High Value Gray Cast Iron Material for Heavy Duty Diesel Cylinder Liners

2011 ◽  
Author(s):  
Edney Rejowski ◽  
Edmo Soares ◽  
Samantha Uehara
Keyword(s):  
Cast Iron ◽  
Gray Cast Iron ◽  
Gray Cast ◽  
Heavy Duty ◽  
Heavy Duty Diesel ◽  
Diesel Cylinder ◽  
Cylinder Liners ◽  
Iron Material

Influence of chemical composition and microstructure of gray cast iron on wear of heavy duty diesel engines cylinder liners

Wear ◽  
2007 ◽  
Vol 263 (7-12) ◽  
pp. 1158-1164 ◽  
Author(s):  
J. Keller ◽  
V. Fridrici ◽  
Ph. Kapsa ◽  
S. Vidaller ◽  
J.F. Huard
Keyword(s):  
Cast Iron ◽  
Chemical Composition ◽  
Diesel Engines ◽  
Gray Cast Iron ◽  
Gray Cast ◽  
Heavy Duty ◽  
Heavy Duty Diesel ◽  
Cylinder Liners

Tribological assessment of NiCr, Al2O3/TiO2, and Cr3C2/NiCr coatings applied on a cylinder liner of a heavy-duty diesel engine

2020 ◽  
pp. 146808742093016
Author(s):  
Onur Biyiklioğlu ◽  
Mustafa Ertunc Tat
Keyword(s):  
Cast Iron ◽  
Diesel Engine ◽  
Wear Rate ◽  
Gray Cast Iron ◽  
Cylinder Liner ◽  
Gray Cast ◽  
Economic Evaluations ◽  
Heavy Duty ◽  
Heavy Duty Diesel Engine ◽  
Heavy Duty Diesel

Internal combustion engines consume about 90% of fuel refined from crude oil which supplies 30% of the annual global flow of energy. Heavy-duty diesel engines are the primary source of power used in highways, marine, railroads, and power stations. The right coating can improve the tribological properties of cylinder liners and increase the mechanical efficiency of an engine. Also, it can help to extend the maintenance periods, and enhance the reliability of the vehicles. In this research, tribological and economic evaluations were performed for coated and uncoated substrates from a cylinder liner of a heavy-duty diesel engine, aiming to lower friction, wear rate, and maintenance cost. A reciprocating friction test was conducted under dry condition using Wolfram carbide (tungsten carbide) ball applied a 10 N normal load on a ball on disk geometry. The cylinder liner was made of gray cast iron, and the substrates obtained were coated with three different coating materials (Cr3C2/NiCr, NiCr, and Al2O3/TiO2) through the thermal spray and high-velocity oxy-fuel coating process. Tribological evaluations showed that the substrates coded with Al2O3/TiO2 and Cr3C2/NiCr had the lowest friction coefficient and wear rate. The most economical coating was Al2O3/TiO2, being able to supply about 61% lower coefficient of friction and 94% less wear rate relative to the uncoated sample, for the price of one-third of the Cr3C2/NiCr coating and one half of a new gray cast iron cylinder liner.

Cylinder Liner in Ductile Cast Iron for High Loaded Combustion Diesel Engines

2011 ◽  
Author(s):  
Edney Deschauer Rejowski ◽  
Edmo Soares ◽  
Ingo Roth ◽  
Steffen Rudolph
Keyword(s):  
Mechanical Properties ◽  
Cast Iron ◽  
Wall Thickness ◽  
Diesel Engines ◽  
Ductile Iron ◽  
Gray Cast Iron ◽  
Young Modulus ◽  
Gray Cast ◽  
Cast Material ◽  
Cylinder Liners

With the increase of combustion loading and the trend to reduce engine size, there is a need for thinner but stronger wet cylinder liners. While most of the current cylinder liners are made of gray cast iron, due to its good tribological behavior, machinability performance and competitive price, alternative casting materials like compact graphite iron, ductile iron and even steel are being considered to cover the future engine demands. In this paper, a new ductile iron (DI) cast material for wet cylinder liners is presented. The material has about 60 and 70% higher limits respectively for tensile stress and fatigue resistance as compared to conventional gray cast irons, but without penalty on the tribological properties. There is also a potential improvement to avoid cavitation on the outside surface due to its higher young modulus, which also equates to a higher stiffness. The tested cylinder liners were induction hardened on the running surface and a slide hone process was used to improve wear and scuffing resistance. The liners were tested in a HDD engine with PCP of 245 bar and showed similar wear as observed with conventional cylinder liners of gray cast iron material. The DI cylinder liners were also tested in an abusive scuffing engine test without any concern. The improved mechanical properties of the described new DI material introduce possibilities to reduce liner wall thickness or increase specific output. The preliminary evaluation in this paper showed that this new material is feasible for HDD diesel engines with PCP up to 250 bar. In cases that the customer needs to increase the bore diameter for output reasons there is the potential to reduce the liner wall thickness up to 25% based on high mechanical properties (UTS, Young Modulus and fatigue strength). In both cases, it’s recommended a FEA analysis to support the new component design.

