Paint Coating ADI Casting Green Sand Casting Process Lower Operating Noise

Paint Coating ADI Casting Green Sand Casting Process

 

Product Description and Process

ADI Casting Parts Austempered Ductile Iron Castings Process Foundry ADI supplier China

 

Production process: green sand molding

Machining process:

Heat treatment process: isothermal quenching process

Surface treatment process: paint coating

 

Product Material and Uses

Normally produce with ASTM A897/897M Grade 900/650/09, Grade 1050/750/07, Grade 1200/850/04,Grade 1400/1100/02,Grade 1600/1300/01, etc.

 

The austempered ductile iron casting products are widely used for auto-car components, trailer suspension system, truck parts, crankshafts, railcar wheels, cylinder lock cases, tow hooks, cylinder liner, agricultural machinery components, etc.

 

What is Austempered Ductile Iron (ADI)?

Austempered ductile iron castings, or more commonly ADI castings, is a ductile iron casting which is processed by a special heat treatment. The austempering process, with ductile iron’s superior castability, results in a material which can be used to cast complex shapes, with a greater consistency of quality, and often at less cost. The heat treatment requires an interrupted quench, usually into a salt bath, to cool the cast part at a planned rate and long enough to achieve the desired austempered result. The resulting material has a combination of exceptional strength and toughness, meeting and often exceeding those of alloy steels.

 

What are some Benefits of Austempered Ductile Iron Castings?

Up to 40% less cost than hardened steel forgings.

Lower operating noise levels.

10% less weight than steel.

Better wear than case hardened steel.

Excellent resistance to crack propagation.

Good impact strength to -120ºF.

Work hardening.

 

What Can Austempered Ductile Iron Castings (ADI) be Used for? – Application Data

Austempered ductile iron (ADI) is often used where high strength is needed and where excellent wear resistance and fatigue strength are required. Applications like for gears ADI has been used with great success. This tough work-hardening material has proved to be an excellent replacement for hardened steels. The use of austempered ductile iron can result in less weight, reduced number of components, and quieter running. Due to the lower modulus of ADI better face to face contact can be achieved which reduces Hertzien or contact stress on the teeth surfaces. Also austempered ductile iron will work harden which adds to the contact fatigue strength. As a result, gear face widths and diameters can be reduced which will make the gear run better axially and reduces weight, and at the same time provide better protection under overload conditions. The superior tribological properties of ADI have resulted in the elimination of bronze bearing bushings, and will allow the gears to run temporarily without lubrication. Due to the type of matrix structure, the softer grades of ADI can be shot-peened to double the root fatigue strength.

Another common application of austempered ductile iron castings has been crankshafts and axles. The majority of sealed-for-life refrigeration units are made with austempered crankshafts. Axle applications benefit from the materials lack of notch sensitivity, good fatigue strength, and reasonable machinability.

The railroad industry has an immense application both in retarders and rolling stock. Austempered ductile iron is very popular for retarder brake shoes, where its superior quietness and wear resistance is well received in urban semi residential communities. ADI brake beams have also been shown to outlast steel beams, and withstand the cold weather, at more than 20% less cost.

For low speed rolling stock austempered ductile iron wheels have been very successful in Europe. It has been shown that ADI railroad wheels can take larger loads than quenched and tempered steel wheels of the same hardness. ADI will also wear better when sliding between the rail and wheel exceeds more than 10%. One caveat to ADI is that it should not be used in applications where the temperature exceeds 300ºC. (570ºF) for consistently long periods. Thus high speed train wheels are not an appropriate application, nor are wheels which are braked by peripheral blocks. will allow the gears to run temporarily without lubrication. Due to the type of matrix structure, the softer grades of ADI can be shot-peened to double the root fatigue strength.

The military is becoming a major user of austempered ductile iron for shells and projectiles. Also steel forged track shoes are being replaced with ADI It is estimated that over 50,000 tons are presently produced for these military applications, and that this will grow to over 100,000 tons within the next five years. Track shoes in ADI have also been very successful both in construction, and earth moving equipment.

 

The etched microstructure of Austempered Ductile Iron at higher magnification shows details of Ferritic needles in austenitic matrix.

 

 

 

 

What are typical ADI Applications?

Abrasive Protection Liners

Bearing Sleeves

Brake Shoes

Bushing Sleeves

Cable Drums

Camshafts

Chain Sprockets

Connecting Rods

Crankshafts

Cultivating Tools

Differential Spiders

Drive Shafts

Engine Mounting Brackets

Friction Blocks

Ground Engaging Tools

Guide Rollers

Hydraulic Pump Bodies

Piston Sleeves

Pulleys

Pump Impellers

Rack and Pinion Gearing

Rocker Arms

Railroad Car Wheels

Rollers and Sprockets

Shredder Knives

Steering Knuckles

Trolley Wheels

Wear Plates and Guides

Wire Guides

 

Is Machining of Austempered Ductile Iron Difficult?

Machining of A.D.I. is generally speaking, possible, using normal machining techniques. Only the tapping of small diameter holes (especially dead end) and scraping of the softest type is very difficult due to work hardening. It is however common practice to machine to near final size and then heat treat. This is possible because the heat treatment is considered “soft”, and the consequent volume changes are small, and predictable with volume expansion of between only 0.2% – 0.4%.

 

British Standards Specification for ADI EN 1564:1997

 

Mechanical Properties measured on test pieces from separately cast samples
Material Symbol	Number	Tensile Strength N/mm2 (min)	0.2% Proof Stress N/mm2 (min)	Elongation % (min)
EN-GJS-800-8	EN-JS1100	800	500	8
EN-GJS-1000-5	EN-JS1110	1000	700	5
EN-GJS-1200-2	EN-JS1120	1200	850	2
EN-GJS-1400-1	EN-JS1130	1400	1100	1
Refer to relevant Standard for full details

 

 

Standard ADI Grades (USA) ASTM 897-90 (ASTM 897M-90)

Grade	Tensile Strength (min)		Yield Strength (min)		Elongation%	Impact Energy *		Typical Hardness BHN
	Ksi	Nmm2	Ksi	Nmm2		Ft-lbs	Joules
1	125	850	80	550	10	75	100	269-321
2	150	1050	100	700	7	60	80	302-363
3	175	1200	125	850	4	45	60	341-444
4	200	1400	155	1100	1	25	35	388-477
5	230	1600	185	1300	-	-	-	444-555
* Un-notched charpy bars tested @ 22'C (+/-4'C) Refer to relevant Standard for full details