FEATURES
• 2CONEXPO-CON/AGG & IFPE Highlights
• F2016 FEF Conference
• FEF Keith Millis Scholarship Awards
• 2016 World ADI Conference
• ADI A North American Perspective in 2016 - Kathy Hayrynen
• Application of Differential Scanning Calorimetry for the Determination of ADI Service Temperature Limits - Karl Warsinski
• Austempering of Thin Wall Ductile Iron - Dr. Paul Sanders
DEPARTMENTS
• News Briefs
• Back Issues
• DIS Home Page
Note: To return to the newsletter after viewing a presentation, go to the end of the presentation and click "Return to DI News" link
Ductile Iron News
Issue #1 - April 2017
Please stop by and visit the Ductile Iron Society Booth #455 at the 121st Metalcasting Congress in Milwaukee, WI from 10am to 6pm on Wednesday April 26th and 9am to 3pm on Thursday April 27, 2017.
CONEXPO-CON/AGG & IFPE - Las Vegas, NV:
In March, the Ductile Iron Society booth was on the road again. We once again with the help of the DIMG were exhibiting at the CONEXPO-CON/AGG & IFPE at the Las Vegas Convention in Las Vegas.
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As in previous shows, there was a huge group of attendees. They were expecting well over 125,000 people. This is a great opportunity for the DIS and DIMG to talk one on one with design engineers, OEMs, and other users of ductile iron castings.
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As always, there were a few folks that stopped by looking for producers of Ductile Iron and technical questions about Ductile Iron and CGI. We always have a poster in the booth with all the DIS members.
Also we handed out a small wallet size brochure that lists all the members.
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Thanks to the following volunteers and companies that helped work the booth during this show. They were Dave Gilson of SinterCast, Dylan Bruins and Mark Mundell of Lethbridge Iron, Vadim Pikhovich of Magma, Mark Fields of Glidewell Foundry, Matt Schindle of Dotson Foundry, Kirk McCullough of Seneca Foundry and Bob O'Rourke of H-Bar.
2016 FEF Conference - Chicago, IL.
The 2016 College Industry Conference (CIC) for the FEF was held on November 17th and 18th in Chicago, Illinois at the Westin- Michigan Avenue. The DIS did have a tabletop display during the Career Information Session on Thursday evening.
We handed out this year's T-Shirts with the logo "Ductile Iron - Born in the USA". Once again THANKS to those sponsors who paid for the T-Shirts. They were Dura-Bar, Superior Graphite, Elkem, Cat, RMP, Applied Process, Inductotherm, Rex Heat Treat, Green Packaging, OmniSource, Foseco, Hickman, Williams & Company, ASI International, St. Mary's Foundry, ACC, Midvale, Buck Company, Neenah, ASK Chemicals & Allied Mineral Products.
Thanks also to our Treasurer Pete Guidi for his assistance in the booth. On Friday during the awards luncheon, the FEF handed out 4-$3000 scholarships to the following deserving students. They were,
FEATURES
• 2CONEXPO-CON/AGG & IFPE Highlights
• F2016 FEF Conference
• FEF Keith Millis Scholarship Awards
• 2016 World ADI Conference
• ADI A North American Perspective in 2016 - Kathy Hayrynen
• Application of Differential Scanning Calorimetry for the Determination of ADI Service Temperature Limits - Karl Warsinski
• Austempering of Thin Wall Ductile Iron - Dr. Paul Sanders
DEPARTMENTS
• News Briefs
• Back Issues
• DIS Home Page
Note: To return to the newsletter after viewing a presentation, go to the end of the presentation and click "Return to DI News" link
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Mattie LaPrade of Virginia Tech University
Gabrielle Martin of the University of Alabama Birmingham
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Nathan Peplinski of the University of Wisconsin Platteville
Connor Rittman of the University of Michigan
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2016 World ADI Conference - Atlanta, GA:
The Ductile Iron Society held the 2016 World Conference on Austempered Ductile Iron (ADI) at the Westin Peachtree Hotel in Atlanta, GA from October 27-28, 2016. The turnout was not what the organizing group wanted to see, however it still was a great Conference. The attendees were presented with the top technical presentations in the field of ADI.
A big THANKS goes to Kathy Hayrynen of Applied Process for being the Technical Chairperson for the event. She work hard over the past year to make this the best ADI Conference ever. We were just hit with a bad economic downturn in the foundry business. Also, the election of a new President for the USA was about to happen and many businesses were unsure of the future. Following is a copy of the Program for that Conference.
The DIS would like to thank all the Speakers for their presentations and travel to Atlanta. We also wish to thank the Technical Chair persons and all other volunteers. Also there were a few DIS Members we wish to thank for their generous contributions to the Conference as Sponsors. They were Rex Heat Treat, THORS, Farrar Corporation, Applied Process, Magma, Larpen Metallurgical, Prohimsa Mexico, Hoosier Pattern, Capital Refractories, Lethbridge Iron, Joyworks, LLC, FasCast Incorporated, Allied Mineral and Hunter Foundry Machinery Corporation.
FEATURES
• 2CONEXPO-CON/AGG & IFPE Highlights
• F2016 FEF Conference
• FEF Keith Millis Scholarship Awards
• 2016 World ADI Conference
• ADI A North American Perspective in 2016 - Kathy Hayrynen
• Application of Differential Scanning Calorimetry for the Determination of ADI Service Temperature Limits - Karl Warsinski
• Austempering of Thin Wall Ductile Iron - Dr. Paul Sanders
DEPARTMENTS
• News Briefs
• Back Issues
• DIS Home Page
Note: To return to the newsletter after viewing a presentation, go to the end of the presentation and click "Return to DI News" link
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Should any DIS member want a memory stick copy of the presentations, please drop a line to Jim Wood at [email protected]. If not a DIS member they are for sale for $100.00 each. They are only available until the inventory is gone.
Jim Wood DIS Executive Director 4/12/2017
Links to ADI Presentations not included on memory stick.
