106 Mat.-wiss. u. Werkstofftech. 2014, 45, No. 2 DOI 10.1002/mawe.

201400207

Study in the variation of mechanical properties

of nodular cast iron depending upon section thickness
Variation der mechanischen Eigenschaften von Gusseisen
mit Kugelgrafit in Abhängigkeit der Abschnittsdicke

C. S. Çetinarslan, S. Karaman Genç

Cast iron has become a popular cast metal material which is widely used in modern
industry and today’s technology because of its low cost and desirable properties
such as good castability, convenient machining properties, better wear resistance,
etc. This paper is concerned with the variation of mechanical properties depending
on section thickness of nodular cast iron. Firstly manufacturing process of GGG40
(EN-GJS-400-15/DIN 1693 or 60-40-18/ASTM A536) nodular (ductile) cast iron was
performed. Sand mould casting was only used as a molding process. Following,
convenient moulds were prepared and the casting process was carried out in
moulds that have different diameters (≤30 mm) to examine the cooling rate effects
to the mechanical properties. Finally, tensile, hardness, metallography and fatigue
tests were applied to cast materials test specimens. The results show that the cool-
ing rate which is related to the section thickness affects the mechanical properties
clearly.

Keywords: Casting / nodular cast iron / mechanical properties / cooling rate / section
thickness

Schlüsselwörter: Gießen / Gusseisen mit Kugelgrafit / mechanische Eigenschaften /

Abkühlrate / Abschnittsdicke

1 Introduction
Casting is one of the most significant processes in
the metal and alloys manufacturing area. Nowadays,
nodular (ductile) cast irons are significant and are
the preferred type of cast irons. When gray iron was
most popular in the 1900’s nodular cast iron had
been a result from experiments involving a graphite
matrix to change into spherical form since the late
1940’s. This spheroidal form brings it good mechan-
ical properties. In addition to that, nodular cast iron
has a higher casting yield and it is easier to make
sound castings. Since that time, nodular cast iron has
become a popular material in the industry. Nodular
Corresponding author: Dr. Cem S. Çetinarslan, Trakya
University, Faculty of Engineering, Department of Me-
chanical Engineering, 22180 Edirne/ Turkey, E-mail:
cemc@trakya.edu.tr
cast irons that are similar to steels from the point of
their mechanical properties are the most popular en-
gineering materials; at the same time they are similar
to cast irons in terms of chemical and physical prop-
erties. The spheroidal graphite interrupts the continu-
ity of the matrix much less than graphite flakes;
which gives nodular iron better in strength and
toughness compared to gray iron [1]. It has about
30% of the cast iron production in most industrial
countries and it will undoubtedly keep rising [2].
The application of nodular cast iron in the industry
spans very wide ranges and various areas; for exam-
ple automotive, agricultural, earth-moving applica-
tions, etc [3].
Up to today, so many studies have been done
about the control of the composition of nodular cast
iron. In nodular cast iron, sundry trace elements like
lead, antimony, titanium, etc. are kept in as low

