Analysis of Fatigue Behaviour and Impact Strength of IS 500/7 Grade Ductile Iron Subjected To Austempering Heat Treatment

IPASJ International Journal of Mechanical Engineering (IIJME)
A Publisher for Research Motivation........
Volume 3, Issue 5, May 2015
Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441
Analysis of Fatigue behaviour and Impact

strength of IS 500/7 Grade Ductile Iron
Subjected to Austempering Heat treatment
1
Muhammed Naseef M.A, Sameer2, Vijaykumar H.K3
B.E. Student, Bearys Institute of Technology, Mangalore, Karnataka, India
B.E. Student, Bearys Institute of Technology, Mangalore, Karnataka, India
Assistant Professor, Bearys Institute of Technology, Mangalore, Karnataka, India
ABSTRACT
Austempered Ductile Iron (ADI) is replacing steel and it is finding applications in agriculture, mining, construction and
automotive sector due to its superior mechanical properties and cost-effectiveness in manufacturing. In this study IS500/7
grade ductile iron castings were made subjected to austempering heat treatment to get ADI i.e., to bring about changes in
microstructure and hence therefore mechanical properties. Austempering heat treatment involves austenisation at 9000C
temperature for 2 hours duration, austempering temperatures selected was 3600C and 4300C and austempering duration
selected were 50,100,150,200 and 250 minutes.Fatigue behaviour and impact strength of the ADI specimens were analysed and
compared with as cast condition specimen. The results of the investigation indicate that the ADI castings possess better impact
strength compared to as cast specimens and fatigue strength decreases with increase in austempering temperature.
Keywords: Austempered ductile iron (ADI), Ductile Iron, Fatigue behaviour, Impact strength.
1.INTRODUCTION
Austempered ductile iron (ADI) is new, perspective construction material with an excellent combination of strength,
plasticity and toughness. Special properties of ADI are given by unique structure of matrix which is created by acicular
ferrite and retained austenite. Technical literature often describes this matrix as bainite (although it does not contain
carbides). The matrix is also referred to as ausferrite microstructure (high carbon austenite + ferrite). The structure of
ADI is obtained by exactly controlled process of heat treatment of nodular cast iron as shown in Figure.1 [1], [2].
Figure 1 Process of Isothermal Heat treatment

The isothermal heat treatment consists of the following stages:
heating to the austenitisation temperature (AB).
holding time at the austenitisation temperature (BC).
quick cooling to the temperature of isothermal transformation of austenite (CD) so that no other transformation of
austenite is carried out before reaching the temperature of isothermal transformation.
holding time at this temperature (DE) until austenite is transformed into bainite.
cooling to the ambient temperature (EF) which is usually realized slowly in order to prevent formation of stress [3].
The final structure and properties of Austempered ductile iron are dependent on the following metallurgical factors.
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Microstructure of initial nodular cast iron.

Basic chemical composition.
Austenitisation temperature and holding time at this temperature.
Cooling rate to the temperature of isothermal transformation of austenite.
Temperature of isothermal transformation of austenite and holding time at this temperature.
alloying elements [4], [5].
The objective of this research carried out was to analyze mechanical properties such as fatigue strength and impact
strength of ADI and as cast condition of IS500/7 grade ductile iron specimen and to compare.
2.EXPERIMENTAL METHOD
2.1Moulding
Moulding sand used for production of casting possessed American Foundry mans Society (AFS No.) 60 in the present
analysis. Sand moulding was used for obtaining castings with permeability and compression strength of the sand being
120 and 1250 N/mm2 respectively. Figure 2 shows the sand moulds. Mould sizes were prepared such that castings
obtained were as per specifications of ASTM A897 standard.
Figure 2 Sand Moulds as per ASTM A897

2.2Melting and Pouring
Melting of the charge was carried out using 200Kg capacity, 200Hz frequency induction furnace. Figure 3 shows the
preparation of IS500/7 grade ductile iron melt.
Figure 3 Preparation of IS500/7 ductile iron by melt

