Vermicular cast iron alloy for internal combustion engine block and head

Abstract

The present invention refers to a vermicular cast iron alloy specially designed for internal combustion engine blocks and heads having special requirements of mechanical strength and fatigue strength. Vermicular iron alloy with high mechanical strength and high fatigue strength for the production of internal combustion engines blocks and heads characterized by having a microstructure of pearlitic matrix and predominantly vermicular graphite (>70%) and presence of graphite nodules in up to 30%, wherein its graphite microstructure is described by the Microstructure Factor (FM), as defined below, with Microstructure Factor values higher than 0.94.

Claims

1. A vermicular iron alloy with high mechanical strength and high fatigue strength for the production of internal combustion engine blocks and heads having a microstructure of pearlitic matrix and predominantly vermicular graphite (>70%) and presence of graphite nodules in up to 30%, wherein the vermicular iron alloy's graphite microstructure is described by the Microstructure Factor (FM), as defined below, with Microstructure Factor values higher than 0.94; FM=(8.70×A1−0.541×A2+0.449×A3+0.064×A4)/1000, where: A1—percentage of nodulization, referring to the number of spherical particles of graphite divided by particles smaller than 10 μm; A2—number of graphite particles greater than 10 μm, per mm.sup.2; A3—number of graphite particles smaller than 10 μm, per mm.sup.2; and A4—number of eutectic cells, per cm.sup.2; wherein a chemical composition of the vermicular iron alloy consists of: carbon (3.0-3.9% by weight), manganese (0.1-0.6% by weight), silicon (1.5-3.0% by weight), magnesium (0.005-0.030% by weight), cerium (0.005-0.030% by weight), tin (0.04-0.12% by weight), copper (0.2-1.2% by weight), sulfur residual (less than 0.030% by weight), phosphorus residual (less than 0.050% by weight), and titanium residual (less than 0.020% by weight), including iron and common impurities as being the balance of the alloy; and said vermicular iron alloy having a minimum Strength Limit of 500 MPa, a minimum Yield Stress of 350 MPa, a minimum Fatigue Limit of 190 MPa measured by a tension-compression test, with 10.sup.7 cycles, with stress ratio (R=−1), and a hardness in values up to 255 HB.

2. An internal combustion engine block, produced with the vermicular iron alloy as defined in claim 1, having, in samples obtained from the support bearings, a minimum Tensile Strength of 500 MPa, a minimum Yield Stress of 350 MPa, and a minimum Fatigue Limit of 190 MPa measured by a tension-compression test, with stress ratio (R=−1).

3. An internal combustion engine head, produced with the vermicular iron alloy as defined in claim 1, having, in samples obtained from the combustion face, a minimum Tensile Strength of 500 MPa, a minimum Yield Stress of 350 MPa, and a minimum Fatigue Limit of 190 MPa measured by a tension-compression test, with stress ratio (R=−1).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present patent of invention will be described in detail on the basis of the figures listed below, which:

(2) FIG. 1 shows micrographs of the vermicular iron, object of the present invention in which: (a)—Optical microscopy, 200× magnification, without attack; (b)—Scanning electron microscopy, with deep attack, 1,000× magnification;

(3) FIG. 2 shows microstructure of the vermicular iron, object of the present invention (Nital attack and 400× magnification);

(4) FIG. 3 shows Results of Tensile Strength Limit and Yield Stress for the vermicular iron, object of the present invention. Samples obtained from bearing of V6 engine block. Average Strength Limit of sampling=540 MPa. Average Yield Stress of sampling=390 MPa.

DETAILED DESCRIPTION OF THE INVENTION

(5) The present invention provides a novel vermicular cast iron alloy with a microstructure that allows obtaining high levels of mechanical properties obtained from as cast material, in particular fatigue strength. This microstructure can be seen in FIGS. 1 and 2, consisting of a pearlitic matrix and a predominantly vermicular graphite structure (form III of the standard ISO 945/1975), with a minimum of 70% vermicular graphite, and the presence of graphite nodules (form VI of the standard ISO 945/1975), by up to 30%. The main microstructural difference of this new type of vermicular iron, compared to the vermicular irons of the CGI 400 and CGI 450 grades, is described in the Microstructure Factor (FM), defined as:

(6) FM=(8.70×A1−0.541×A2+0.449×A3+0.064×A4)/1000, wherein: A1—percentage of nodulization, referring to the number of spherical particles of graphite, considering particles smaller than 10 μm; A2—number of graphite particles greater than 10 μm, per mm.sup.2; A3—number of graphite particles smaller than 10 μm, per mm.sup.2; and A4—number of eutectic cells, per cm.sup.2.

(7) The vermicular irons of CGI 400 and CGI 450 grades present Microstructure Factor values between 0 and 0.93, while the vermicular iron of the present invention shows Microstructure Factor of greater than 0.94. This microstructure difference is obtained by treatments of the liquid bath, prior to the casting of the metal in the mold, and involving the combined addition of balanced proportions of Mg (from 0.010 to 0.070%), Rare Earths (from 0.005 to 0.050%), and of Si-rich inoculant (from 0.005 to 0.150%). The chemical composition of vermicular iron is characteristic of this material, without special alloying elements, and contains carbon (3.0-3.9%), manganese (0.1-0.6%), silicon (1.5-3.0%), magnesium (0.005-0.030%), cerium (0.005-0.030%), tin (0.04-0.12%), copper (0.2-1.2%), sulfur residual (less than 0.030%), phosphorus residual (less than 0.050%) and titanium residual (less than 0.020%), all these percentages by weight. Other common impurities in the cast irons may further be present.

(8) The microstructure thus obtained, with the Microstructure Factor of greater than 0.94, allows obtaining a minimum Strength Limit of 500 MPa, a minimum Yield Stress of 350 MPa, and a minimum Fatigue Limit of 190 MPa, in a tension-compression test with 107 cycles, with R=−1. The hardness is in values up to 255 HB.

(9) Specifically, said vermicular iron alloy is characterized by the fact that it presents a microstructure which results in high values of mechanical properties. The mechanical properties are characterized by a minimum Strength Limit of 500 MPa, a minimum Yield Stress of 350 MPa, and a minimum Fatigue Limit of 190 MPa, in a tension-compression test with 107 cycles. This set of properties is obtained with a pearlitic matrix, and with graphite morphology and distribution described by the Microstructure Factor, as described in the text.

(10) This Microstructure Factor should assume a minimum value of 0.94, with predominance of vermicular graphite (>70%) and presence of nodular graphite in up to 30%.

(11) With this set of properties it is then possible to design new engine blocks and heads in order to reduce the weight of the components and increase the engine power.

(12) FIG. 3 shows a set of results of tensile tests of vermicular cast iron, object of the present invention. It is verified that this vermicular iron presents a Strength Limit of more than 500 MPa, and a Yield Stress of more than 350 MPa, in samples obtained from part, in the case from support bearing of V6 engine block. This sample provided a Fatigue Limit, in the tension-compression test with R=−1, by the staircase method, with a value of 193 MPa.

(13) Thus, the present invention of vermicular irons with high mechanical strength, in particular high fatigue strength, allows the development of high performance engine blocks and heads suitable for high power density engines involving high levels of mechanical stress.