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Mat.-wiss. u. Werkstofftech. 2014, 45, No. 2
Table 1. Classifications of ductile iron according to micro
structure
Material GGG GGG GGG GGG GGG
Type 40 50 60 70 80
Micro Ferritic ! Pearlitic
Structure
quantities as possible for a good graphite structure
and small amounts of cerium will be added to the
cast to remove the raw material’s undesirable ef-
fects.
Carbon, silicon, magnesium, etc. elements are
also prominent in nodular iron casting [4–5].
Furthermore, magnesium is the most popular ele-
ment in the industry due to its effectiveness in nodu-
larity of nodular cast iron, but the addition of this
element to cast iron is very difficult. Because of this
reason, many processes were developed [6]. Further-
more, its addition time is also effective on nodularity
[7–9]. Most preferred ductile irons are respectively
GGG 40, 50, 60 and 70, according to micro structure
in the industry, Table 1.
All properties of nodular cast iron, especially me-
chanical behaviors, could not be imagined separately
from nodularity. When the nodularity ratio increases
in nodular cast iron, tensile and yield strength are
also increased [10]. Some studies were carried out
that related a new method for prediction of nodular
cast iron fatigue limits. Costa et al. proposed a new
method for prediction of nodular cast iron fatigue
limit [11]. This model takes into consideration both
intrinsic properties as well as some new geometrical
material features. Influence of casting defects on the
fatigue limit of nodular cast iron were analyzed by
Nadot et al. [12]. Furthermore, another study was to
evaluate the fatigue are various theoretical and ex-
perimental studies related to the investigations in
ductile iron and its mechanical properties (mainly
about fatigue).The fatigue behavior of nodular cast
iron used at room and elevated temperatures for rail-
way brake discs by Šamec et al. [13]. Low percen-
tage in nodularity is known to lower impact energy
in ductile condition. It reduces fatigue strength and
electrical resistivity but increases damping capacity
and thermal conductivity [10, 14 and 15]. There are
various theoretical and experimental studies related
to the investigations in ductile iron and its mechan-
ical properties (mainly about fatigue). For example,
Xue et al. examined fatigue behaviour in the very
© 2014 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim
Study in the variation of mechanical properties 107
high cycle regime was investigated with a nodular
cast iron under ultrasonic fatigue test system [16].
Yano, mentioned an elastic effect by which nodules
partially support the applied loading. According to
the study the microstructure compress effect no-
dules, increasing their density, resulting in a 20–
24% increase in fatigue strength [17–18]. In addition
to all these, Niimi et al. focused on the effect of the
size of the graphite nodules on fatigue strength of
the ductile irons [19]. Their results indicate that the
material with the smallest nodule size has the highest
fatigue strength. An experimental and theoretical
work on stress–strain data for grey and nodular cast
irons was reported by Kohout [20].
Experimental investigations of tensile strength ver-
sus elongation and also versus hardness on various
ductile iron were carried out by Gilbert [21]. Basaj
et al. focused on tensile properties continuum with
Brinell hardness of as-cast ductile iron [22].
The purpose of this study was to investigate the
manufacturing process and to be able to determine
the changes which occur in mechanical properties
and microstructure of GGG40 (EN-GJS-400-15/DIN
1693 or 60-40-18/ASTM A536) depending on sec-
tion thickness during the casting process.
2 Experimental procedure
2.1 Casting
All type test specimens were prepared using the mould
model in Fig. 1a. Various sand tests were applied for
mould sand. Then, test moulds were prepared utiliz-
ing a vertical molding process (Disamatic).
Some of the elements, such as cerium, calcium,
lithium and magnesium are known to develop nod-
Figure 1. A model for sand molding (a) and ultimate product
(b)
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108 C. S. Çetinarslan. S. Karaman Genç Mat.-wiss. u. Werkstofftech. 2014, 45, No. 2

Table 2. The Spectrum and C–S analysis results 2.3 Heat treatment

Ele- Spec. C–S Ele- Spec. C–S The thermal process, which is commonly preferred in
ments test Ana- ments test Ana- the industry for having a fully ferritic structure, was
lysis lysis applied to some of test specimens (only to hardness
%C 3.18 3.62 %Ni 0.015 – and metallography test specimens) to examine the ef-
%Si 2.59 – %V 0.0036 – fect on properties of hardness and graphite structure.
%P 0.031 – %Ti 0.014 – The test specimens were first heated to 900 °C in nine
%S 0.004 0.0033 %Al 0.014 – hours, and then they were kept at 900 °C in seven
%Cr 0.023 – %B 0.00019 – hours. Then, they were further heated to 950 °C and
%Cu 0.023 – %Bi 0.00053 – kept at this temperature for about seven hours again.
%Sn 0.031 – %La 0.004 – Later, they were cooled to 750 °C in two hours, then
%Mg 0.029 – %Ce 0.003 –
to 700 °C in four hours. Samples taken out from the
%Mo 0.0005 – %Fe 93.8 –
furnace were left to equilibrate with the room tem-
perature. Additionally, the heat-treated samples were
sandpapered and polished to improve the surface
ular graphite structures in cast iron [6]. Magnesium
prior to the hardness and metallographic tests.
was used in this study. In this process, the sand-
wich method was used and sand moulds were filled
with molten iron during cast utilizing an automatic 2.4 Mechanical and metallographic tests
pouring device. The cast temperature was deter- Specimens firstly were cast from GGG40 as diam-
mined by measuring apparatus during the cast as eters of 20/25/30 mm and lengths of 225 mm; then
1401 °C. they were machined to the same measurements sepa-
In this part, chemical composition tests were ap- rately by lathe for tensile and fatigue tests in accor-
plied to the casting metal sample during casting. dance with standards.
Two type analysis methods were realized. Firstly, a The fatigue tests were performed by Instron 8501
spectrum analysis test was performed. Subse- universal test machine with different mean stresses
quently, a C–S analysis test was performed and the and added same stress amplitudes of ±32 MPa,
test result of C and S were read on the digital dis- Fig. 2a. This test machine has three channels (posi-
play as: C 3.62% and S 0.0033% material. And tion, load and strain). Load controlled channel was
these results for GGG 40 were given in Table 2. chosen and a sinusoidal axial tension (pull) load was
The probable difference of %C value at spectrum applied (R > 0; σm > σA). Kt factor wasn’t taken into
and C–S analysis method is depends on device cali- account in this fatigue investigation. The initial posi-
bration. tion of specimen at the experiment is documented in
Fig. 2b and the fatigue crack in Fig. 2c.
2.2 Supplementary processes The metallographic and hardness test specimens
Supplementary processes have many various types. were prepared from GGG 40 cast bars by cutting
Bull block, vibratory tank, and strainer were used in lengthwise, which resulted in 20 mm, 25 mm, and
this manufacturing process to clean the product suf-
ficiently. After casting, products arrived at the vibra-
tory tank by belt conveyor. Then, the mould sand
was cut loose from the product into the vibratory
tank. After this process they were traversed from the
strainer; so most of mould sand was taken out of the
manufacturing process at this time. At the end of this
process the ultimate products were occurred. The
product was placed into the bull block and it was
cleaned by steel ball impact. At the end of the manu-
facture process, the ultimate product was taken from
the bull block, which was filled with steel balls, Figure 2. Instron test machine (a), initial position of specimen
Fig. 1b. (b) and fatigue crack at specimen (c)