• ADI - A North American Perspective in 2016 - Dr. KathyHayrynen
• Application of Differential Scanning Calorimetry for theDetermination of ADI Service Temperature Limits - KarlWarsinski
• Austempering of Thin Wall Ductile Iron - Dr. PaulSanders
FEATURES
• 2CONEXPO-CON/AGG & IFPE Highlights
• F2016 FEF Conference
• FEF Keith Millis Scholarship Awards
• 2016 World ADI Conference
• ADI A North American Perspective in 2016 - Kathy Hayrynen
• Application of Differential Scanning Calorimetry for the Determination of ADI Service Temperature Limits - Karl Warsinski
• Austempering of Thin Wall Ductile Iron - Dr. Paul Sanders
DEPARTMENTS
• News Briefs
• Back Issues
• DIS Home Page
Note: To return to the newsletter after viewing a presentation, go to the end of the presentation and click "Return to DI News" link
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NEWS BRIEFS
For Release: April 10, 2017
U.S. Manufacturing Technology Orders on Path for Strong Recovery
U.S. manufacturing technology orders increased more than expected in February, up 19.6 percent from January, according to the latest U.S. Manufacturing Technology Orders report from AMT – The Association For Manufacturing Technology. Orders were up 1.7 percent year over year.
“We anticipated an increase in orders after a soft January, but we are surprised by the strength of the February numbers,” said AMT President Douglas K. Woods. “What’s even more encouraging is the pickup wasn’t a spike related to any specific industry or region, but rather was broad-based – from Northeast to West as well as everything from aerospace to consumer products. This activity reinforces our projections for a full recovery in manufacturing technology orders by the end of the second quarter.”
While all regions reported growth, the Northeast grew by 41 percent led by the small arms and aerospace industries. Nationally, aerospace had the largest growth rate, more than doubling January’s total. There was also surprising strength reported in appliances; medical devices; and off-road and highway equipment. The February data is aligned with other key indicators of the manufacturing sector’s health. For example, every component of the March Purchasing Managers Index was up; the Federal Reserve’s manufacturing output data had its best back-to-back monthly increases in three years; and durable goods orders and housing starts climbed in February.
(link to more info)
AMT – The Association For Manufacturing Technology 7901 Jones Branch Drive, Suite 900,
McLean, VA 22102 703-893-2900 ▪ 703-893-1151 fax ▪ www.AMT online.org
FEATURES
• 2CONEXPO-CON/AGG & IFPE Highlights
• F2016 FEF Conference
• FEF Keith Millis Scholarship Awards
• 2016 World ADI Conference
• ADI A North American Perspective in 2016 - Kathy Hayrynen
• Application of Differential Scanning Calorimetry for the Determination of ADI Service Temperature Limits - Karl Warsinski
• Austempering of Thin Wall Ductile Iron - Dr. Paul Sanders
DEPARTMENTS
• News Briefs
• Back Issues
• DIS Home Page
Note: To return to the newsletter after viewing a presentation, go to the end of the presentation and click "Return to DI News" link
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NEWS BRIEFS
For Release: April 12th, 2017
U.S. Cutting Tool 2017 YTD Consumption up 4.5% in February
February U.S. cutting tool consumption totaled $174.98 million according to the U.S. Cutting Tool Institute (USCTI) and AMT – The Association For Manufacturing Technology. This total, as reported by companies participating in the Cutting Tool Market Report (CTMR) collaboration, was up 1.1% from January’s $173.05 million and up 0.6% when compared with the total of $173.88 million reported for February 2016. With a year-to-date total of $348.02 million, 2017 is up 4.5% when compared with 2016.
These numbers and all data in this report are based on the totals reported by the companies participating in the CTMR program. The totals here represent the majority of the U.S. market for cutting tools.
“There is a feeling of optimism in the air that is backed up by the positive growth the cutting tool market data shows after the first 2 months of the year,” says Steve Stokey, President of USCTI. “Manufacturing continues to be a hot topic and continues to have a seat at the table in the new Trump administration. The strong dollar will continue to challenge our ability to export but with the US automotive and aerospace markets remaining steady, it should provide a firm foundation for growth as the other industrial sectors rebound from a weak 2016. This should bode well for cutting tool manufacturers.”
Scott Hazelton, Managing Director of Economics & Country Risk at IHS Markit adds that “The economy is enjoying improved business and consumer confidence, resulting in strong momentum in employment growth and single
FEATURES
• 2CONEXPO-CON/AGG & IFPE Highlights
• F2016 FEF Conference
• FEF Keith Millis Scholarship Awards
• 2016 World ADI Conference
• ADI A North American Perspective in 2016 - Kathy Hayrynen
• Application of Differential Scanning Calorimetry for the Determination of ADI Service Temperature Limits - Karl Warsinski
• Austempering of Thin Wall Ductile Iron - Dr. Paul Sanders
DEPARTMENTS
• News Briefs
• Back Issues
• DIS Home Page
Note: To return to the newsletter after viewing a presentation, go to the end of the presentation and click "Return to DI News" link
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NEWS BRIEFS, Cont'd
family housing as well as a rebound in nondefense capital spending, including the important energy sector. Consumption of cutting tools is forecasted to respond with increasing growth over the year. Acceleration of growth in 2018 is expected as tax reform and infrastructure investment enhance the investment outlook.”
The Cutting Tool Market Report is jointly compiled by AMT and USCTI, two trade associations representing the development, production and distribution of cutting tool technology and products. It provides a monthly statement on U.S. manufacturers’ consumption of the primary consumable in the manufacturing process – the cutting tool. Analysis of cutting tool consumption is a leading indicator of both upturns and downturns in U.S. manufacturing activity, as it is a true measure of actual production levels.
Historical data for the Cutting Tool Market Report is available dating back to January 2012. This collaboration of AMT and USCTI is the first step in the two associations working together to promote and support U.S.-based manufacturers of cutting tool technology.
# # #
(CTMR data is also available at www.AMTonline.org.)
ISSN# 10807756
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Mfrs Shipments, Durable Goods N.S.A Cutting Tools
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NEWS BRIEFS, Cont'd
AMT – The Association For Manufacturing Technology represents and promotes U.S.-based manufacturing technology and its members—those who design, build, sell, and service the continuously evolving technology that lies at the
heart of manufacturing. Founded in 1902 and based in Virginia, the association specializes in providing targeted business assistance, extensive global support, and business intelligence systems and analysis. AMT is the voice that communicates the importance of policies and programs that encourage research and innovation, and the development of educational initiatives to create tomorrow’s Smartforce. AMT owns and manages IMTS – The International Manufacturing Technology Show, which is the premier manufacturing technology event in North America. The CTPG report is compiled by AMT and all data in the report is based on the totals of actual data reported by companies participating in the CTPG program.
