Vol. 24 No. 4 2022 3 EDITORIAL COUNCIL EDITORIAL BOARD EDITOR-IN-CHIEF: Anatoliy A. Bataev, D.Sc. (Engineering), Professor, Rector, Novosibirsk State Technical University, Novosibirsk, Russian Federation DEPUTIES EDITOR-IN-CHIEF: Vladimir V. Ivancivsky, D.Sc. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Vadim Y. Skeeba, Ph.D. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Editor of the English translation: Elena A. Lozhkina, Ph.D. (Engineering), Department of Material Science in Mechanical Engineering, Novosibirsk State Technical University, Novosibirsk, Russian Federation The journal is issued since 1999 Publication frequency – 4 numbers a year Data on the journal are published in «Ulrich's Periodical Directory» Journal “Obrabotka Metallov” (“Metal Working and Material Science”) has been Indexed in Clarivate Analytics Services. We sincerely happy to announce that Journal “Obrabotka Metallov” (“Metal Working and Material Science”), ISSN 1994-6309 / E-ISSN 2541-819X is selected for coverage in Clarivate Analytics (formerly Thomson Reuters) products and services started from July 10, 2017. Beginning with No. 1 (74) 2017, this publication will be indexed and abstracted in: Emerging Sources Citation Index. Journal “Obrabotka Metallov” (“Metal Working & Material Science”) has entered into an electronic licensing relationship with EBSCO Publishing, the world's leading aggregator of full text journals, magazines and eBooks. The full text of JOURNAL can be found in the EBSCOhost™ databases. Novosibirsk State Technical University, Prospekt K. Marksa, 20, Novosibirsk, 630073, Russia Tel.: +7 (383) 346-17-75 http://journals.nstu.ru/obrabotka_metallov E-mail: metal_working@mail.ru; metal_working@corp.nstu.ru
OBRABOTKAMETALLOV Vol. 24 No. 4 2022 4 EDITORIAL COUNCIL EDITORIAL COUNCIL CHAIRMAN: Nikolai V. Pustovoy, D.Sc. (Engineering), Professor, President, Novosibirsk State Technical University, Novosibirsk, Russian Federation MEMBERS: The Federative Republic of Brazil: Alberto Moreira Jorge Junior, Dr.-Ing., Full Professor; Federal University of São Carlos, São Carlos The Federal Republic of Germany: Moniko Greif, Dr.-Ing., Professor, Hochschule RheinMain University of Applied Sciences, Russelsheim Florian Nürnberger, Dr.-Ing., Chief Engineer and Head of the Department “Technology of Materials”, Leibniz Universität Hannover, Garbsen; Thomas Hassel, Dr.-Ing., Head of Underwater Technology Center Hanover, Leibniz Universität Hannover, Garbsen The Spain: Andrey L. Chuvilin, Ph.D. (Physics and Mathematics), Ikerbasque Research Professor, Head of Electron Microscopy Laboratory “CIC nanoGUNE”, San Sebastian The Republic of Belarus: Fyodor I. Panteleenko, D.Sc. (Engineering), Professor, First Vice-Rector, Corresponding Member of National Academy of Sciences of Belarus, Belarusian National Technical University, Minsk The Ukraine: Sergiy V. Kovalevskyy, D.Sc. (Engineering), Professor, Vice Rector for Research and Academic Affairs, Donbass State Engineering Academy, Kramatorsk The Russian Federation: Vladimir G. Atapin, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Victor P. Balkov, Deputy general director, Research and Development Tooling Institute “VNIIINSTRUMENT”, Moscow; Vladimir A. Bataev, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Vladimir G. Burov, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Aleksandr N. Gerasenko, Director, Scientifi c and Production company “Mashservispribor”, Novosibirsk; Sergey V. Kirsanov, D.Sc. (Engineering), Professor, National Research Tomsk Polytechnic University, Tomsk; Aleksandr N. Korotkov, D.Sc. (Engineering), Professor, Kuzbass State Technical University, Kemerovo; Evgeniy A. Kudryashov, D.Sc. (Engineering), Professor, Southwest State University, Kursk; Dmitry V. Lobanov, D.Sc. (Engineering), Associate Professor, I.N. Ulianov Chuvash State University, Cheboksary; Aleksey V. Makarov, D.Sc. (Engineering), Corresponding Member of RAS, Head of division, Head of laboratory (Laboratory of Mechanical Properties) M.N. Miheev Institute of Metal Physics, Russian Academy of Sciences (Ural Branch), Yekaterinburg; Aleksandr G. Ovcharenko, D.Sc. (Engineering), Professor, Biysk Technological Institute, Biysk; Yuriy N. Saraev, D.Sc. (Engineering), Professor, Institute of Strength Physics and Materials Science, Russian Academy of Sciences (Siberian Branch), Tomsk; Alexander S. Yanyushkin, D.Sc. (Engineering), Professor, I.N. Ulianov Chuvash State University, Cheboksary
