Abstract
Recent years have seen increasing use of solidification process modeling as a tool to aid in the analysis and elimination of manufacturing defects in castings. Grain size and other microstructural features such as second-phase morphology and distribution are the primary factors in determining the mechanical properties in cast metals. In this work, a representation of nucleation and growth kinetics for gray cast irons, based on a statistical description of the microstructure, has been coupled with a commercial finite-element method code for transient heat-flow calculation to determine microstructure. Features predicted include eutectic cell size, fractions of gray and white iron, graphite morphology, percent pearlite, percent ferrite, and pearlite spacing. The predicted microstructure can then be used to determine the strength and fatigue properties using published correlations. The theoretical development and results of the finite-elementbased model will be discussed and compared with experimental results.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
J.W. Wiese and J.A. Dantzig:Metall. Trans. A, 1990, vol. 21A, pp. 489–97.
J.A. Dantzig and J.W. Wiese:Adv. Manufac. Proc, 1986, vol. 1, pp. 437–54.
K. Kubo and R.D. Pehlke:Metall. Trans. B, 1985, vol. 16B, pp. 359–66.
W. Oldfleld:Trans. ASM, 1966, vol. 59, 945–60.
A. Hellawell: inSolidification Processing, Institute of Metals, London, 1977, pp. 161–68.
M. Rappaz:Int. Mater. Rev., 1989, vol. 34, pp. 93–123.
M. Rappaz and D. Stefanescu: inSolidification Processing of Eutectic Alloys, D.M. Stefanescu, G.J. Abbaschian, and R.J. Bayuzick, eds., TMS, Warrendale, PA, 1988, pp. 133–51.
D. Stefanescu and D. Bandyopadhyay: inCasting of Near Net Shape Products, Y. Sahai, J.E. Battles, R.S. Carbonara, and C.E. Mobley, eds., TMS, Warrendale, PA, pp. 153–65.
W.A. Johnson and R.F. Mehl:Reaction Kinetics in Processes of Nucleation and Growth, 1939, AIME Technical Publication No. 1089, pp. 1-27.
M. Avrami:J. Chem. Phys., 1940, vol. 8, pp. 212–24.
C. Price:Acta Metall., 1987, vol. 35, pp. 1377–90.
T. Clyne and W. Kurz:Metall. Trans. A, 1981, vol. 12A, pp. 965–71.
R.W. Heine:AFS Trans., 1986, vol. 94, pp. 391–402.
D. Glover, C.E. Bates, and R. Monroe:AFS Trans., 1982, vol. 90, pp. 745–57.
D. Turnbull and J.C. Fisher:J. Chem. Phys., 1949, vol. 17, p. 71.
R. Elliott:Eutectic Solidification Processing, Butterworths and Co., Ltd., London, 1983.
J.-T. Thorgrimsson, H. Fredriksson, and I. Svensson: inSolidification Processing, Institute of Metals, London, 1987, pp. 83–86.
P. Magnin and W. Kurz:Acta Metall., 1987, vol. 35, pp. 1119–28.
M. Hillert and V.V. Subba Rao: inThe Solidification of Metals, The Iron and Steel Institute, London, 1967, pp. 205–12.
G. Ruffand J. Wallace:AFS Trans., 1976, vol. 84, pp. 705–28.
R. Mehl and A. Dube: inPhase Transformations in Solids, R. Smoluchowski, J.E. Mayer, and W.A. Weyl, eds., John Wiley and Sons, Inc., New York, NY, 1951.
D.M. Stefanescu and C. Kanetkar: inComputer Simulation of Microstructural Evolution, D.J. Srolovitz, ed., Warrendale, PA, 1986, pp. 171–88.
W. Press, B. Flannery, S. Teukolsky, and W. Vetterling:Numerical Recipes. Cambridge University Press, Cambridge, United Kingdom, 1986.
T. Tszeng, Y. Im, and S. Kobayashi:Int. J. Mach. Tools Manufac, 1989, vol. 29, pp. 107–200.
M. Engelman:FIDAP Theoretical Manual, Fluid Dynamics International, Evanston, IL, 1990.
W. Oldfield:BCIRA J., 1961, vol. 9, pp. 506–18.
W. Oldfield:BCIRA J., 1960, vol. 8, pp. 177–92.
M. Horsfall:BCIRA J., 1982, vol. 30, pp. 134–39.
M. Horsfall: BCIRA Technical Report, 1981.
H.D. Merchant:Foundry, 1963, vol. 91, pp. 59–65.
Metals Handbook, 4th ed. E.E. Underwood, ed., ASM, Metals Park, OH, 1985, pp. 123-34.
J.V. Dawson and W. Oldfield:BCIRA J., 1960, vol. 8, pp. 221–31.
C.E. Bates:AFS Trans., 1986, vol. 94, pp. 889–912.
D.K. Banerjee, G. Upadhya, and D.M. Stefanescu: inF. Weinberg Int. Symp. on Solidification Processing, J.E. Lait and I.V. Samarasekera, eds., Pergamon Press, Inc., New York, NY, 1990, pp. 319–32.
J. Zou and A.A. Tseng:Metall. Trans. A, 1992, vol. 23A, pp. 457–67.
R.D. Pehlke, A. Jeyarajan, and H. Wada:Summary of Thermal Properties for Casting Alloys and Mold Materials NITS-PB83- 211003, University of Michigan, Ann Arbor, 1982.
D.M. Stefanescu: inThe Physical Metallurgy of Cast Iron, H. Fredriksson and M. Hillert, eds., North-Holland, Amsterdam, 1984.
C. Zener:Trans. AIME, 1946, vol. 167, pp. 550–67.
L.S. Darken and R.P. Smith:Ind. Eng. Chem., 1951, vol. 43, pp. 1815–19.
Author information
Authors and Affiliations
Additional information
Formerly Research Assistant, University of Illinois
Rights and permissions
About this article
Cite this article
Goettsch, D.D., Dantzig, J.A. Modeling microstructure development in gray cast irons. Metall Mater Trans A 25, 1063–1079 (1994). https://doi.org/10.1007/BF02652281
Received:
Issue Date:
DOI: https://doi.org/10.1007/BF02652281