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Nodularity Measurement and Correlation with Mechanical Properties

in Heavy Section Ductile Iron Castings

Conference Paper · May 2016

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4 authors, including:

Giacomo Bertuzzi Matteo Cova

Petrolvalves S.p.A. SACMI Imola S.C.
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 Schaffausen, May, 12th, 2016
ECI Meeting 2016

Nodularity Measurement and

Correlation with Mechanical
Properties in Heavy Section Ductile
Iron Castings

G. Bertuzzi, M. Cova, R. Cenni G. Geminiani

ALMA MATER STUDIORUM - UNIVERSITÀ
DI BOLOGNA
 Agenda

Agenda Background
Experimental
Set-Up
Validation
• Background: Nodularity
• Graphite Particles: some basic definitions
Mechanical
• Graphite Particles classification
Properties
• Nodularity: different definitions Statistical
• Nodularity vs. Mechanical Properties Analysis
• Experimental Set-Up: Conclusion
• Castings
• Tensile and microstructure specimens
• Graphite Particle classification using Open Source Image Analysis Software
• Graphite Particles Classification: Visual Analysis and Image Analysis in reference images
• Experiment
• Graphite particles classification in current production
• «Nodularities» measurment and comparison
• Mechanical Properties vs. Microstructure Features (Pearlite and Nodularity)
• Mechanical Properties vs. Microstructure Statistical Analysis
• Conclusions & Suggestions

2
 Agenda

Graphite Particles: some basic definitions Background

Experimental
Set-Up
Validation

Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion
Caliper diameter (Feret diameter): Normal distance between two parallel tangent planes
touching the particle surface (in 3D) or two parallel tangents touching the particle outline
(in 2D)
W. Pabst / E. Gregorová, «Characterization of particles and particle systems»

Roundness: Ratio between the object area (A) and the area of the circle (Acir2) having
the Maximum Feret diameter as diameter.
A. Velichko, «Quantitative 3D Characterization of Graphite Morphologies in
Cast Iron using FIB Microstructure Tomography»

3
 Agenda

Graphite particles classification Background

Experimental
Set-Up
In 2015 Joop Kikkert collected and elaborate all the information related to nodularity
Validation
present in different standards:
Nodularity
A Nodule is a graphite particle that meets both the dimensional and
Mechanical
morphological requirements.
Properties
Statistical
Analysis
Conclusion

4
 Agenda

Nodularity: different definitions Background

Experimental
Set-Up
Validation
Nodularity is a ratio between nodules and all the graphite particles.
Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion

5
 Agenda

Nodularity vs. Mechanical Properties Background

Experimental
Set-Up
Validation
In R&D field there are correlations between “Nodularity” and Mechanical Properties
Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion

Kitsuki Hiroyuki，Takahashi Aguri, «Influence of graphite

nodularity on fatigue property of ductile Castlron»

6
 Agenda

Nodularity vs. Mechanical Properties Background

Experimental
Set-Up
Validation
In R&D field there are correlations between “Nodularity” and Mechanical Properties
Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion

7
 Microstructure Evaluation: some open Agenda

Background
points Dr. I. Steller, BDG, «Determination of Nodularity» Experimental
Set-Up

Microstructure Evaluation – Aims Validation

Nodularity
o Quality assurance, mechanical properties to be safeguarded
Mechanical
o Best properties (S.G. Iron) with Forms V+VI (generally) Properties
o Graphite shape deviations (extreme: spiky) anticipates lower tensile strength and fatigue Statistical
Analysis
limit (stated by R&D)
Conclusion

BUT

Properties are not only determined by graphite shape, but also by:

o Matrix (ferrite / pearlite), ferrite grain size

o Non-metallic inclusions, carbides
o Microstructure deviations (lamellae, chunky graphite, flotations, ...)
o Wall thickness (extreme: heavy-wall, properties in the centre)

WHAT has to be evaluated ?

Form („Nodularity“), number + area, homogeneity, local structure, ...

8
 Agenda

Project Scope Background

Experimental
Set-Up
Validation

Nodularity
Mechanical
• Investigate if image analysis software can classify different graphite particles Properties
according to ISO 945-1 classes both in reference images and current production Statistical
Analysis
samples;
Conclusion
• Evaluate “nodularity” according to different standards and compare the results;
• Correlate microstructure features like pearlite content and nodularity with
mechanical properties in heavy section ductile iron;

9
Experimental setup: the Agenda

Background

castings Experiment
al Set-Up
Validation

Nodularity
Mechanical
Properties
Statistical
Investigation based on different items from Analysis
different suppliers Conclusion

Material investigated: nominally

EN-GJS-400-18 (prEN1563:2015)
From Cast-On Sample

Items’ weight from 8 to 40 tons

Wall thickness from 200 to 1000 mm

10
Experimental setup: the tensile Agenda

Background

specimens Experiment
al Set-Up
Validation

Nodularity
Mechanical
Properties
Statistical
From each items a core drilled specimen has Analysis
been trepaned. Conclusion

The core drilled specimen is taken in area

with solidification time from 5 to 30 hours.