The United States Cutting Tool Institute (USCTI) was formed in 1988 and resulted from a merger of two national associations representing the cutting tool manufacturing industry. The Institute works to
represent, promote, and expand the U.S. cutting tool industry and to promote the benefits of buying American-made cutting tools manufactured by its members. Membership includes North American manufacturers and/or remanufacturers of cutting tools, as well as tool surface treatment providers. Members, which number over 70, belong to ten product divisions: Carbide Tooling, Drill & Reamer, Metal Cutting Saw Blades, Milling Cutter, Polycrystalline Diamond & Polycrystalline Cubic Born Nitride, Substrate Materials, Surface Coating, Tap & Die, Tool Holder and All Other Tooling. A wide range of activities include a comprehensive statistics program, human resources surveys, development of product specifications and standards, and semi-annual meetings to share ideas and receive information on key industry trends.
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NEWS BRIEFS
UNDERGROUND CORROSION TRAINING OFFERED AT AUCSC 2017
(Morgantown, WV) … The 62nd annual Appalachian Underground Corrosion Short Course (AUCSC 2017) will take place May 9-11, 2017 in Morgantown, WV. Detailed information and on-line registration is available at www.aucsc.com.
AUCSC offers over 100 hours of basic, intermediate, and advanced training providing attendees with technical information about the causes and prevention of corrosion on underground structures. Licensed professional engineers (P.E.’s) may earn professional development hours (PDH’s) for attending AUCSC; P.E.’s should submit proof of their completion of AUCSC courses to their state’s engineering licensing board. A NACE Technician Review Course is also offered, and AUCSC course hours may be applied towards NACE recertification requirements. NACE will offer its NACE Corrosion Exam during AUCSC 2016; please contact NACE directly for additional information regarding the exam at (281) 228-6211.
The pre-registration fee for the entire AUCSC 2017 program is $150.00 before May 1, and on-site registration is $200.00. Please visit www.aucsc.com for pre-registration and additional information, or contact AUCSC at [email protected] or (304) 293-4307.
If you would consider listing or linking our website address, www.aucsc.com, on your website it would be appreciated.
Thank you for your consideration.
Frank Rampton, AUCSC Publicity Chairman
FEATURES
• 2CONEXPO-CON/AGG & IFPE Highlights
• F2016 FEF Conference
• FEF Keith Millis Scholarship Awards
• 2016 World ADI Conference
• ADI A North American Perspective in 2016 - Kathy Hayrynen
• Application of Differential Scanning Calorimetry for the Determination of ADI Service Temperature Limits - Karl Warsinski
• Austempering of Thin Wall Ductile Iron - Dr. Paul Sanders
DEPARTMENTS
• News Briefs
• Back Issues
• DIS Home Page
Note: To return to the newsletter after viewing a presentation, go to the end of the presentation and click "Return to DI News" link
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NEWS BRIEFS FEATURES
• 2CONEXPO-CON/AGG & IFPE Highlights
• F2016 FEF Conference
• FEF Keith Millis Scholarship Awards
• 2016 World ADI Conference
• ADI A North American Perspective in 2016 - Kathy Hayrynen
• Application of Differential Scanning Calorimetry for the Determination of ADI Service Temperature Limits - Karl Warsinski
• Austempering of Thin Wall Ductile Iron - Dr. Paul Sanders
DEPARTMENTS
• News Briefs
• Back Issues
• DIS Home Page
Note: To return to the newsletter after viewing a presentation, go to the end of the presentation and click "Return to DI News" link
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Acknowledgements
• Michigan Tech: Alex Reinl, Steph Tankersley, Ale Almaza Perales, Russ Stein
• Grede: Jay Solomond • LIFT
4
Austempering
• Mechanical properties of steel
• Castability of ductile iron • Possible to eliminate
carbides in thin sections
www.totalmateria.com
Mechanical Properties
Fras 2014 Thin Wall Ductile Iron Castings as Substitutes for Aluminum Alloy Castings
A) Relative strength B) Yield strength C) Stiffness D) Fatigue strength E) High temp strength F) Damping capacity
A) B)
C) D)
E) F)
Thin Wall DI vs. Aluminum
Fras 2014 Thin Wall Ductile Iron Castings as Substitutes for Aluminium Alloy Castings
Nodule Count and Strength vs. Wall Thickness
K. M. Ibrahim, 2013. Effect of cast wall thickness, composition and austempering temperature on microstructure and properties of ductile cast iron
Wall Thickness vs. Toughness
K. M. Ibrahim, 2013. Effect of cast wall thickness, composition and austempering temperature on microstructure and properties of ductile cast iron
Mechanical Property
Correlations
• Convert hardness to strength and elongation – Applied in this
work; will discuss later
– ADI vs conventional Robert J. Warrick, 2000. Austempered Ductile Iron Castings for Chassis Applications. ADI Castings for Chassis Applications SAE 2000 Paper
Select process for balance of strength and toughness
10
Austempering Process
Hayrynen, Kathy. "The Production of Austempered Ductile
Iron." World Conference on ADI (2002).
