Toughness and Micro-Hardness

studies on ADI subjected to Two step

Austempering Process
Team:
Anurag Singh N.S (1PI08ME017)
Aravind.C (1PI08ME018)
Artik Patel (1PI08ME020)
Under the Guidance of:
Prof D. Sethuram
Assistant Professor,
Mechanical Department,
PESIT, Bangalore.
CONTENTS
1. Introduction on ADI.
2. LITREATURE SURVEY.
3. What is Austempering.
4. Austempering applied to Ductile Iron.
5. Applications.
6. Methodology.
7. Expected results.


Steps to be followed
1) Problem formulation
2) Literature survey.
3) Obtaining the Ductile iron castings from a permanent
mould.
4) Sample preparations.
5) Two step Austempering heat treatment.
6) An investigation will be taken up to evaluate
systematically the toughness and micro-hardness.
7) Mechanical properties of the material will be
compared to steel.
8) Results will be analyzed based on micro-structural
features.
9) Also we are planning to study the variation of micro-
hardness.
Introduction On ADI:
Austempered Ductile Iron (ADI) belongs to the family of
Ductile Iron. Surveys of published literature indicate that
considerable research work has been carried out on ADI.
Austempered Ductile Irons (ADI) are an interesting class of
materials because of their unique microstructure and
interesting properties such as excellent characteristics of
strength, toughness and wear resistance.
When subjected to austempering treatment, ductile iron
transforms to a micro-structure consisting of ferrite and
retained austenite .

Due to the presence of retained austenite ADI
exhibits excellent combination of strength and
ductility, together with good fatigue and wear
properties.
Obtaining the ADI castings from a permanent mould
has several advantages in terms of finer graphite
nodules, good surface finish and repeatability of
castings.
Reported results of castings produced out of
permanent moulds indicate that there is an
improvement in mechanical properties.
LITREATURE SURVEY
Influence of Two-Step Austempering Heat Treatment
Process on the Mechanical Properties of a Low Manganese
Austempered Ductile Cast Iron (ADI)
Author(s): Susil K.Putatunda, Wayne State University; Avnish Patel,
Wayne State University
In this investigation, a low manganese ductile cast iron with predominantly
pearlitic as-cast structure was processed by a unique two-step austempering
process.
Two batches of samples were prepared. All the specimens were initially
austenitized at 927C (1700F) for 2 hrs.
The first batch of samples were processed by single step austempering process
at several temperatures whereas the second batch of samples were processed by
two-step austempering process.
The effect of this two step austempering heat treatment on the microstructure
and mechanical properties of the material were examined and compared with the
samples processed by single step austempering process.
Test results show significant improvement in mechanical properties of the
material as a result of two step austempering process.

What is Austempering?

The Austempering process was first pioneered by Edgar C. Bain and
Edmund S. Davenport in the 1930s who were working for the United States
Steel Corporation.
Austempering is an isothermal heat treatment applied to ferrous materials.
It produces a microstructure that is stronger and tougher than the
structures resulting typically from conventional heat treatment.
Austempering calls for very precise control of process times and
temperatures.
The Ductile Iron casting is initially heated to Austenitizing temperature to
get austenitic matrix. It is then cooled at a faster rate to avoid the formation
of pearlite to an intermediate temperature ranging from 250 C to 450 C and
held at this temperature for a required length of time.
The part is held at this quench temperature for a recommended time to
transform the Austenite into Bainite. The part is then removed from the salt
quench and air cooled to room temperature.


Austempering applied to Ductile Iron
ADI is produced by heat treating ductile cast iron to which sometimes small
amounts of copper, nickel and molybdenum are added to improve
hardness.
The Austempering heat treatment process converts Ductile Iron into ADI.
To improve farther properties of ADI, another heat treatment cycle has
been introduced, which is called two step austempering process.
Here the material is quenched to a temperature which is increased just
after quenching to a final temperature.
The final properties of the ADI are governed by the austempering
temperature and duration.

Austempering Process

One Step Austempering Process Two Step Austempering Process
Summary of Austenite Transformation
Applications & Examples:

The properties of ADI coupled with the cost and flexibility benefits of ductile iron castings
means the potential for ADI applications is vast:

Agriculture - excellent resistance to soil wear.
Digger/Grab teeth - high strength and wear resistance.
Industrial - wear components, pumps, etc.
Gears - for wear resistance and better vibration damping than steel.
Construction - crushing, grading and wear components etc.
Food & feed milling - grinding, mixing, pelletizing etc.

COMPARISON

ADI
Low machining cost.
Low heat treating cost.
Typically an ADI component
consumes 50% less energy
than a steel casting, and
nearly 80% less energy than a
steel forging.
ADI exhibits excellent
combination of strength and
ductility due to a combination
of ferrite and retained
austenite after austempering.
Steel
High machining cost.
High heat treating cost.
Steel castings are high
energy intensive castings.
Steels when subjected to
austempering result in the
formation of ferrite and
carbide resulting in lower
strength and ductility when
compared to ADI.
Experimentations To be Conducted
1) Charpy Impact test(notched & un-notched).
2) Micro Hardness test.

Composition
Grade used:- 600-3
Tensile strength:- 600Mpa; Elongation:-3% .
Carbon:- 3.8-3.95%
Silicon:- 2.6%
Manganese:- 0.8%
Sulphur:- 0.002%
Phosphorus:- 0.012%
Magnesium:- 0.045%
Specifications
Permanent Mould

Methodology that will be followed
During 7
th
SEMESTER:

1)Problem formulation.
2)Literature survey.
3)Production of castings.
4)Sample preparation.