Cylinder Liner in Ductile Cast Iron for High Loaded Combustion Diesel Engines

2012 ◽  
Vol 134 (7) ◽  
Author(s):  
Edney Deschauer Rejowski ◽  
Edmo Soares ◽  
Ingo Roth ◽  
Steffen Rudolph
Keyword(s):  
Mechanical Properties ◽  
Cast Iron ◽  
Wall Thickness ◽  
Diesel Engines ◽  
Ductile Iron ◽  
Gray Cast Iron ◽  
Gray Cast ◽  
Preliminary Evaluation ◽  
Cast Material ◽  
Cylinder Liners

With the increase of combustion loading and the trend to reduce engine size, there is a need for thinner but stronger wet cylinder liners. While most of the current cylinder liners are made of gray cast iron, due to its good tribological behavior, machinability performance, and competitive price, alternative casting materials such as compact graphite iron, ductile iron, and even steel are being considered to address future engine demands. In this paper, a new ductile iron (DI) cast material for wet cylinder liners is presented. The material has about 60 and 70% higher limits, respectively, for tensile stress and fatigue resistance as compared to conventional gray cast irons, but without a penalty on the tribological properties. There is also a potential improvement to avoid cavitation on the outside surface due to its higher young modulus, which also equates to a higher stiffness. The tested cylinder liners were induction hardened on the running surface and a slide hone process was used to improve wear and scuffing resistance. The liners were tested in a heavy duty diesel (HDD) engine with a peak cylinder pressure (PCP) of 245 bar and showed similar wear as observed with conventional cylinder liners of gray cast iron material. The DI cylinder liners were also tested in an abusive scuffing engine test without any concern. The improved mechanical properties of the described new DI material introduce possibilities to reduce the liner wall thickness or increase specific output. The preliminary evaluation in this paper showed that this new material is feasible for HDD diesel engines with a PCP up to 250 bar. In cases where the customer needs to increase the bore diameter for output reasons there is the potential to reduce the liner wall thickness by up to 25% based on high mechanical properties (UTS, Young’s modulus and fatigue strength). In both cases, a FEA analysis to support the new component design is recommended.

scholarly journals Increase of strength of cast-iron cylinder liners of engines of road construction vehicles

2020 ◽  
Vol 1 (3) ◽  
pp. 36-40
Author(s):  
V.E. Ovsyannikov ◽  
◽  
G.N. Shpitko ◽  
R.Yu. Nekrasov ◽  
D.E. Vas'kov ◽  
...  
Keyword(s):  
Cast Iron ◽  
Thermal Treatment ◽  
Gray Cast Iron ◽  
Experimental Studies ◽  
Road Construction ◽  
Hardened Layer ◽  
Gray Cast ◽  
Urgent Problem ◽  
Ansys Software ◽  
Cylinder Liners

Cylinder liners made of gray cast iron are quite widespread in the design of engines of road con-struction vehicles. The negative properties of this structural material include relatively low strength and high fragility. This increases the probability of both manufacturing and operational defects. Therefore, improving the performance of the considered parts is an urgent problem. A promising direction in this case is the use of chemical-and-thermal treatment. The aim of the work is to study the effect of chemical-and-thermal treatment of gray cast iron on strength. The paper investigates the strength of cast iron subjected to chemical-and-thermal treatment (thermal diffusion surface al-loying). On the basis of experimental studies, the effect of the thickness of the hardened layer on the strength was studied. A numerical model is created in the Ansys software. The effect of the hardened layer on the strength of cylinder liners of engines of road-building vehicles is investigated.

Teknologi Inokulasi Besi Cor Kelabu FC-250 Untuk Mencegah Pengerasan Pada Dove Tale Produk Ragum Tipe 125

2019 ◽  
Vol 16 (2) ◽  
Author(s):  
Amin Suhadi ◽  
Seodihono
Keyword(s):  
Mechanical Properties ◽  
Cast Iron ◽  
Treatment Process ◽  
Gray Cast Iron ◽  
Spare Parts ◽  
Gray Cast ◽  
Micro Structure ◽  
Control Factors ◽  
Seed Inoculation ◽  
Casting Industry

