Spheroidal graphite cast iron

Abstract

A spheroidal graphite cast iron comprising: C: 3.3 to 4.0 mass %, Si: 2.1 to 2.7 mass %, Mn: 0.20 to 0.50 mass %, S: 0.005 to 0.030 mass %, Cu: 0.20 to 0.50 mass %, Mg: 0.03 to 0.06 mass % and the balance: Fe and inevitable impurities, wherein a tensile strength is 550 MPa or more, and an elongation is 12% or more.

Claims

1. A spheroidal graphite cast iron comprising: C: 3.3 to 4.0 mass %, Si: 2.1 to 2.4 mass %, Mn: 0.20 to 0.50 mass %, S: 0.005 to 0.030 mass %, Cu: 0.20 to 0.50 mass %, Mg: 0.03 to 0.06 mass %, Mn and Cu: 0.45 to 0.60 mass % in total and the balance: Fe and inevitable impurities, wherein a tensile strength is 550 MPa or more, and an elongation is 12% or more, a ratio of the content of Si by mass % and the total contents of Mn and Cu by mass % (Si/(Mn+Cu)) is 4.0 to 5.5, the pearlite area ratio is 30 to 55%, and an impact value at normal temperature and −30° C. is 10 J/cm.sup.2 or more, wherein a graphite nodule count is 300/mm.sup.2 or more and an average grain size of graphite is less than 20 μm.

2. The spheroidal graphite cast iron according claim 1, wherein a percentage brittle fracture of an impact fracture surface at 0° C. is 50% or less.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 A top view showing a beta set mold having cavities for producing an example material.

(2) FIG. 2 A photograph showing a structure of a test specimen cross-section in Example 1.

(3) FIG. 3 A photograph showing a structure of a test specimen cross-section in Example 2.

(4) FIG. 4 A photograph showing a structure of a test specimen cross-section in Comparative Example 1.

(5) FIG. 5 A photograph showing a structure of a test specimen cross-section in Comparative Example 2.

(6) FIG. 6 A photograph showing a fractured surface of a test specimen after an impact test (RT: room temperature) in Example 1.

(7) FIG. 7 A photograph showing a fractured surface of a test specimen after an impact test (RT: room temperature) in Example 2.

(8) FIG. 8 A photograph showing a fractured surface of a test specimen after an impact test (RT: room temperature) in Comparative Example 1.

(9) FIG. 9 A photograph showing a fractured surface of a test specimen after an impact test (RT: room temperature) in Comparative Example 2.

(10) FIG. 10 A drawing showing a relationship between a tensile strength and an elongation in each Example (the present invention) and Comparative Example.

(11) FIG. 11 A drawing showing a relationship between an impact value and a temperature in each Example (the present invention) and Comparative Example.

DESCRIPTION OF THE EMBODIMENTS

(12) Hereinafter, embodiments of the present invention will be described. In the context of the present invention, “%” denotes “mass(weight) %” unless otherwise specified.

(13) The spheroidal graphite cast iron according to the embodiment of the present invention includes C: 3.3 to 4.0 mass %, Si: 2.1 to 2.7 mass %, Mn: 0.20 to 0.50 mass %, P: 0.05 mass % or less, S: 0.005 to 0.030 mass %, Cr: 0.1 mass % or less, Cu: 0.20 to 0.50 mass %, Mg: 0.03 to 0.06 mass % and the balance: Fe and inevitable impurities, and has a tensile strength of 550 MPa or more and an elongation of 12% or more.

(14) <Composition>

(15) C (carbon) is an element of forming a graphite structure. If the content of C is less than 3.3%, a graphite nodule count decreases and pearlite increases, thereby improving the strength, but decreasing the elongation and the impact value. If the content of C exceeds 4.0%, a grain size of graphite increases to form exploded graphite, thereby decreasing a spheroidizing ratio, the elongation and impact value. Therefore, the content of C is 3.3 to 4.0%.

(16) Si is an element for facilitating crystallization of graphite. If the content of Si is less than 2.1%, the elongation increases, but the strength may decreases. If the content of Si exceeds 2.7%, the impact value may decreases by the effect of silicon ferrite. Therefore, the content of Si is preferably 2.1 to 2.7%. In order to dissolve an optimal amount of Si into a matrix structure, the content of Si is more preferably 2.1 to 2.4%. If the content of Si is 2.7% or less, it is conceivable that the amount of dissolving Si into the matrix structure decreases, an embrittlement at a low temperature is mitigated, and impact absorption energy increases.