From each core drilled specimen two tensile

specimens Ø14 mm are machined (according
to prEN1563:2015)

11
 Experimental setup: the tensile Agenda

tests and metallographic Background

Experiment
al Set-Up

analysis Validation

Nodularity
Each tensile specimen has been tested Mechanical
according to ISO 6892-1:2009 using a Properties
N/mm2

Statistical
Zwick/Roell Z250 Analysis
Conclusion
One half of the broken specimen has been
cut along the axis and polished.
Elongation %
The microstructure analyses performed in
400 mm2 according to ISO\TR 945-2 using a
“mosaic” technicque. Analyses performed on
the not-etched metallographic specimen
(graphite nodules), and Nital 2% etched
(pearlite content).
Microscope: Leica DM 6000 M

12
 Experimental setup: the image Agenda

Background
Experiment

analysis al Set-Up
Validation

Nodularity
Images imported into the open source software for Image Analysis Fiji Mechanical
to be processed: Properties
Statistical
Analysis
1 Binarization 2 Cleaning 3 Particles Analysis Conclusion

13
Experimental setup: the Agenda

Background
Experiment

metallographic analysis al Set-Up

Validation

The data are post-processed in Microsoft® Office Excel Nodularity

according to the different standards: Mechanical

• Graphite particles classification Properties
Statistical
• “Nodularity” calculation Analysis
Conclusion

The data are exported back to Fiji to visualize

the results

14
 Agenda
Validation of the Image Analysis Background

Method
Experimental
Set-Up
Validation

Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion

15
 Agenda
Validation of the Image Analysis Background

Method
Experimental
Set-Up
Validation

Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion

16
 Agenda

Background
Comparison of different nodularity definitions Experimental
Set-Up
Validation

Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion

Comparison of the “Nodularity” calculated according to

different standard of the reference pictures
17
 Agenda

Background
Graphite particles classification in current production
Experimental
Set-Up
Validation

Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion

168 specimens:

11 removed due to degenerated

graphite, mainly chunky.

The Mechanical Properties

analysis is based on 157 tensile
specimens

18
 Agenda

Summary of calculated nodularity Background

Experimental
Set-Up
Validation

Nodularity
Mean Mechanical
Properties
Nodularity % according to ISO 1083 Statistical
Analysis
Conclusion
Number of elements

19
 Agenda

«Nodularities» comparison Background

Experimental
Set-Up
Validation

Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion

20
Error estimation between Agenda

different methods to calculate Background

Experimental
Set-Up

nodularity Validation

Nodularity
Reference Nodularity as “described” in ISO 1083 Mechanical
Properties
Statistical
Each specimen collected in a “Nodularity Range” Analysis
Conclusion
For each specimen we evaluate the nodularity
according to all the other methods and we calculated
the difference compared to the reference

For each range we evaluated the average and

standard deviation of all the differences in the range

Considering the distribution of the difference as

Gaussian we estimated for each range the confidence
interval with confidence level 95%

21
Error estimation between Agenda

different methods to calculate Background

Experimental
Set-Up

nodularity Validation

Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion

22
 Agenda
Summary of the mechanical Background

properties
Experimental
Set-Up
Validation

Nodularity
Mean
Mechanical
Properties
Statistical
Analysis
Conclusion

23
 Agenda

Rp0.2 vs. Pearlite % Background

Experimental
Set-Up
Validation

Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion

24
 Agenda

Rm (UTS) vs. Pearlite % Background

Experimental
Set-Up
Validation

Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion

25
 Agenda

Elongation vs. Pearlite % Background

Experimental
Set-Up
Validation

Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion

26
 Agenda

Rm vs. Nodularity Background

Experimental
Set-Up
Validation

Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion

27
 Agenda

Elongation vs. Nodularity Background

Experimental
Set-Up
Validation

Nodularity
Mechanical
Properties
Statistical
Analysis
Conclusion

28
Statistical analysis of the influence of Agenda

Background
microstructure features on mechanical Experimental
Set-Up
properties Validation

Nodularity
Factors Influence
Mechanical
on Rm
Properties
Statistical
Analysis
Conclusion

Factors Influence
on A%

The analysis is really preliminary and more

work needs to be done in this field.

29
 Agenda

Conclusions Background
Experimental
Set-Up
Validation

• Classification of particles using only Roundness is satisfying as a first approach, but Nodularity

some efforts has to be done to: Mechanical

Properties
• Improve the classification; Statistical
Analysis
• Determine defects and clusters (Fuzzy Logic ?); Conclusion

• The different methods used to estimate “Nodularity” bring to totally different

results;
• In heavy section ductile iron the relationship between microstructure and
mechanical properties is not well established. Some work needed to find it.

Suggestion
Does it make sense to define one “Nodularity” or is “Nodularity” related to the
performance the designer needs ?

30
 Thanks for your attention.
Questions ?

Contatto:
Giacomo Bertuzzi
giacomo.bertuzzi@sacmi.it
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