The charge consisting of ductile Iron, Grey Iron returns, pig iron, and mild steel punching were melted and
superheated to a temperature range 1450oC-1560oC. After removing off the impurities and slag the molten metal was
poured into the prepared sand moulds. The carbon equivalent of the iron was aimed to meet specification of IS 500/7
grade ductile iron. The chemical composition of IS 500/7 grade ductile iron is as shown in the table 1.The molten metal
was poured in the mould cavity as shown in the Figure 4.Then molten metal was allowed to cool in the moulds and
solidified castings taken out were used for preparation of test specimen.
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Table 1: Chemical composition of IS 500/7 grade ductile iron specimens
Figure 4 Pouring of IS 500/7 grade ductile iron molten metal

2.3Heat treatment
Standard austempering heat treatment cycle as shown in the Figure.5 was employed in the present analysis. Initially
IS500/7 grade ductile iron specimens were transferred to a salt bath furnace maintained at 9000C.The specimens were
dipped completely in the salt bath and maintained at the same temperature for 120minutes.The samples at the end of
austenitisation were then quenched into austempering salt baths held at 3600C and 4300c .The specimens were then
held at this austempering temperature for 50,100,150,200 and 250 minutes duration in order to bring about isothermal
transformation to bainite stabilized austenite matrix. Later the specimens were removed from the furnace and cooled in
air till room temperature is reached.
Figure 5 Austempering Heat treatment cycle
3.TESTING OF SPECIMENS AND RESULTS

Mechanical properties such as fatigue strength and impact strength are considered for analysis since these properties
plays an important role in applications of ADI in many fields.
3.1 Impact test
Impact strength is a measure of the energy absorbed during the fracture of a specimen of standard dimensions and
geometry when subjected to impact loading. The Charpy impact test is a standardized high strain-rate test, which
determines the amount of energy absorbed by the material during fracture. This absorbed energy is the measure of
toughness of the given material. The Impact test specimens were prepared as per ASTM E23 standards. Tests are
conducted on unnotched test samples of size 10mm x 10mm x 55mm. Figure 5 shows the Charpy test specimens of
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ISSN 2321-6441
ADI held at different austempering durations. The impact test was carried out on impact testing machine for all the five
different specimens held at each austempering temperature i.e., at 3600C and 4000C and finally results of impact
strength were tabulated.
Figure 6 Charpy test specimens of ADI held at different austempering durations.

