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Thermal Microstructural Multiscale Simulation of Solidification and Eutectoid Transformation of Hypereutectic Gray Cast Iron

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Abstract

Although the gray cast iron solidification process has been the subject of several modeling studies, almost all available models appear to deal with only the more widely used hypoeutectic compositions. Models related to hypereutectic gray iron compositions with lamellar (or flake) graphite, and in particular for the proeutectic and eutectoid zones, are hard to find in the open literature. Hence, in the present work, a thermal microstructural multiscale model is proposed to describe the solidification and eutectoid transformation of a slightly hypereutectic composition leading to lamellar graphite gray iron morphology. The main predictions were: (a) temperature evolutions; (b) fractions of graphite, ferrite, and pearlite; (c) density; and (d) size of ferrite, pearlite, and gray eutectic grains; (e) average interlamellar graphite spacing; and (f) its thickness. The predicted cooling curves and fractions for castings with two different compositions and two different pouring temperatures were validated using experimental data. The differences between this model and existing models for hypoeutectic compositions are discussed.

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Abbreviations

Γ:

Gibbs–Thomson coefficient

δ :

thickness of the pearlite boundary

ΔH :

enthalpy change

∆T :

undercooling

Θ:

wetting angle

Λ:

average interlamellar spacing

λ :

interlamellar spacing

ρ :

density

σ :

ferrite/cementite interfacial energy

ϕ :

correction factor

A :

nucleation parameter

B :

growth parameter

c :

specific heat

C o :

carbon concentration difference

CE:

Carbon equivalent

CR:

cooling rate

D :

diffusion coefficient

f :

volumetric fraction

f pc :

phase change function

h :

effective heat transfer coefficient

K :

material constant

k :

thermal conductivity

L :

latent heat

m :

growth exponent

η :

liquidus slope

N :

grain density

n :

nucleation exponent

N gl :

number of graphite lamellae

Pe:

function for lamellar eutectics

R :

grain radius

S :

lamellar thickness

\( \bar{S} \) :

average lamellae thickness

T :

temperature

t :

time

T C :

Curie temperature

α :

ferrite

γ :

austenite

θ :

cementite

B:

boundary

c:

white eutectic

cr:

critical

eud:

eutectoid

eut:

eutectic

g:

gray eutectic

Gr:

primary graphite

gr:

graphite

l:

liquid

max:

maximum

p:

pearlite

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Acknowledgments

The authors are grateful for the financial support provided by FONDECYT (Project No. 1130404) and CSIRO Minerals Down Under Flagship. Associate Professor D. Maijer (University of British Columbia) and D. Molenaar (CSIRO) provided valuable feedback on the manuscript. The experimental program associated with this work was carried out at the CSIRO iron foundry by D. Molenaar, T. Kilpatrick, B. Muldowney, and B. Washington.

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Authors and Affiliations

  1. Departamento de Ingeniería Mecánica y Metalúrgica, Pontificia Universidad Católica de Chile, Santiago, Chile

    Alejandro Urrutia (M.Sc. Student) & Diego J. Celentano (Professor)

  2. Commonwealth Scientific and Industrial Research Organization (CSIRO), Melbourne, VIC, Australia

    Dayalan R. Gunasegaram (Senior Research Scientist) & Natalia Deeva (Research Project Officer)

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  1. Alejandro Urrutia
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  2. Diego J. Celentano
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  3. Dayalan R. Gunasegaram
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  4. Natalia Deeva
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Correspondence to Diego J. Celentano.

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Manuscript submitted July 1, 2013.

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Urrutia, A., Celentano, D.J., Gunasegaram, D.R. et al. Thermal Microstructural Multiscale Simulation of Solidification and Eutectoid Transformation of Hypereutectic Gray Cast Iron. Metall Mater Trans A 45, 3954–3970 (2014). https://doi.org/10.1007/s11661-014-2340-z

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