Vol. 24 No. 4 2022 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Dyuryagin A.A., Ardashev D.V. A study of the relationship between cutting force and machined surface roughness with the feed per tooth when milling EuTroLoy 16604 material produced by the DMD method...................... 6 Ulakhanov N.S., Tikhonov A.G., Mishigdorzhiyn U.L., Ivancivsky V.V., Vakhrushev N.V. The features of residual stresses investigation in the hardened surface layer of die steels after diffusion boroaluminizing............... 18 Rubtsov V.E., Panfi lov A.O., Knyazhev E.O., Nikolaeva A.V., Cheremnov A.M., Gusarova A.V., Beloborodov V.A., Chumaevskii A.V., Ivanov A.N. Development of plasma cutting technique for C1220 copper, AA2024 aluminum alloy, and Ti-1,5Al-1,0Mn titanium alloy using a plasma torch with reverse polarity................ 33 Amirov A.I., Moskvichev E.N., Ivanov A.N., Chumaevskii A.V, Beloborodov V.A. Formation features of a welding joint of alloy Ti-5Al-3Mo-1V by the friction stir welding using heat-resistant tool from ZhS6 alloy....... 53 EQUIPMENT. INSTRUMENTS Ardashev D.V., Zhukov A.S. Investigation of the relationship between the cutting ability of the tool and the acoustic signal parameters during profi le grinding..................................................................................................... 64 Bataev D. K-S., Goitemirov R. U., Bataeva P. D. Studies of wear resistance and antifriction properties of metalpolymer pairs operating in a sea water simulator........................................................................................................ 84 Zakovorotny V.L., Gvindjiliya V.E., Fesenko E.O. Application of the synergistic concept in determining the CNC program for turning............................................................................................................................................ 98 MATERIAL SCIENCE Sokolov R.A., Novikov V.F., Kovenskij I.M., Muratov K.R., Venediktov A.N., Chaugarova L.Z. The effect of heat treatment on the formation of MnS compound in low-carbon structural steel 09Mn2Si................................ 113 Burkov А.А., Krutikova V.O. Deposition of titanium silicide on stainless steel AISI 304 surface...................... 127 Pugacheva N.B., NikolinYu.V., BykovaT.M., Goruleva L.S. Chemical composition, structure and microhardness of multilayer high-temperature coatings..................................................................................................................... 138 Saprykina N.А., Chebodaeva V.V., Saprykin A.А., Sharkeev Y.P., Ibragimov E.А., Guseva T.S. Synthesis of a three-component aluminum-based alloy by selective laser melting............................................................... 151 Gabets D.A., MarkovA.M., Guryev M.A., Pismenny E.A., NasyrovaA.K. The effect of complex modifi cation on the structure and properties of gray cast iron for tribotechnical application..................................................... 165 Ivanov I.V., Yurgin A.B., Nasennik I.E. Kuper K.E. Residual stress estimation in crystalline phases of highentropy alloys of the AlxCoCrFeNi system........................................................................................................... 181 Korosteleva E.N., Nikolaev I.O., Korzhova V.V. Features of the structure formation of sintered powder materials using waste metal processing of steel workpieces................................................................................. 