Study on the Austemperability of Thin-wall Ductile Cast Iron Produced by High-Pressure Die-casting

The production of thin-wall ductile iron (TWDI) by high-pressure die-casting (HPDC) is complex because of several metallurgical and microstructural challenges. The present work aims to evaluate the austemperability of components (4 mm thickness) produced by HPDC process. The graphitization kinetics, the pearlite formation during continuous cooling, and the effect of austempering on the evolution of the ausferritic microstructure were investigated using dilatometric tests, microstructural analysis as well as Vickers hardness tests and tensile tests. Results show that components exhibit a brittle behavior because of white structures, small shrinkage cavities, and microporosity in the as-cast condition. Graphitization at 1100 degrees C allows rapid formation of small graphite particles within a short time (40 s). The critical cooling time (t(8/5)) to avoid the formation of pearlite upon cooling was found to be 5 s at a martensite start temperature of 193 +/- 14 degrees C. Austempering at 360 degrees C for 40 min results in an ausferritic microstructure with stable carbon-enriched austenite which provides a high hardness (355 +/- 4 HV10) and tensile strength (R-m = 709 +/- 65 MPa). The results represent main criteria regarding the producibility of die-casted TWDI, which are helpful for future alloy and heat treatment design.

Automated summary

The production of thin-wall ductile iron by high-pressure die-casting faces various challenges, but results show that graphite formation at 1100°C and austempering at 360°C for 40 minutes can improve mechanical properties and microstructure of the components.