(17) Mn is an element for stabilizing a pearlite structure. If the content of Mn is less than 0.20%, the strength decreases. If the content of Mn exceeds 0.5%, pearlite increases, and the elongation and the impact value decrease. Therefore, the content of Mn is 0.20 to 0.5%.

(18) If the content of S is less than 0.005%, the graphite nodule count decreases to less than 300/mm.sup.2, pearlite increases, and the elongation and the impact value decrease. If the content of S exceeds 0.030%, graphitization is inhibited, the spheroidizing ratio of graphite decreases, and the elongation and the impact value decrease. Therefore, the content of S is 0.05 to 0.030%.

(19) Cu is an element for stabilizing the pearlite structure. If the content of Cu increases, the matrix structure includes a high percentage of pearlite, and the strength increases. If the content of Cu is less than 0.2%, the strength decreases. On the other hand, if the content of Cu exceeds 0.5%, pearlite excessively increases, and the elongation and the impact value decrease. Therefore, the content of Cu is 0.2 to 0.5%.

(20) Mg is an element for affecting graphite spheroidization. A residual amount of Mg is an index for determining the graphite spheroidization. If the residual amount of Mg is less than 0.03%, the graphite spheroidizing ratio decreases, and the strength and the elongation decrease. If the residual amount of Mg exceeds 0.06%, carbide (chilled structure) is easily precipitated, and the elongation and the impact value significantly decrease. Therefore, the content of Mg is 0.03 to 0.06%.

(21) The total contents of Mn and Cu may be 0.45 to 0.60%. If the contents of Mn and Cu are less than 0.45%, the tensile strength is not sufficiently improved. If the contents of Mn and Cu exceed 0.60%, the elongation and the impact value decrease, and desired mechanical properties may not be provided.

(22) By setting a ratio of the content of Si and the total contents of Mn and Cu (Si/(Mn+Cu)) from 4.0 to 5.5, the strength and the elongation may be improved well-balanced, and the amounts of Mn and Cu added may be reduced to minimum. If the ratio is less than 4.0, the elongation and the impact value significantly decrease. If the ratio exceeds 5.5, the tensile strength may decrease.

(23) The tensile strength should be high by including a fixed amount of Mn and Cu in the spheroidal graphite cast iron to increase pearlite in the matrix structure. If large amounts of Mn and Cu are included, the pearlite becomes excess, thereby significantly decreasing the elongation and the impact value. On the other hand, by increasing ferrite in the matrix structure, the elongation and the impact value may be maintained. If Si is dissolved in the ferrite matrix structure, the tensile strength may increase. Note that if excess Si is dissolved, the impact value decreases.

(24) In view of the above, the ratio (Si/(Mn+Cu)) is specified such that the percentage of pearlite and ferrite in the matrix structure is balanced within a specific range, thereby increasing the tensile strength and improving the elongation and the impact value.

(25) An area ratio of pearlite (pearlite ratio) in the matrix structure is calculated using image processing of a metal structure photograph of a cast iron cross-section by (1) extracting a structure excluding graphite, and (2) excluding graphite and ferrite, and extracting a pearlite structure in accordance with (area of pearlite)/(areas of pearlite+ferrite).

(26) Preferably, the pearlite ratio is 30 to 55%.

(27) Examples of the inevitable impurities include P and Cr. If the content of P exceeds 0.05%, steadite is excessively produced, which decreases the impact value and the elongation. If the content of Cr exceeds 0.1%, carbide is easily precipitated, which decreases the impact value and the elongation.

(28) Preferably, the graphite nodule count is 300/mm.sup.2 or more, and the average grain size of graphite is 20 μm or less. As described above, when the percentage of pearlite and ferrite in the matrix structure is balanced within a specific range, a graphitization element such as silicon for ferritization is added, thereby increasing the graphite nodule count, and decreasing the grain size of graphite. If the graphite nodule count is 300/mm.sup.2 or more, and the average grain size of graphite is 20 μm or less, a large number of minute graphite is distributed, thereby improving an impact value property. On the other hand, if coarse graphite is present in the structure, an internal notch effect is great, a crack length increases to be easily integrated and fractured. The conditions to provide the graphite nodule count being 300/mm.sup.2 or more and the average grain size of graphite being 20 μm or less include decreasing the elements (Mn and Cr) added that increase the solubility of C or increasing a cooling speed.