Standard ADI Grades per ASTM A897/A897M-15
11
Austempered Properties
Grade Tensile Strength* (Mpa)
Yield Strength* (Mpa)
Elongation* (%)
Impact Energy* (J)**
Hardness (HBW)
Grade 1 900-650-09 900 650 9 100 269-341
Grade 2 1050-750-07 1050 750 7 80 302-375
Grade 3 1200-850-04 1200 850 4 60 341-444
Grade 4 1400-1100-02 1400 1100 2 35 388-477
Grade 5 1600-1300-01 1600 1300 1 20 402-512 * Minimum Values **Unnotched Charpy Tests
Target Grade 1.6
Thin Wall Casting at Michigan Tech Developed pattern to assess cooling rate effects
Finger mold design 3D printed pattern
4”
12
Casting Thin Plates • Standard 4512, 5506, 7003 • Utilization of 3D-printed patterns • Replicate vertical molding to cast plates from 2 - 6 mm
Finger casting Chem bond molds
13
MAGMASOFT Process Modeling
• Temperature • Cooling Rate • Fill Time • Carbides • Ferrite and Pearlite
14
Temperatures Fill Time
Cooling Rate Air Entrapment
Chemistry and Pouring Details
18
Grede 4512 DI
Element Wt%
C 3.7
Si 2.6
Cu 0.29
Mn 0.46
Mg 0.038
S 0.006
CE 4.5
Grede DISAMATIC Process • Pour Time: 6 seconds • Pour Temp: 2460°F • Casting Weight: 10.5 lbs
ADI Mechanical Properties
21
Thickness(mm)
UTS(Mpa)
Yield(Mpa)
Elong(%) Comments
6 1040 880 3.3 1 small inclusion6 1068 873 5.3 1 small inclusino4 1086 931 3.6 1 very small inclusion4 1033 882 2.0 1 small inclusion3 1000 717 2.0 1 small inclusion
2.5 944 689 1.1 2 very small inclusionsADI Grade 1.6 1000 700 8 www.appliedprocess.com
Mechanical Properties
* Inclusions present in samples
** Robert J. Warrick, 2000. Austempered Ductile Iron Castings for Chassis Applications. ADI Castings for Chassis Applications SAE 2000 Paper
Material UTS (MPa) YS (MPa) %Elong Source
DI-5506 552 379 6 Handbook (CES)
DI-7003 689 483 3 Handbook (CES)
ADI Grade 1 900 650 9 www.appliedprocess.com
ADI Grade 2 1050 750 7 www.appliedprocess.com
ADI from 4512 1050 880 2.5* Grede - Brewton
ADI from 4512 900 600 9 Hardness Conversion**
ADI Heat Tinting – 2 Trial Images
28
Phase Identification •Unreacted austenite Light Blue •Reacted (↑C austenite) Purple •Ferrite Beige •Eutectic carbide White/Cream •Martensite Dark Blue 75 Microns 75 Microns
4512 DI from Grede – 6 mm thickness
For additional information, please contact:
• Paul Sanders• 1400 Townsend Dr ,Houghton, MI 499341• 906 487 2339• 906 487 2934• [email protected]• www.mtu.edu/materials/department/faculty/sanders/
RETURN TO DI NEWS
Contact:Penny Brown, AMT, 703-827-5275
For Release: April 10, 2017
U.S. Manufacturing Technology Orders on Path for Strong Recovery
U.S. manufacturing technology orders increased more than expected in February, up 19.6 percent
from January, according to the latest U.S. Manufacturing Technology Orders report from AMT – The
Association For Manufacturing Technology. Orders were up 1.7 percent year over year.
“We anticipated an increase in orders after a soft January, but we are surprised by the strength of the
February numbers,” said AMT President Douglas K. Woods. “What’s even more encouraging is the pickup
wasn’t a spike related to any specific industry or region, but rather was broad-based – from Northeast to
West as well as everything from aerospace to consumer products. This activity reinforces our projections
for a full recovery in manufacturing technology orders by the end of the second quarter.”
While all regions reported growth, the Northeast grew by 41 percent led by the small arms and
aerospace industries. Nationally, aerospace had the largest growth rate, more than doubling January’s total.
There was also surprising strength reported in appliances; medical devices; and off-road and highway
equipment. The February data is aligned with other key indicators of the manufacturing sector’s health.
For example, every component of the March Purchasing Managers Index was up; the Federal Reserve’s
manufacturing output data had its best back-to-back monthly increases in three years; and durable goods
orders and housing starts climbed in February.
U.S. Manufacturing Technology Orders a statistical program of AMT
(more)
AMT – The Association For Manufacturing Technology7901 Jones Branch Drive, Suite 900, McLean, VA 22102703-893-2900 ▪ 703-893-1151 fax ▪ www.AMTonline.org
Orders for February 2017 totaled $300.51 million, up from January’s $251.36 million. USMTO is a reliable
leading economic indicator as manufacturing companies invest in capital metalworking equipment to increase
capacity and improve productivity.
# # #
The United States Manufacturing Technology Orders (USMTO) report
These numbers and all data in this report are based on the totals of actual data reported by companies participating in the USMTO program. This report, compiled by AMT – The As-
sociation For Manufacturing Technology, provides regional and national U.S. orders data of domestic and imported machine tools and related equipment. Analysis of manufacturing
technology orders provides a reliable leading economic indicator as manufacturing industries invest in capital metalworking equipment to increase capacity and improve productivity.
About AMT – The Association For Manufacturing Technology
AMT represents U.S.-based builders and distributors of manufacturing technology – the advanced machinery, devices, and digital equipment that U.S. manufacturing relies on to be pro-
ductive, innovative, and competitive. Located in McLean, VA, near the nation’s capital, AMT acts as the industry’s voice to speed the pace of innovation, increase global competitiveness
and develop manufacturing’s advanced workforce of tomorrow. With extensive expertise in industry data and intelligence, as well as a full complement of international business opera-
tions, AMT offers its members an unparalleled level of support. AMT also produces IMTS – The International Manufacturing Technology Show, the premier manufacturing technology
event in North America.
IMTS – International Manufacturing Technology Show
The largest and longest running manufacturing technology trade show in the United States is held every other year at McCormick Place in Chicago, Ill. IMTS 2018 will run Sept. 10-15.