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Mat.-wiss. u. Werkstofftech. 2014, 45, No. 2 Study in the variation of mechanical properties 109

Figure 4. Variation of ultimate tensile strength according to

cooling rate due to cast section thickness

in compliance with the results of Goodrich and Lo-

Figure 3. (a) Schematic drawing of application zones and (b)
upper view of hardness test specimens (heat-treated) of var-
ious diameters (20 mm/25 mm/30 mm)
30 mm diameters, and 225 mm lengths. As a result,
the hardness and metallographic test samples lengths
have become 20 mm and their diameters remained
same. These specimens were grouped into two, and
heat treatment was applied to one of these groups.
Subsequently, sandpapering and polishing were ap-
plied respectively to the two groups. At the end of
the surface treatments, metallographic investigations
and Brinell Hardness Tests were performed.
In this test, a 5 mm diameter tungsten carbide ball
attached to a hardness tester and 750 kgf was applied
to the test specimens at different points (on the as-
sumed circular lines on the Fig. 3a) on the surface
from the centre to outward like Fig. 3 [23]. SOIF
XJP-6A metallurgical microscope with the X 100
magnification was used in metallographic examines.
benhofer [24].
As expected, the highest maximum tensile values
were observed in specimens that had the minimum
cast diameter (the specimen with diameter 20 mm).
The values of the specimen with diameter 25 mm
were lower in comparison to values of 20 mm, and
also the values of 30 mm were lower in comparison
to values of 25 mm. This situation correlated with
the rate of cooling. Fast cooling rates in the thin cast-
ing section produced stronger castings with greater
pearlite content [25]. The amount of ferrite in the
cast matrix depends on not only composition but
also the rate of cooling [1].
3.2 Fatigue test results
The results of fatigue tests which were carried out
by the Instron universal test machine were shown in
Fig. 5. Pre-machined diameters (cast diameters)
were given on the graphic with different symbols
(Namely, the specimens that have same diameters
machined from cast bars that have different thick-

3 Results and discussion Table 3. Tensile properties of different cast section thick-
ness
3.1 Tensile test results
Diameter UTS YS Elongation
The results of tensile tests which were carried out (mm) (MPa) (MPa) %
are shown in Fig. 4 and listed in Table 3. Maximum 20 491 298 16.96
(ultimate) tensile stress values were given on the ver- 20 548.9 327 16.228
tical axis and the diameters before machined (cast 20 539.7 313 16.48
diameters) were given on the horizontal axis 25 464.6 268 16.596
(Namely, the specimens that have same diameters 25 487.6 260 18.48
machined from cast bars that have different thick- 25 478 271 14.8
ness (20/25/30 mm)). According to the tensile test 30 419.4 211 14.24
30 480.1 272 12.556
results, when the casting diameters decrease, the
30 435.2 244 15.48
maximum tensile results increase. These results are

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110 C. S. Çetinarslan. S. Karaman Genç Mat.-wiss. u. Werkstofftech. 2014, 45, No. 2

mally. This situation which cannot be correlated

with hardness and tensile test results can be ex-
plained by examining the internal structure of mate-
rials due to the fatigue characteristics. The experi-
ments were stopped after 600 000 cycles if the speci-
mens didn’t get damaged (these specimens abso-
lutely weren’t used once again).

