On the microstructure and mechanical

properties of automotive parts made

of ductile iron
Juan José Ramírez-Natera1, Rafael Colás1, Sergio Haro-Rodriguez2, Patricio Gil-Ramos3
1 Universidad Autónoma de Nuevo León
2 Universidad Autónoma de Zacatecas
3Black Hawk de México, S.A. de C.V.
• The changes taken place in
the microstructure and
mechanical properties of an
automotive part
manufactured with a piezas
ferritic-pearlitic ductile iron
was investigated.
Demoulding time at 2, 4, 6
and 8 hours after pouring
at 1400 °C analyzing three
thicknesses from 25 to 53
mm
• Se estudiaron los cambios
que se presentan en la
microestructura y
propiedades mecánicas en
automotrices
fabricadas a partir de un
hierro dúctil ferrítico-
perlítico. El metal se vertió
a 1400 °C en un molde
desmoldeando a las 2, 4, 6
y 8 horas analizando tres
espesores que van desde
los 25 mm hasta los 53 mm
Introduction
• In 2010 94.1 million of tonns of metallic pieces
were produced, 25% were ductile iron and
continuous increasing still (1). Annual worldwide
production is of 12 millions of tonnes and it’s
expected that in 10 year get over 20 millions of
tonnes. One third of the ductile iron production is
for water pipes, another third for automotive
parts and another for general castings. It is
important to note that automotive sector is the
most successful, in addition to the high demand, it
has high requirements for quality and low cost
with specific properties (2).

Ductile iron
• Ductile iron is known for its ductility and
toughness after special magnesium, cerium,
lanthanum treatment. Carbon forms spheroidal
particles instead of sheets (Gray iron). Due to the
spheroidal shape of the carbon the matrix keeps Fig. 1. Carbon and silicon ranges for cast
its continuity for achieve with good ductility. irons and steels [4].
 Trace elements influence
• Carbon. Average value
between 2.5-4.5%. It
decrease yield strength and
hardness and increased
elongation and impact
resistance.
• Silicon. Average value
between 1.8-2.8%. increase
nodule counting and
decrease tendency to form
carbide. Increase yield
strength and decreased
hardness and elongation.
• Sulfur. Decrease
magnesium effect, high
quality irons have less
0.02% wt.
• Phosphorus. Decrease
ductility and toughness. But
small quantities refine
pearlite increasing yield-
tensile strength ratio [6].
• Manganese. Av value
between 0.5-0.7% increase
tensile strength and yield
strength while decrease
ductility
 Microstructure and properties
The microstructure is based in a matrix of ferrite and a second element
of pearlite.
Ferrite. It has a BCC structure and it Pearlite. Is a mix of laminate ferrite
is relatively ductile and soft. with cementite. It has a good
Hardness varies from 140-200 HB. strength but poor ductility and the
In ductile irons the ferrite is around hardness varies form 200-300 HB.
the graphite nodule and it can be Pearlite content depend of the
extended to the grain boundaries. graphitization grade and the
cooling rate.

Fig. 2. Typical microstructure of ductile iron.

Table I The UNS designations for Ductile Irons, cross-referenced to
the corresponding ASTM, AMS, SAE and MIL specifications [3].
 Solidification Phenomena
Solidification is due the • (I) The melt theory, proposing
precipitation of two phases: that graphite forms in the melt
austenite and graphite in the same simultaneously with austenite
way of gray iron. Nucleation and dendrites, which rapidly
growth of these two phases encapsulate graphite in an
determine the mechanical austenite shell.
properties and they are affected by • (II) The dendritic growth theory,
the chemical composition (mainly maintaining that austenite
carbon and silicon) inoculation and dendrites precipitate from the
finally the cooling rate. melt, enriching it in carbon and
There are two theories about that later graphite grows from
solidification: this supersaturated residual melt,
in the interstices amongst the
dendrites [11].
 Justification
In ductile iron production several factors affect the
microstructure and the mechanical properties. From the melt
preparation, the quality of the charge, chemical composition,
type of furnace, nodularization treatment, pouring conditions
and others but if we take in account that controlling the
cooling time in mold can increase the mechanical properties
without any additional cost, it take great importance.
This research is carried out in order to identify how much the
cooling time in the mold affect on the microstructure and
mechanical properties for a No bake mold casting.
 Objective
Evaluate the cooling conditions in mold and its effects on:
• Microstructure.
• Mechanical properties.
For different thicknesses
 Hypothesis
Solidification time affected by the thickness of the
transverse section modify the microstructure of the
ductile iron.
Increasing the cooling time in the mold reduces the
tensile strength and hardness of ductile iron.
 Experimentation

Condition Cooling time, h Thickness

25, 40 and 53 mm for microstructure

1 2
53 mm for tension and hardness test
25, 40 and 53 mm for microstructure
2 4
53 mm for tension and hardness test
25, 40 and 53 mm for microstructure
3 6
53 mm for tension and hardness test
25, 40 and 53 mm for microstructure
4 8
53 mm for tension and hardness test

Table II Experimental procedure

Results
Fig. 3. Nodules density according with the demoulding time for
different thicknesses.
Fig. 4. Nodules size according with the demoulding time for
different thicknesses.
Fig. 5. Nodules area fraction according with the demoulding time
for different thicknesses.
Fig. 6. Pearlite and ferrite content for 2, 4, 6 and 8 hours.
Fig. 7. Hardness for 2, 4, 6 and 8 hours of demoulding time.
Fig. 8. Tensile and yield strength for 2, 4, 6 and 8 hours of
demoulding time.
Fig. 9. Elongation for 2, 4, 6 and 8 hours of demoulding time.
Conclusion
• The results indicate that the
demoulding time and cross-
section thickness have a great
influence on the
microstructure and
mechanical properties of the
part. Solidification time,
influenced by the thickness
section, determines the size
and number of graphite
nodules and the pearlite to
ferrite ratio of the matrix,
with the consequent increase
in ductility and tensile
strength of the casting.
Conclusión
• Los resultados indican que el
tiempo de desmoldeo y el
espesor de la sección
transversal afectan
significativamente a la
microestructura y propiedades
de la parte. El tiempo de
solidificación, afectado por el
espesor de la sección,
determinan el tamaño y
número de los nódulos de
grafito y la relación entre
ferrita y perlita de la matriz,
con el consecuente
incremento de ductilidad y de
la resistencia a la tensión de la
pieza.
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