(29) The spheroidal graphite cast iron of the present invention has a tensile strength of 550 MPa or more as-cast state, an elongation of 12% or more, an impact value at normal temperature and −30° C. of 10 J/cm.sup.2 or more, and percentage brittle fracture of an impact fracture surface at 0° C. of 50% or less.

(30) Accordingly, the spheroidal graphite cast iron of the present invention is applicable to parts requiring more toughness, e.g., undercarriage such as a steering knuckle, a lower arm, an upper arm and a suspension, and engine parts such as a cylinder head, a crank shaft and a piston.

(31) If the spheroidal graphite cast iron of the present invention is produced, it is preferable to add an inoculant such as a Fe—Si alloy (ferrosilicon) including at least two or more selected from the group consisting of Ca, Ba, Al, S and RE upon casting. A method of inoculating may be selected from ladle inoculation, pouring inoculation, and in-mold inoculation depending on a product shape and a product thickness.

(32) Upon casting, it is preferable to add one or two or more RE selected from the group consisting of La, Ce and Nd as the graphite nodule count increases.

(33) If RE and S are added as the inoculant, a compounding ratio (mass ratio) of (RE/S) is desirably 2.0 to 4.0. S may be added either alone or as a form of Fe—S.

(34) As a method of increasing the graphite nodule count, it is known that lanthanide sulfide is generated as a core of graphite. Only with S in a molten metal, the core is insufficiently generated. As described in Patent Document 1, if an excessive amount of sulfide is added directly before graphite spheroidization, it causes poor spheroidization. In view of this, the inoculant is preferably added after spheroidization.

EXAMPLES

(35) A Fe—Si based molten metal was melted using a high frequency electric furnace. A spheroidizing material (Fe—Si—Mg) was added thereto for sheroidization. Next, Fe—S was added as the inoculant to an Fe—Si alloy (Si: 70 to 75%) including Ba, S, RE such that a compounding ratio of (RE/S) was 2.0 to 4.0. A total of these inoculants were adjusted to about 0.2 mass % to a total of the molten metal to provide each composition shown in Table 1.

(36) The molten metal was poured into a beta set mold 10 having cavities shown in FIG. 1. The mold was cooled to normal temperature, and each molded product was taken out from the mold. The cavities of the beta set mold 10 were simulated for a thickness of a steering knuckle of the vehicle parts, and a plurality of round bars 3 each having a cross-sectional diameter of about 25 mm were disposed. In FIG. 1, a reference numeral 1 denotes a pouring gate, and a reference numeral 2 denotes a feeding head.

(37) Comparative Examples 1 and 2 are the FCD400 material and the FCD550 material in accordance with JIS G 5502, respectively.

(38) The resultant molded products were evaluated as follows:

(39) A graphite nodule count and an average grain size of graphite: An observation site was taken as an image by an optical microscope of 100 magnifications. The image was binarized by an image analysis system. A number and an average grain size of parts darker than a matrix (corresponding to graphite) were measured. The measurement result was an average value of five observation sites. The graphite to be measured had the average grain size of 10 μm or more. The average grain size is an equivalent circle diameter.

(40) The spheroidizing ratio was measured in accordance with JIS G 5502.

(41) FIG. 2 to FIG. 5 show structure photographs of cross-sections of test specimens in Example 1, Example 2, Comparative Example 1, and Comparative Example 2.

(42) Tensile strength and elongation at break: Each round bar 3 of the molded product was cut to produce tensile test specimens by a turning process in accordance with JIS Z 2241. The tensile test specimens were subjected to a tensile test in accordance with JIS Z 2241 using an Amsler universal testing machine (1000 kN) to measure tensile strength and elongation at fracture.

(43) Impact value and percentage brittle fracture: Impact specimens with U-notches were produced from the round bars 3 of the molded product in accordance with JIS Z 2241, and were subjected to an impact test using a Charpy impact tester (50 J) to measure impact values. Fracture surfaces of the specimens after the impact test were taken as images by a microscope. Brittle parts (metallic luster parts) were measured for area percentages using area calculation software to determine a percentage brittle fracture.