IMTS is ranked among the largest trade shows in the world. Recognized as one of the world’s preeminent stages for introducing and selling manufacturing equipment and technol-
ogy, IMTS attracts more than 114,000 visitors from every level of industry and more than 112 countries. IMTS is owned and managed by AMT – The Association For Manufacturing
Technology. www.IMTS.com
(USMTO data is also available at www.AMTonline.org.) ISSN# 10807756
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$ Thousands
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
2013
2014
2015
2016
2017
0
100,000
200,000
300,000
400,000
500,000
600,000
700,000
800,000
FEB 17 (P) PreviousMonth
%Change
Year AgoMonth
%Change
YTD 17 (P) YTD 16(R) % Change
YTD
National
Regional
U.S. Manufacturing Technology Orders a statistical program of AMT
February 2017
$ = millions of dollars P – preliminaryR – revised* – percent change greater than 1,000%Totals may not match due to rounding
288.37 243.92 18.2% 287.46 0.3% 532.28 556.35 -4.3% 12.15 7.44 63.2% 7.97 52.4% 19.59 23.75 -17.5% 300.51 251.36 19.6% 295.43 1.7% 551.87 580.11 -4.9% 64.85 46.09 40.7% 43.64 48.6% 110.94 100.07 10.9% 1.61 1.10 46.2% D D 2.71 D D 66.46 47.19 40.8% D D 113.65 D D 27.44 27.06 1.4% 43.45 -36.8% 54.50 82.20 -33.7% 2.55 0.47 438.0% 1.10 130.6% 3.02 D D 29.99 27.53 8.9% 44.55 -32.7% 57.52 D D 72.96 58.39 24.9% 82.56 -11.6% 131.35 144.47 -9.1% 4.75 5.35 -11.1% 2.79 70.1% 10.10 6.62 52.6% 77.71 63.74 21.9% 85.35 -9.0% 141.45 151.09 -6.4% 45.90 42.55 7.9% 49.64 -7.5% 88.45 95.39 -7.3% 1.86 0.30 525.2% 0.72 159.2% 2.16 D D 47.76 42.85 11.4% 50.35 -5.2% 90.61 D D 27.39 21.19 29.3% 19.73 38.8% 48.59 33.54 44.9% D D * D D D D D D D D D D D D D 49.83 48.63 2.5% 48.45 2.9% 98.46 100.69 -2.2% D D 130.1% 2.09 D D D D D D 3.0% 50.54 D D D D
Metal Cutting Metal Forming & Fabricating
Total
Northeast Metal Cutting Metal Forming & Fabricating
TotalSoutheast
Metal Cutting Metal Forming & Fabricating
TotalNorth Central-East
Metal Cutting Metal Forming & Fabricating
TotalNorth Central-West
Metal Cutting Metal Forming & Fabricating
TotalSouth Central
Metal Cutting Metal Forming & Fabricating
TotalWest
Metal Cutting Metal Forming & Fabricating
Total
Note on fields marked D: Due to a change in survey participants the year over year comparison number for Metal Forming and Fabricating is not an accurate reflection of the data. We have adjusted the data for the past 12 months to take this change into consideration. The new chart reflects a consistent year over year comparison of the data at the current participation level.
Net New Orders for U.S. Consumption
Total National Orders (Thousands of Dollars)
METAL CUTTING METAL FORMING & TOTAL ORDERS MACHINES FABRICATING MACHINES DATE Units Value Units Value Units Value
REGIONAL
2016 FEB 1,743 $295,427 1,692 $287,456 51 $7,9712016 MAR 2,269 $394,539 2,227 $384,505 42 $10,0342016 APR 1,674 $288,801 1,627 $277,050 47 $11,7512016 MAY 1,729 $288,925 1,685 $283,489 44 $5,4362016 JUN 1,899 $333,749 1,826 $318,827 73 $14,9222016 JUL 1,469 $258,774 1,432 $245,855 37 $12,9182016 AUG 1,989 $329,549 1,948 $318,502 41 $11,0472016 SEP 2,838 $517,059 2,787 $504,377 51 $12,6822016 OCT 1,994 $348,357 1,950 $325,248 44 $23,1092016 NOV 2,080 $344,834 2,027 $333,764 53 $11,0702016 DEC 2,645 $425,175 2,594 $416,856 51 $8,3192017 JAN 1,588 $251,358 1,529 $243,916 59 $7,4412017 FEB 1,743 $300,513 1,690 $288,368 53 $12,146 Average 1,974 $336,697 1,924 $325,247 50 $11,450
Northeast Region (Thousands of Dollars)
METAL CUTTING METAL FORMING & TOTAL ORDERS MACHINES FABRICATING MACHINES DATE Units Value Units Value Units Value
2016 FEB 337 D 333 $43,637 4 D2016 MAR 417 $89,994 410 $88,553 7 $1,4412016 APR 345 D 344 $55,755 1 D2016 MAY 336 $54,894 323 $53,429 13 $1,4662016 JUN 422 $85,403 403 $77,874 19 $7,5292016 JUL 273 $49,597 268 $48,794 5 $8032016 AUG 330 D 327 $56,384 3 D2016 SEP 508 $95,973 497 $94,210 11 $1,7632016 OCT 381 $57,099 370 $54,988 11 $2,1112016 NOV 374 $64,557 363 $59,886 11 $4,6712016 DEC 502 D 496 $82,156 6 D2017 JAN 319 $47,192 309 $46,092 10 $1,1002017 FEB 364 $66,461 358 $64,852 6 $1,609 Average 378 $65,484 369 $63,585 8 $1,899
Note on fields marked D: Due to a change in survey participants the year over year comparison number for Metal Forming and Fabricating is not an accurate reflection of the data. We have adjusted the data for the past 12 months to take this change into consideration. The new chart reflects a consistent year over year comparison of the data at the current participation level.
U.S. Manufacturing Technology Orders a statistical program of AMT
February 2017
Southeast Region (Thousands of Dollars)
METAL CUTTING METAL FORMING & TOTAL ORDERS MACHINES FABRICATING MACHINES DATE Units Value Units Value Units Value
2016 FEB 296 $44,551 288 $43,446 8 $1,1042016 MAR 295 D 292 $38,470 3 D2016 APR 189 $36,620 178 $29,273 11 $7,3482016 MAY 220 D 215 $33,024 5 D2016 JUN 207 D 204 $37,271 3 D2016 JUL 217 D 213 $43,676 4 D2016 AUG 360 $67,115 353 $64,940 7 $2,1752016 SEP 383 D 378 $80,837 5 D2016 OCT 211 D 210 $45,408 1 D2016 NOV 245 D 240 $31,902 5 D2016 DEC 309 D 308 $42,590 1 D2017 JAN 194 $27,531 185 $27,058 9 $4732017 FEB 185 $29,988 176 $27,442 9 $2,547 Average 255 $43,444 249 $41,949 5 $1,495
North Central-East Region (Thousands of Dollars)
METAL CUTTING METAL FORMING & TOTAL ORDERS MACHINES FABRICATING MACHINES DATE Units Value Units Value Units Value
2016 FEB 394 $85,354 376 $82,559 18 $2,7952016 MAR 550 $104,204 536 $98,791 14 $5,4132016 APR 343 $68,239 325 $65,882 18 $2,3572016 MAY 366 $66,307 354 $65,169 12 $1,1382016 JUN 457 $85,442 444 $84,902 13 $5402016 JUL 335 $52,283 322 $49,957 13 $2,3262016 AUG 460 $84,539 445 $77,517 15 $7,0232016 SEP 724 $130,389 707 $123,797 17 $6,5922016 OCT 513 $109,381 492 $90,583 21 $18,7982016 NOV 511 $82,926 494 $79,961 17 $2,9652016 DEC 628 $97,961 616 $95,255 12 $2,7062017 JAN 356 $63,738 328 $58,391 28 $5,3472017 FEB 424 $77,710 409 $72,957 15 $4,754 Average 466 $85,267 450 $80,440 16 $4,827
Net New Orders for U.S. Consumption
Note on fields marked D: Due to a change in survey participants the year over year comparison number for Metal Forming and Fabricating is not an accurate reflection of the data. We have adjusted the data for the past 12 months to take this change into consideration. The new chart reflects a consistent year over year comparison of the data at the current participation level.