Production technology of metal casting industry in Indonesia needs to be improved, especially in the manufacturing of spare parts and box engine made of gray cast iron which has various wall thick such as dove tale construction. Microstructure of gray cast iron is influenced by cooling rate during casting, chemical composition and melting treatment process (inoculation). The part which has the thinnest thickness has the fastest cooling therefore, the grain boundary is smaller compared to other section. As a result this part has highest hardness and difficult to be machined. This research is conducted to solve this problem by modifying melting and solidification treatment process. The research starting from micro structure analysis, composition and mechanical properties tests on the product, and then conducting modification treatment through Taguchi method approach. Experimental results obtained show that the best level settings to control factors which affect to the uniformity of the microstructure and mechanical properties in gray cast iron is the addition of seed inoculation super ® 75, as much as 0.25% with the method of inoculation material entering into the Transfer Ladle.Teknologi produksi pada industri pengecoran di Indonesia masih membutuhkan perbaikan terutama dalam pembuatan komponen mesin perkakas dan peralatan pabrik yang terbuat dari besi tuang kelabu yang mempunyai variasi ketebalan yang besar seperti konstruksi ekor burung (dove tale). Pada pengecoran, struktur mikro dari besi tuang kelabu sangat dipengaruhi oleh kecepatan pendinginan, komposisi kimia dan proses perlakuan pada logam cair (inokulasi). Bagian yang mempunyai ukuran paling tipis mempunyai kecepatan pendinigan paling tinggi karena itu ukuran butirnya jauh lebih kecil dari bagian lain, akibatnya bagian ini mempunyai kekerasan lebih tinggi dan sulit dilakukan pengerjaan mesin. Penelitian ini bertujuan untuk memperbaiki hal ini yang terjadi pada dove taledengan cara memodifikasi proses perlakuan pada cairan besi dan proses pendinginan. Penelitian dimulai dari analisa struktur mikro, pengujian komposisi kimia, pengujian sifat mekanis pada produk kemudian dilakukan modifikasi menggunakan pendekatan metode statistik Taguchi. Hasil penelitian menunjukkan bahwa pengaturan terbaik yang dapat diperoleh untuk mendapatkan keseragaman struktur mikro dan sifat mekanis pada pengecoran besi tuang kelabu adalah penambahan seed inoculation super ® 75, sebesar 0.25% dengan metode pemasukan inokulasi kedalam Ladle pengangkut logam cair.Keywords: carbon, micro structure, hardness, inoculation

MEEHANITE GF-20

Alloy Digest ◽  
1973 ◽  
Vol 22 (2) ◽  
Keyword(s):  
Fracture Toughness ◽  
Corrosion Resistance ◽  
Shear Strength ◽  
Cast Iron ◽  
Physical Properties ◽  
Surface Treatment ◽  
Tensile Properties ◽  
Gray Cast Iron ◽  
Heat Treating ◽  
Gray Cast

Abstract MEEHANITE GF-20 is a gray cast iron designed principally for high machinability and is used where strength is not an important factor. This datasheet provides information on composition, physical properties, hardness, elasticity, tensile properties, and shear strength as well as fracture toughness and fatigue. It also includes information on corrosion resistance as well as casting, heat treating, machining, joining, and surface treatment. Filing Code: CI-39. Producer or source: Meehanite Metal Corporation.

ISO 185/JL/225

Alloy Digest ◽  
2020 ◽  
Vol 69 (9) ◽  
Keyword(s):  
Tensile Strength ◽  
Cast Iron ◽  
Gray Cast Iron ◽  
Heat Treating ◽  
International Organization ◽  
Gray Cast ◽  
Damping Capacity ◽  
Lower Strength ◽  
Test Pieces ◽  
Lower Carbon

Abstract ISO 185/JL/225 is an intermediate-tensile-strength gray cast iron that has a predominantly pearlitic matrix, and a tensile strength of 225–325 MPa (33-47 ksi), when determined on test pieces machined from separately cast, 30 mm (1.2 in.) diameter test bars. Compared with the lower strength gray cast iron grades, ISO 185/JL/225 contains lower carbon and silicon contents, while still maintaining excellent thermal conductivity, damping capacity, and machinability. This datasheet provides information on composition, physical properties, tensile properties, and compressive strength as well as fatigue. It also includes information on heat treating. Filing Code: CI-73. Producer or source: International Organization for Standardization (ISO).

Morphology and mechanism of cavitation degradation of gray cast iron surfaces with lamellar graphite

2021 ◽  
Author(s):  
Eduard Riemschneider ◽  
Ilare Bordeasu ◽  
Ion Mitelea ◽  
Ion Dragos Utu ◽  
Corneliu Marius Crăciunescu
Keyword(s):  
Cast Iron ◽  
Gray Cast Iron ◽  
Gray Cast ◽  
Lamellar Graphite

Damage Development in Gray Cast Iron under Static Deformation

2003 ◽  
Vol 35 (6) ◽  
pp. 568-573 ◽  
Author(s):  
A. A. Lebedev ◽  
I. V. Makovetskii ◽  
V. P. Lamashevskii ◽  
N. L. Volchek
Keyword(s):  
Cast Iron ◽  
Gray Cast Iron ◽  
Static Deformation ◽  
Gray Cast ◽  
Damage Development
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