(44) FIG. 6 to FIG. 9 show facture surface photographs of the specimens in Example 1, Example 2, Comparative Example 1, and Comparative Example 2 after the impact test (RT: room temperature). White parts with metallic luster in the fracture surfaces are brittle fracture surfaces. As upper white parts of the fracture surfaces are U-notched parts, the U-notched parts are excluded.

(45) TABLE-US-00001 TABLE 1 Graphite Constituent (mass %) Spheroidizing Graphite nodule Average Pearlite (Mn + Si/ ratio count grain ratio C Si Mn P S Cr Cu Mg Cu) (Mn + Cu) (%) (number/mm2) size (μm) (%) Example 1 3.64 2.14 0.26 0.022 0.008 0.028 0.24 0.045 0.5 4.28 90.6 347.9 16.6 52.6 Example 2 3.63 2.23 0.25 0.022 0.005 0.025 0.24 0.04 0.49 4.55 92.2 351.2 16.9 41.9 Comparative 3.65 2.5 0.26 0.021 0.007 0.022 0.16 0.046 0.42 5.95 91.7 208.2 23.3 26.6 Example 1 (FCD450) Comparative 3.59 2.54 0.35 0.017 0.006 0.026 0.34 0.034 0.69 3.68 91.4 236.8 20.9 52.7 Example 2 (FCD550)

(46) TABLE-US-00002 TABLE 2 0.2% Impact Percentage Yield Tensile value brittle Number of Strength strength Elongation (J/cm2) fracture (%) experiments (MPa) (MPa) (%) RT −30° C. RT 0° C. Example 1 n = 1 347 592 14.8 16.1 11.1 1.5 34.4 n = 2 340 582 15.2 16.2 11.3 1.1 40.7 n = 3 331 570 16.1 17 11.6 1.3 35.1 Example 2 n = 1 338 565 16.8 17.3 12.3 1 8 n = 2 328 555 17 18 12.9 0.4 12.6 n = 3 326 553 17.1 18.4 12.3 0.3 12.2 Comparative n = 1 306 477 20.8 19.8 12.6 2.5 58 Example 1 n = 2 304 465 21.4 19.8 12.8 2.5 60 (FCD450) Comparative n = 1 361 615 10.7 10.7 6.6 62.5 100 Example 2 n = 2 355 613 10.9 11 6.8 62.5 100 (FCD550)

(47) As apparent from Table 1 and Table 2, in each Example where 0.45 to 0.60% of Mn and Cu are contained in total and a ratio (Si/(Mn+Cu)) is 4.0 to 5.5, the tensile strength is 550 MPa or more and the elongation is 12% or more. Thus, both of the strength and the ductility are improved. Also, in each Example, the graphite nodule count is 300/mm.sup.2 or more, the average grain size of graphite is 20 μm or less, the impact value at normal temperature and −30° C. is 10 J/cm.sup.2 or more, and the percentage brittle fracture of the impact fracture surface at 0° C. is 50% or less, thereby improving the ductility.

(48) On the other hand, in Comparative Example 1 where less than 0.45% of Mn and Cu are contained in total and the ratio (Si/(Mn+Cu)) exceeds 5.5, the strength decreases.

(49) In Comparative Example 2 where exceeding 0.60% of Mn and Cu are contained in total and the ratio (Si/(Mn+Cu)) is less than 4.0, the ductility decreases.

(50) FIG. 10 shows a relationship between the tensile strength and the elongation in each Example (the present invention) and Comparative Example. In Comparative Example 1, although the elongation is as high as 20% or more, a sensitivity of the elongation to the strength is high (the elongation significantly decreases caused by an increase of the strength). Thus, with a slight increase in the strength, the elongation rapidly decreases, resulting in a poor stability of the material. On the other hand, in each Example, the sensitivity of the elongation to the strength is low and stable.

(51) FIG. 11 shows a relationship between an impact value and a temperature in each Example (the present invention) and Comparative Example. In Comparative Example 2, the impact value at a low temperature (−30° C.) was less than 10 J/cm.sup.2.

DESCRIPTION OF REFERENCE NUMERALS

(52) 1 pouring gate 2 feeding head 3 round bar 10 beta set mold