U.S. Manufacturing Technology Orders a statistical program of AMT
February 2017
North Central-West Region (Thousands of Dollars)
South Central Region (Thousands of Dollars)
Net New Orders for U.S. Consumption
Note on fields marked D: Due to a change in survey participants the year over year comparison number for Metal Forming and Fabricating is not an accurate reflection of the data. We have adjusted the data for the past 12 months to take this change into consideration. The new chart reflects a consistent year over year comparison of the data at the current participation level.
METAL CUTTING METAL FORMING & TOTAL ORDERS MACHINES FABRICATING MACHINES DATE Units Value Units Value Units Value
2016 FEB 283 $50,353 276 $49,635 7 $7182016 MAR 421 $76,024 409 $73,758 12 $2,2662016 APR 308 $52,613 297 $51,309 11 $1,3042016 MAY 309 $62,869 300 $62,084 9 $7852016 JUN 337 $54,518 327 $53,289 10 $1,2292016 JUL 268 $56,729 257 $48,854 11 $7,8752016 AUG 331 D 327 $53,173 4 D2016 SEP 497 $84,357 490 $82,401 7 $1,9562016 OCT 377 $64,104 369 $62,450 8 $1,6542016 NOV 380 $86,291 374 $85,451 6 $8402016 DEC 425 $75,313 409 $72,737 16 $2,5762017 JAN 259 $42,850 251 $42,552 8 $2982017 FEB 246 $47,756 233 $45,895 13 $1,861 Average 342 $62,143 332 $60,276 9 $1,867
METAL CUTTING METAL FORMING & TOTAL ORDERS MACHINES FABRICATING MACHINES DATE Units Value Units Value Units Value
2016 FEB 124 D 118 $19,731 6 D2016 MAR 129 D 127 $25,560 2 D2016 APR 156 D 154 $21,058 2 D2016 MAY 133 D 129 $17,111 4 D2016 JUN 135 $20,667 117 $18,754 18 $1,9122016 JUL 106 D 105 $14,106 1 D2016 AUG 143 D 139 $18,294 4 D2016 SEP 187 D 185 $22,725 2 D2016 OCT 136 D 136 $15,945 0 D2016 NOV 178 D 175 $18,545 3 D2016 DEC 233 D 227 $36,524 6 D2017 JAN 145 D 144 $21,193 1 D2017 FEB 188 $28,301 181 $27,394 7 $908 Average 153 $21,688 149 $21,303 4 $385
U.S. Manufacturing Technology Orders a statistical program of AMT
February 2017
U.S. Manufacturing Technology Orders a statistical program of AMT
Net New Orders for U.S. Consumption
West (Thousands of Dollars)
Note on fields marked D: Due to a change in survey participants the year over year comparison number for Metal Forming and Fabricating is not an accurate reflection of the data. We have adjusted the data for the past 12 months to take this change into consideration. The new chart reflects a consistent year over year comparison of the data at the current participation level.
METAL CUTTING METAL FORMING &TOTAL ORDERS MACHINES FABRICATING MACHINES
DATE Units Value Units Value Units Value
2016 FEB 309 $50,536 301 $48,448 8 $2,0882016 MAR 457 D 453 $59,372 4 D2016 APR 333 D 329 $53,772 4 D2016 MAY 365 D 364 $52,672 1 D2016 JUN 341 $50,364 331 $46,737 10 $3,6272016 JUL 270 D 267 $40,468 3 D2016 AUG 365 $48,729 357 $48,194 8 $5342016 SEP 539 D 530 $100,407 9 D2016 OCT 376 D 373 $55,874 3 D2016 NOV 392 $58,848 381 $58,018 11 $8302016 DEC 548 D 538 $87,594 10 D2017 JAN 315 D 312 $48,630 3 D2017 FEB 336 D 333 $49,829 3 D
Average 380 $58,670 375 $57,694 6 $977
February 2017
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ADI – A North American Perspective in 2016
Kathy L. Hayrynen Applied Process Companies
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
A look back at 2002 in NA
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
What’s next in the USA? • Continued growth in Ductile Iron production • More steel and aluminum conversions
– Aggressive FEA modeling • Increased exploitation Carbidic ADI (CADI) • High integrity, 3mm wall ADI components • Increasing fatigue performance:
– Surface treatments • More possibilities for ADI gears if we can:
– Increase bending fatigue – Reduce gear noise
• VERY large ADI components • Grade 800 ADI? (intercritical ADI)
2016 Perspective: Today’s Discussion
• Innovations in applications of ADI continue, but constraints of NDAs limit what can be discussed in most instances;
• High integrity 3mm wall castings are not yet readily available;
• Large ADI Components – now a reality; • CADI usage continues to increase, especially in
the agricultural sector;
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
2016 Perspective: Today’s Discussion
• Gears – Standards work with AGMA – Noise Study at OSU
• Intercritical ADI (Grade 800 or Grade 750) • Other Developments
– Alloy developments – Surface hardening – Heavy section Properties
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
The ADI Market in North America
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Estimated North American ADI Market Distribution (2002)
Railroad Equipment
13%
General Manufacturing
13%
Construction & Mining13% Heavy Vehicle
25%
Light Vehicle25%
Agricultural Equipt.
