Founding Research Journal

Founding Research Journal

The Effect of Metallurgical Parameters on Casting Defects of Ductile Iron

Document Type : Original Research Article

Authors
1 M.Sc. in Materials Engineering, Department of Engineering, FZA Company, Amol, Mazandaran, Iran.
2 Assistant Professor, Faculty of Chemistry, Polymer and Material Engineering, Buein Zahra Technical University, Buein Zahra, Qazvin, Iran.
10.22034/frj.2025.553160.1213
Abstract
In this research, to investigate the effect of metallurgical parameters such as pouring temperature, equivalent carbon and feeding conditions on the metallurgical quality of ductile iron parts (absence of shrinkage hole and cold shut defects), a bell-shaped piece used in the suspension system of automobile parts was used. For this purpose, equivalent carbon from 4.3 to 4.5 wt%, pouring temperature from 1380 to 1440°C and feeding in three conditions of no feeding, closed feeding and open feeding were investigated. In order to reduce the number of experiments, the Taguchi method was used to design the experiments. The results of the experiments showed that equivalent carbon of nearly 4.3 wt%, high pouring temperature for cold shut and low pouring temperature for shrinkage hole defects and the use of open feeding conditions provided the most suitable conditions so that none of the shrinkage hole and cold shut defects were observed under these conditions.
Keywords
Subjects

[1]      Stefanescu D.M., Solidification and modeling of cast iron—A short history of the defining moments, Materials Science and Engineering: A, 2005, 413-414, 322-333.
[2]      Hellström K., Diószegi A., Diaconu L., A broad literature review of density measurements of liquid cast iron, Metals, 2017, 7(5) 165.
[3]      Campbell J., Index, in Complete Casting Handbook (Second Edition), Butterworth-Heinemann: Boston, 2015, 993-1028.
[4]      Kweon E., et al., Computational modeling of shrinkage porosity formation in spheroidal graphite iron: a proof of concept and experimental validation, International Journal of Metalcasting, 2020, 14.
[5]      Valipour M., Khayat K.H., Coupled effect of shrinkage-mitigating admixtures and saturated lightweight sand on shrinkage of UHPC for overlay applications, Construction and Building Materials, 2018, 184, 320-329.
[6]      Xu C., et al., Shrinkage effect and mechanical performance of steel-ultra-high performance concrete composite deck under negative bending action, Engineering Structures, 2022, 273, 115025.
[7]      Bommannan, C., et al., Investigation of shrinkage defect in castings by quantitative ishikawa diagram, Archives of Foundry Engineering, 2017, 17(1)174-178.
[8]      Kanno T., Effect of pouring temperature, composition, mould strength and metal flow resistance on shrinkage cavities in spheroidal graphite cast iron, International Journal of Cast Metals Research, 2008, 21, 2-6.
[9]      Ghassemali E., Jarfors A.E.W., Diószegi A., On the formation of micro-shrinkage porosities in ductile iron cast components, Metals, 2018, 8 8(7) 551, DOI: 10.3390/met8070551.
[10]    دیواندری م.، نیکوکار ح.، بختیاری ر.، بهینه‌سازی شاخص حلالیت منیزیم در تولید چدن نشکن به روش افزودن در راهگاه, پژوهشنامه ریخته‌گری، 1398، 3(1) 37-43.
[11]    لیمویی, م.ب., et al., اثر جوانه‌زاهای پایه سیلیسیم و باریم روی ریزساختار و خواص مکانیکی قطعات ریختگی چدن نشکن فریتی. پژوهشنامه ریخته‌گری، 1400، 5(3) 215-222.
[12]    پیرنجم الدین ن.، محمدصادقی ب.، بوترابی س.م.ع. ، تاثیر افزودن آنتیموان و مدول ریختگی بر مورفولوژی گرافیت، ریزساختار و خواص مکانیکی چدن نشکن. پژوهشنامه ریخته‌گری، 1400، 5(2) 67-77.
[13]    Zhao, L., et al., Effect of Pouring and Preheating Temperature on Shrinkage Cavity and Porosity Defects of Nickel-Based Cast Superalloy, Metallurgical and Materials Transactions B, 2025, 56(2) 1316-1333.
[14]    رحیم‌پور بصرا ر.، ترابی کفشگری م. ، عباسی م.، تأثیر جوانه‌زا و مدول ریختگی بر ریزساختار انجمادی چدن آستنیتی منگنزی با گرافیت کروی. پژوهشنامه ریخته‌گری، 1400، 5 (1) 19-30.
[15]    Singh S., Khanna D.R., Sharma D.N., Study and control of factors influencing casting shrinkage using DOE and numerical simulation, IOP Conference Series: Materials Science and Engineering, 2019, 624(1) 012021.
[16]    Shabestari S.G., Moemeni H., Effect of copper and solidification conditions on the microstructure and mechanical properties of Al-Si-Mg alloys, Journal of Materials Processing Technology, 2004, 153, 193-198.
[17]    Library. MRS Bulletin, 2003, 28(9) 674-675.
[18]    Wang T., Yao S., Research of feeding effect of ductile cast iron under different riser conditions, Metals, 2022, 12, 412.
[19]    Sertucha J., Lacaze J., Casting defects in sand-mold cast irons—an illustrated review with emphasis on spheroidal graphite cast irons, Metals, 2022, 12(3) 504, DOI: 10.3390/met12030504.
[20]    Chatrad B., et al., A Study on minimization of critical defects in casting process considering various parameters, International Journal of Innovative Research in Science, Engineering and Technology, 2016, 5(5) 9.
[21]    Jadhav B.R., Jadhav S.J., Investigation and analysis of cold shut casting defect and defect reduction by using 7 quality control tools, International Journal of Advanced Engineering Research and, 2013, 28-30.
[22]    Feng, Y.-s., D.-M. Liao, and T. Chen, Confluence and cold shut computation based on time field in casting simulation, China Foundry, 2021, 18(2) 101-109.
Volume 9, Issue 2 - Serial Number 27
Autumn and Winter
Autumn 2025
Pages 121-129

  • Receive Date 25 October 2025
  • Revise Date 10 November 2025
  • Accept Date 29 November 2025