3.3 Metallography test results

Changes of spherical graphite in heat-treated and
non-heat-treated conditions were observed by a me-
tallurgical microscope in three different diameter
Figure 5. Variation of cycle number according to mean stress
for different cast section thickness related cooling rate
specimens that were made from GGG40, Figs. 6, 7.
It appears that the specimen with diameter 20 mm
and 30 mm’s graphite size, closeness and disper-
ness (20/25/30 mm). According to the fatigue tests
sions are similar according to 25 mm, and forms of
results, as shown in the graphic, fatigue life of the
nodular graphites were slightly misshaped in heat-
specimen with diameter 30 mm is less regular then
treated specimens in comparison with non heat-treat-
20 mm and 25 mm. In other words, the results of the
ed specimens. Ductile iron nodule count is one of
specimen with diameter 20 mm and 25 mm were
the important factors in achieving the desired me-
close to each other, but the results of 30 mm were
chanical properties. In addition, nodule size also af-
dispersed. Furthermore, the highest fatigue life and
fects mechanical properties; increasing the nodule
average stress values were observed in 20 mm that
size decreases the tensile strength of the harder duc-
also had the lowest diameter. And also, an unex-
tile irons [26]; also fatigue life decreases with in-
pected result was observed. The fatigue life values
creasing nodule size, Figs. 5, 6.
didn’t increase proportionally when the cast diam-
eters decreased, Fig. 5.
Apparently, the results of the fatigue tests were far 3.4 Hardness test results
from the expected values according to tensile tests The hardness tests results were shown for non heat-
results. This was caused by working with very small treated condition and heat-treated results in Figs. 8,
diameters (≤30 mm) and also using the cooling rate 9. The Figures show that, generally, maximum hard-
at maximum efficiency in this situation. The GGG40 ness values are in the centers of specimens for each
material has a ferritic structure by definition, but in
this situation it diverged from a ferritic structure and
into a pearlitic structure by the effect of the cooling
rate, and this phase transformation expected to
change the mechanical properties. And also, the in-
creased pearlitic structure will increase hardness and
decrease ductility. These features could explain why
the results are lower than ones relatively expected.
Figure 6. Image of morphology of nodular graphite in non-
The overall distribution is seen to be ranked relative heat-treated different sized samples (GGG 40)
to each other in definite regions for the fatigue test
results of the GGG40 relating to the specimen with
diameter 20 mm, 25 mm and 30 mm. But number of
cycle followed by the sequence of thickness of the
specimen with diameter 20 mm, 30 mm, 25 mm and
it is clearly observed that this situation occurred
while the mean stress is 75–80 MPa, whereas num-
ber of cycle that will be obtained at same mean stress Figure 7. Image of morphology of nodular graphite in heat-
was followed as 20 mm, 25 mm and 30 mm nor- treated different sized samples (GGG 40)