13%
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Heavy Vehicle
Railroad Equipment
Agricultural Equipment
General Manufacturing
Construction & Mining
Large ADI Components
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Size constraints exist because of equipment constraints.
ADI Gears
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
ADI Gear Development Needs . . .
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Database Development
Inclusion into ANSI/AGMA/ISO Gear Standards
Gear Research Institute Results
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Gear Noise Terminology
• Gear Whine – tonal sound related to the gear mesh frequency that is calculated by taking the product of the number of teeth multiplied by the shaft speed;
• Gear Rattle – generated when gear teeth come out of contact and then impact
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
OSU / AP Gear Noise Study
• Objective – Design a test where there is no difference in
microgeometries of the gear sets. • The only difference in results should be due to modulus
differences and possibly damping between the gears.
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Predicted Noise Results (LDP model – gear whine excitation metric)
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
• ADI gears 1 – 4 dB at low frequencies;
• ADI gears 1-3 dB noisier above notch;
• Differences drop at highest torque.
Ref: An Experimental and Analytical Comparison of Noise Generated by Gears of ADI and Steel Materials – D. Houser, S. Shon, K. Hayrynen and J. Lefevre, AGMA Fall Technical Meeting October 2016, Paper 16FTM18
Summary of Results
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Load (Nm) TR1, avg TR2, avg TR4, avg 82 -2.07 -2.12 -1.92
143 -1.20 -0.83 -0.83 199 -1.22 -0.67 -1.57 302 -0.90 -0.73 -1.17
*Negative implies ADI is quieter than steel
TR1: Closest microphone to gearbox (1 meter)
TR2: Farthest microphone from gearbox (2 meters)
TR4: Accelerometer located at the center of the gearbox top plate
Ref: An Experimental and Analytical Comparison of Noise Generated by Gears of ADI and Steel Materials – D. Houser, S. Shon, K. Hayrynen and J. Lefevre, AGMA Fall Technical Meeting October 2016, Paper 16FTM18
What did we learn about gear noise?
• Experimental results from this study indicate ADI gears are consistently from 1 to 2 dB quieter than 8620 steel gears, a value that is undetectable by the human ear and within limits of noise level measurement accuracy.
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
ANSI/AGMA 6014-B15 Gear Power Rating for Cylindrical Shell and
Trunnion Supported Equipment
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Applicability This standard provides a method to determine the power rating of gear sets with spur and helical conventional pinions and spur self-aligning pinions for cylindrical grinding mills, kilns, coolers, and dryers. The formulas are applicable to steel, ductile iron (spheroidal graphitic iron), and austempered ductile iron (ADI) with machined spur, single helical, double helical, or herringbone gear teeth.
Intercritical ADI
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Austenitizing Temperature
for ADI and IADI
TADI > TIADI The austenite carbon content for temperature TADI is greater than the austenite carbon content for temperature TIADI.
TADI
TIADI
ASTM A897/897M-06 Grades of ADI
Grade Tensile
Strength (MPa / Ksi)
Yield Strength
(MPa / Ksi) Elongation
(%)
Impact Energy
(Joules / lb.-ft.)
Typical Hardness
(BHN)
110-70-11 750-500-11 750 / 110 500 / 70 11 110 / 80 241-302
130-90-09 900-550-09 900 / 130 550 / 90 9 100 / 75 269 – 341
150-110-07 1050-750-07 1050 / 150 750 / 110 7 80 / 60 302 – 375
175-125-04 1200-850-04 1200 / 175 850 / 125 4 60 / 45 341 – 444
200-155-02
1400-1100-02
1400 / 200 1100 / 155 2 35 / 25 388 – 477
230-185-01
1600-1300-01
1600 / 230 1300 / 185 1 20 / 15 402 - 512
Mixed Microstructure Grades of ADI per ASTM A897/897M-16
GR 750-500-11 GR 110-70-11
UTS [MPa / ksi]
750 / 110
Yield Strength [MPa / ksi]
500 / 70
% Elongation 11
Typical Brinell Hardness (HBW)
241 - 302
Grade 750 ADI
ASTM A897/897M-16 Grades of ADI
Grade
Tensile Strength
(MPa / ksi)
Yield Strength
(MPa / ksi)
Elongation (%)
Typical Hardness
(HBW)
1 900 / 130 650 / 90 9 269 – 341
2 1050 / 150 750 / 110 7 302 – 375
3 1200 / 175 850 / 125 4 341 – 444
4 1400 / 200 1100 / 155 2 388 – 477
5 1600 / 230 1300 / 185 1 402 - 512
Alloy Developments for ADI
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Microsegregation Low vs... High Nodule Count
Suggested Chemical Composition Ranges
Manganese Max Section > 13mm 0.35% max +/- 0.05% Max Section < 13mm 0.60% max +/- 0.05% Copper (only as needed) 0.80% max +/- 0.05% Nickel (only as needed) 2.00% max +/- 0.10% Molybdenum (only as needed) 0.30% max +/- 0.03%
The Case for Mn • Relatively inexpensive alloying element; • Relatively potent hardenability agent; • Segregates to LTF – delays formation of
ausferrite.
• Challenge – find a way to mitigate segregation tendencies - control of nodule count
• Can a semi-quantitative relationship between Mn level and nodule count be developed?
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Low (0.31 Mn) vs High (0.61 Mn)
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
What about Nickel?
• Advantages – No deleterious segregation issues; – Increased toughness; – Low temperature properties; – Increased corrosion resistance.
• Disadvantage – Cost
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Low Temperature Properties
• The target – V-notch Charpy at -40°
• 8 ft-lb (11 J)
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
CVN Results vs Ni Content
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Surface Hardening
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Welding produces a HAZ
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Hardfacing ADI
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Ref: A. Lundquist and T. Sheets, Hardfacing ADI
• A comparison of welding after and before austempering is shown.
• No HAZ if welding is done prior to austempering
• Additional work is focused on testing the weld media/metal bond.
Hardened area
Base material Base material
Wear resistant cladding
Dilution Zone
Heat affected Zone (hardened)
Micrograph of Laser Cladding on ADI Grade 5, Main Alloys: 0.5Mn, 0.91Cu
Laser Cladding
• Low heat affected zone. • Dilution (mixing) of powder
and base material at the interface creating a true metallurgical bond.