These results of ADI specimens were then compared with as cast IS500/7 grade ductile iron specimen. The impact
strength values obtained for ADI specimens and as cast are as shown in Table2.
Table2: Impact strength values obtained for ADI specimens and as cast specimens
Impact Strength of as cast and Austempered specimens held at 3600C&4300C
Sl.No.
Condition
Austempering Temperature
Impact Energy(J)
1
As cast
NA
21
2
Austempering for 50 minutes
3600C
27
3
3600C
33
4
3600C
39
5
3600C
36
6
3600C
34
7
4300C
29
8
4300C
31
0
9
430 C
30
10
4300C
35
11
4300C
36
3.2 Fatigue test
Fatigue strength of as cast specimen is about 388MPa. The isothermal heat treatment induced a decrease of fatigue
properties in comparison with the as cast specimen. Fatigue endurance of the specimens after isothermal heat treatment
is decreased with a decreasing temperature of isothermal transformation of austenite. Figure 7 shows Fatigue test
specimens held at different austempering duration. Table 3 shows Fatigue strength values obtained for ADI specimens
and as cast specimens.
Figure 7 Fatigue test specimens held at different austempering duration
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Table3: Fatigue strength values obtained for ADI specimens and as cast specimens
Fatigue strength of as cast and Austempered specimens held at 3600C&4300C
Sl.No.
Condition
Austempering Temperature
Fatigue strength(MPa)
1
As cast
NA
388
0
2
360 C
330
3
3600C
323
4
3600C
320
5
3600C
314
6
3600C
326
7
4300C
347
8
4300C
356
9
4300C
359
10
4300C
348
0
11
430 C
367
4.MICROSTRUCTURE
Microstructure analysis is carried out on the specimens using metallurgical microscope. Specimens are polished by
following standard metallographic procedures, etched in 10% Nital (10% Nitric acid and 90% Ethanol) and examined
under optical microscope equipped with digital camera. Figure 8 shows microstructure consisting of Ausferrite which
consists of high carbon Austenite and Bainitic ferrite with graphite nodules dispersed in it. Figure 9 shows
Photomicrograph of as cast IS500/7 grade ductile iron with graphite nodules distributed uniformly.
Figure 8 Microstructure of ADI (100X-10% Nital etched)
Figure 9 Microstructure of as cast IS500/7 grade ductile iron (100X-10% Nital etched)
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5.CONCLUSIONS
From the analysis the following conclusions are drawn:
By subjecting IS500/7 ductile iron casting to austempering heat treatment transformation in the microstructure is
found.
ADI specimens possess improved impact strength when compared with as cast ductile iron specimen but Fatigue
strength decreases.
From experimental investigation it is found that Austempered specimen held at 3600C for 150minutes duration
possess higher impact strength of 39J comparatively with other specimens time durations at 3600C.
It is also found that Austempered specimen held at 4300C for 250minutes duration possess better impact strength
36J comparatively with other specimen time durations at 4300C.
REFERENCES
[1] Salman, S. Findik, F. Topuz, Effects of Various Austempering Temperatures on Fatigue Properties in Ductile
Iron, Materials and Design, Vol. 28, No. 7, pp. 2210-2214, 2007.
[2] Kim, Y. J, Shin H, Park H, Lim J. D, Investigation into Mechanical Properties of Austempered Ductile Cast Iron
(ADI) in Accordance with Austempering Temperature, Materials Letters, Vol. 62, No. 3, pp. 357-360, 2008.
[3] Greno G.L, Otegui J.L, Boeri R.E., Mechanisms of fatigue crack growth in ADI International Journal of Fatigue,
pp. 35-43, 1999.
[4] Olivera Eric, Milan Jovanovic, Leposava S, Dragan Rajnovic, Slavica Zec, The austempering study of alloyed
ductile iron, Materials and Design,pp617-622,2006.
[5] Kim Yoon-Jun, Shin Hochoel, Investigation into mechanical properties of austempered ductile cast iron (ADI) in
accordance with austempering temperature, Materials Letters, Vol. 62,357-360, 2003.
[6] Kustuv A, Taran Y, Uzlov J, Krimmel A, Evsyukov M, Formation of bainite in ductile iron, Materials Science
and Engineering, A 273-275, 480-484,1999.
[7] C.Siddaraju, N.D.Prasanna, M.K.MuralidharaCorrosion characteristics of Ductile iron castings subjected to
Austempering heat treatment Indian foundry journal Vol. 59, No.1, pp 44- 47, Jan 2013.
[8] Carl B. Rundman Austempered Ductile iron; striving for continuous improvement.Transactionof American
foundrymens society, world conference on ADI, pp 1-21, March 1991.
[9] Hughes I.C.H, Austempered Ductile Irons - Their Properties & Significance, Materials & Design, Vol-6, No-3,
pp124-126, 1985.
AUTHORS
Muhammed Naseef M.A, pursuing B.E.degree in Mechanical Engineering at Bearys Institute of
Technology, Mangalore, India. He presented Technical papers inter-college level technical
competition. His area of interest includes Robotics, Foundry Engineering, Rapid prototyping, Non
Traditional Machining Process.
Sameer, pursuing B.E.degree in Mechanical Engineering at Bearys Institute of Technology,

Mangalore, India. He presented Technical papers at symposium and inter-college level technical
program. His area of interest includes Material science and metallurgy, Manufacturing Process.
Vijaykumar H.K. received B.E.and M.Tech degree in Mechanical Engineering.He is presently

pursuing PhD in Visvesvaraya Technological University,Belgaum,Karnataka,India. He possesses
07years teaching experience and 03years Industrial experience, presently serving as Assistant
Professor in Department of Mechanical Engineering at Bearys Institute of Technology, Mangalore,
India. He has Published 9 research papers in International Journals and Conferences. He is a member
of many professional bodies like MIIF, MIE, MISTE, MIAENG. His area of interest includes Foundry
Technology, Composite materials, Robotics, Advanced Manufacturing Engineering and Supply Chain
Management.
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Analysis of Fatigue Behaviour and Impact Strength of IS 500/7 Grade Ductile Iron Subjected To Austempering Heat Treatment

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IPASJ International Journal of Mechanical Engineering (IIJME)

A Publisher for Research Motivation........

Volume 3, Issue 5, May 2015

Web Site: http://www.ipasj.org/IIJME/IIJME.htm