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Mat.-wiss. u. Werkstofftech. 2014, 45, No. 2
Figure 8. Variation of hardness for different zones according
to cooling rate due to cast section thickness in non-heat-treat-
ed condition
Figure 9. Variation of hardness for different zones according
to cast section thickness in heat-treated condition
diameter (application zones are seen in Fig. 3). In other
words, according to both the heat-treated and non
heat-treated test results, generally, a decrease in hard-
ness values from the centre outward was observed. Be-
sides all these, the maximum change in hardness per
unit distance was observed in the smallest diameter
(20 mm).
In addition, the non heat-treated specimen’s test
results in comparison with the heat-treated ones, it is
seen that the maximum values are observed in the
non heat-treated results, and on the other hand, the
minimum values are observed in the heat-treated re-
sults belonging to the smallest diameter (20 mm).
4 Conclusions
This study is a realization and brief explanation
about the casting process of nodular cast iron. GGG
© 2014 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim
Study in the variation of mechanical properties 111
40 was chosen as a cast material in this investiga-
tion. All phases of this casting process were realized
and explained. Subsequently, section thickness, cir-
cumstances of nodular graphite effects, and also in-
terdependence of these to affect the mechanical
properties of GGG 40 were studied.
It is observed that, the tensile strength increased in
specimens having diameters of 20 mm, 25 mm, and
30mm (for ≤ ∅ 30). The increase was very high ac-
cording to the standards, with the same conditions
for this material [2]. So that is not exactly linear (The
rate of increase is higher in diameters smaller than
30 mm than the ones that are larger than 30 mm).
These observations showed that once again, nodu-
lar cast iron is a very functional material in engineer-
ing and can be handled meticulously and in a con-
trolled manner to obtain the expected mechanical
properties.
Proximity rate of graphite nodules to spherical
shape is also effective in fatigue life of material
(high nodule count produced by the rapid cooling
rate or nodule count decreases as section size in-
creases [27, 28]. Benefits of spherical shapes on fati-
gue life are depends on various variables. These
variables (number of graphite nodules, their proxi-
mity to each other, to what extent they are nodular,
smallness and greatness rates and the relationships
of these variables) and their correlations create new
results that depend on new composed dislocation
form. Fig. 5 can be commented according to Fig. 6
based on above mentioned. The estimated values of
fatigue test results were diameter 20 mm > 25 mm
> 30 mm, according to the tensile strength. However,
looking at the Fig. 5, sequence occurred as 20 mm
> 30 mm > 25 mm. In Fig. 6; the size, closeness and
dispersion of nodular graphites which pertain to nod-
ular cast iron show that; 20 mm and 30 mm resem-
bles each other a lot and they are different enough
from 25 mm based on metallographic investigations.
This situation is the reason of fatigue test results were
lined up as in Fig. 5.
Accordingly, it can be said that the effects of nod-
ular graphite’s size, closeness and dispersion on fati-
gue test results are quite important and this should
be taken into consideration at the design stage in
terms of mechanical properties and for preventing
accidents due to the products which are very close to
the critical limits.
As a result of the hardness tests, the high hardness
values of non-heat-treated specimens, according to
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112 C. S. Çetinarslan. S. Karaman Genç
their general value due to their section thickness
(≤30 mm) and related high pearlite rate, were ob-
served by microscopic investigations. In addition,
after heat treatment the smallest diameter (20 mm)
was shown with a lower hardness value than the
others and with the highest loss of hardness value.
The explanation of this situation is associated with
the rate of loss of the pearlitic structure.
The cooling rate which is related with section
thickness affects the mechanical properties [25, 27].
However, although the status is clearly observed in
fatigue due to nodularity, it is not regular and linear
by comparison in regards to hardness and tensile
strength.
In comparison to heat-treated and non-heat-treated
test results, the results of non-heat-treated specimens
had high values and, as expected, their hardness de-
creased from their centre outward. This is caused by
carbon segregation and inclusions [29, 30].
According to the results, hardness values are high-
er in non-heat-treated specimens than in heat-treated
specimens. In that case, we can say that the produc-
tion of a ferritic structure by the breakdown of car-
bide in pearlite resulting from an annealing treatment
according to the production of a ferritic structure di-
rectly in GGG40 means the loss of hardness in terms
of mechanical properties and loss of money because
of heat treatment in terms of cost and expenses.
Based on all these, the trace amount changes in
the chemical composition of nodular cast iron and
the heat treatment’s qualifications and variations
generate a variety of rich mechanical results that
may be controlled through adjustments. This indi-
cates that nodular cast iron is a perfect engineering
material [31]. Furthermore, many more specifica-
tions can occur by interfering with the dependent
and independent variables, and this proves that its
usage can be more extensive.
Also, a part that contains different sections that
are cast as a single part can be highly variable in
terms of mechanical properties. In this situation,
GGG40 material can acquire great advantages with
the informed correct assessments, although this can
lead to vulnerabilities about safety and quality with
the incorrect assessments.
It can be seen that, tensile and hardness tests,
which are utilized in the industry too often, are in-
adequate for determining the behavior of nodular
cast iron. All the tests and analyses are to be taken
into consideration as a whole for a good engineering
© 2014 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim
Mat.-wiss. u. Werkstofftech. 2014, 45, No. 2
design is a result that can be derived from this study.
Different nodular cast iron materials seem to be a
potential studying subject.
Acknowledgements
The authors are grateful to the TRAKYA DÖKÜM/
TURKEY for the technical support in experimental
processes. Authors declare that they have not a fi-
nancial relationship with the organization that spon-
sored the research. The authors also declare that they
have no conflict of interest.
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Received in final form: January 13th 2014 T 207
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