• One step process. • No masking required. • Ability to create very thick
coatings (0.025”). • Greater flexibility in powder
choices. • Completely dense coatings
with no porosity.
Ref: Kondex Corporation, www.kondex.com
Galling Properties of ADI
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Galling Threshold Testing Details
Test method per ASTM D5707-05
Test environment replicated that for an automotive hypoid gear set.
Galling Test Friction and Load vs... Time
Material
Volume Loss (mm3)
Hardness (HRC)
Galling Threshold
(MPa)
Grade 900 ADI (GR 1) 10.9 30 1527+
Grade 1050 ADI (GR 2) 10.7 40 894
Grade 1600 ADI (GR 5) 9.4 52 941
C/A 8620 Surface 10.6 54 512
C/H 8620 Surface 10.6 60 882
SAE 660 Bronze 70.1 27(HRB) 311+
A Comparison of Galling Resistance
Test method per ASTM D5707-05
Heavy Section ADI
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
How is section size addressed in ADI standards?
• ASTM doesn’t address; • SAE – up to 50 mm (2-inches); • ISO – up to 100 mm (4-inches);
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
What’s ahead for 2030?
• Inclusion of ADI in materials text books and design databases;
• ADI is a “standard” material; • Thin wall ADI; • Si-Solution Strengthened ADI; • And a lot of other surprises.
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Thank You
• Angella Sell and Terry Lusk, Applied Process • Stephen Gladieux and Chad Kelsey • Rob Logan, Catherine Hartung and Doug
White – ELKEM • John Keough and Justin Lefevre, Joyworks LLC • Don Houser and Sam Shon – OSU
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
For additional information, please contact:
• Kathy L. Hayrynen• 12202 Newburgh Rd, Livonia, MI 48150• 734-464-8000• [email protected]• www.appliedprocess.com
World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
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Application of Differential Scanning Calorimetry for the Determination of ADI Service Temperature Limits
Karl WarsinskiSt. Marys Foundry, Inc. / Michigan Technological
University
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Project Background
• ADI for railroad wheels– Lighter– Better wear characteristics– Noise damping
• Limited by on‐tread braking– Steel wheels can fail due to overheating– How does ADI compare?
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
ADI Stability
• Several studies from mid‐90s through early 2000s– Isothermal aging, dilatometry, XRD, etc.– Limited alloy scope– Conclusion: Don’t approach austempering temperature
• DIS Research Project #28– Low alloy iron– Exposure time = 1000 hours– ADI did not maintain mechanical properties for exposures at T > (Taustemper – 200°F)
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Kinetics Groundwork• Effect of treatment parameters
– 5 heat treatments of same composition– Determine effective activation energy (EA) for decomposition via Kissinger method (DSC)
• Alloying effects – Produce and test alloy variations– Can we “move the needle” significantly?– HT#1 used for all alloys*
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
What is DSC?• Measures temperature differences between a sample and an inert reference during heating
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
• Deflections/peaks indicate phase changes
• Onset = Start of Transformation
• Peak = Maximum rate
How does this help us?• Peak position shifts
with heating rate when phase changes are thermally activated
• Peak position and heating rate can be used to determine activation energy (EA)
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Experimental Alloys
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Alloy C Si Ni Cu Mo Co Mn P S Mg
AP‐5506 3.56 2.55 0.02 0.48 <0.01 ‐ 0.28 0.027 0.013 0.034
H151201A 3.52 2.45 1.508 0.46 0.003 ‐ 0.160 0.017 0.005 0.017
H160126A 3.48 2.48 0.041 0.769 0.007 0.011 0.273 0.017 <.001 0.040
H160126B 3.50 2.53 0.045 0.479 0.197 0.010 0.276 0.015 <.001 0.035
H160127A 3.42 2.57 0.045 0.476 0.007 0.466 0.245 0.017 <.001 0.037
H160127B 3.41 2.56 0.054 0.48 0.009 2.359 0.34 0.016 <.001 0.041
Casting Geometry• AP‐5506 – 1” Y‐blocks,
Received in heat treated condition– Samples cut via cooled
abrasive saw, wire EDM
• Michigan Tech alloys – ¾”Ø cylinders, 7.5” tall– Turned to ½”Ø before heat
treating– Turned to sub‐size tensile
samples (1/4” gage, 3/8” grip)– DSC samples machined from
grip end remainder
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Heat Treatments
UTS Yield Elongation Austempering
Grade/HT# MPa MPa % Temp. (C) Time (min)
1 900 650 9 382 106
2 1050 750 7 356 135
3 1200 850 4 313 182
4 1400 1100 2 282 217
5 1600 1300 1 260 240
All samples austenitized at 896°C for 122 minutes.
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
DSC Parameters
• N2 or Ar atmosphere• Vacuum and backfill 3x• Stabilize at 100°C• Ramp from 100‐600°C
– 5, 10, and 20°/min scans
• Alumina crucibles• ~170mg Samples
– (4.5mmØ x 3mm typical)
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Analysis
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Effect of Treatment Temperature
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
-11.0-10.8-10.6-10.4-10.2-10.0-9.8-9.6-9.4-9.2-9.0
2 2.1 2.2 2.3 2.4
Ln(ϕ
/T^2
)
1000/Tonset
Grade 1Grade 2Grade 3Grade 4Grade 5
Activation Energy By Treatment Temp.
45
50
55
60
65
70
75
250 300 350 400
Activ
ation En
ergy, K
J/mol
Austempering Temperature, °C
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
Effect of Alloy Additions(HT#1)
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
60.00
65.00
70.00
75.00
80.00
85.00
90.00
95.00
0 0.5 1 1.5 2 2.5
Activ
ation En
ergy (K
J/mol)
% Alloy
Ni
Cu
Mo*
Co*
Further WorkNear Term:• Additional scans to improve regressions• Test existing alloys with varying heat treatments
Recommended:• Fill in additional alloy levels• Develop predictive model for activation energy based on composition and heat treatment temperature
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
AcknowledgementsThis project was supported by the National University Rail (NURail) Center ‐ a
US DOT RITA University Transportation Center
Project ID: NURail2012‐MTU‐R01
Sample ADI (AP‐5506) was provided by Applied Process, Inc.
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
For additional information, please contact:
Karl [email protected]
Paul Sanders, [email protected]
World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA
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