions for pipes with internal defects, subjected to typical operating conditions. As with inherent defect size, the 2-parameter Weibull distribution is shown to be appropriate to model uncertainty in predicted pipe lifetime. The Weibull hazard function for pipe lifetime is then used to estimate the expected failure rate (per pipe length/per year) as a function of pipe age. To validate the model, predicted failure rates are compared to aggregated failure data from 17 UK water utilities obtained from the United Kingdom Water Industry Research (UKWIR) National Mains Failure Database. In the absence of actual operating pressure data in the UKWIR database, typical values from Australian water utilities were assumed to apply. While the physical probabilistic failure model shows good agreement with data recorded by UK water utilities, actual operating pressures from the UK is required to complete the model validation. r

The high cycle fatigue behaviour of a nodular cast iron has been investigated under tension loading. Casting defects are at the origin of crack initiation for all samples tested. Critical defects (shrinkage) are located either at the surface or within the bulk. The role of the size and position of natural defect on the fatigue limit has been established. Results show that, for a given size, internal defects are less damaging than surface located ones. SEM observations revealed the existence of non-propagating surface cracks below the fatigue limit. By means of a marking technique, the 3D shape of these cracks initiated around the defects was fully described. In an attempt to simulate the evolution of the fatigue limit with defect size, some existing approaches are compared to experimental data; it is shown that 2D analysis of defects (crack or notch) is conservative. 