192 EroshenkoA.Yu., Legostaeva E.V., Glukhov I.A., Uvarkin P.V., TolmachevA.I., Luginin N.A., Bataev V.A., Ivanov I.V., Sharkeev Yu.P. Effect of deformation processing on microstructure and mechanical properties of Ti-42Nb-7Zr alloy............................................................................................................................................. 206 Kutkin O.M., Bataev I.A., Dovzhenko G.D., Bataeva Z.B. The study of characteristics of the structure of metallic alloys using synchrotron radiation computed laminography (Research Review)................................ 219 EDITORIALMATERIALS 243 FOUNDERS MATERIALS 255 CONTENTS
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 24 No. 4 2022 The effect of complex modification on the structure and properties of gray cast iron for tribotechnical application Denis Gabets 1, a, Andrey Markov 1, b, Mikhail Guryev 1, c, Evgeny Pismenny 2, d, Alina Nasyrova 3, e, * 1 I.I. Polzunov Altai State Technical University, 46 Lenina avenue, Barnaul, Altai region, 656038, Russian Federation 2 Railway Research Institute of JSC Russian Railways, 10, 3rd Mytishchinskaya st., Moscow, 129851, Russian Federation 3 Novosibirsk State Technical University, 20 Prospekt K. Marksa, Novosibirsk, 630073, Russian Federation a https://orcid.org/0000-0003-0304-4407, gabets22@mail.ru, b https://orcid.org/0000-0002-3101-9711, andmarkov@inbox.ru, c https://orcid.org/0000-0002-9191-1787, gurievma@mail.ru, d https://orcid.org/0000-0002-7454-0830, pysmennyi.eug@gmail.com, e https://orcid.org/0000-0003-2551-3657, nasyrova.alina98@mail.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2022 vol. 24 no. 4 pp. 165–180 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2022-24.4-165-180 ART I CLE I NFO Article history: Received: 15 September 2022 Revised: 29 September 2022 Accepted: 17 October 2022 Available online: 15 December 2022 Keywords: Alloying of cast iron Modification Wear resistance Impact bend Wear resistant cast iron Graphite inclusions Acknowledgements Research were partially conducted at core facility “Structure, mechanical and physical properties of materials”. ABSTRACT Introduction. An approach based on the complex modification of cast irons makes it possible to improve its mechanical properties by changing the structure of the metal matrix, as well as the shape of graphite and its distribution. The aim of this work is to study the influence of alloying elements on the structure and mechanical properties of gray cast irons obtained for operation under friction wear conditions. Research methods. The paper describes the process of obtaining complex modified gray cast irons. Fractographic investigation of dynamically destroyed samples is carried out. Structure’s features of SCh35, ChMN-35M and SChKM-45 gray cast irons are studied. Tribological testing under sliding friction conditions is carried out. Results and its discussion. It is established that the complex modification of SCh35 gray cast iron with molybdenum, nickel and vanadium makes it possible to increase its hardness to 295 HB and tensile strength to 470-505 MPa. Alloying with nickel (0.4-0.7 wt.%), molybdenum (0.4-0.7 wt.%) and vanadium (0.2-0.4 wt.%) leads to a decrease in the interlamellar distance of perlite by 2 times, as well as to the metal matrix grain refining. The length of graphite lamellas of modified cast irons is reduced by 3-5 times. An additional effect on the tensile strength of cast iron is due to the alloying of ferrite with molybdenum and vanadium, which is fallen out along the boundaries of graphite inclusions. Alloying of ferrite with molybdenum and vanadium increases the level of its microhardness by 1.4 times in comparison with the α-phase of SCh35 serial cast iron. The results of tribotechnical tests of the designed materials are presented. Conclusions. It is established that the wear of specimens made of SChKM-45 cast iron is approximately 20-30% lower compared to cast iron SCh35 cast iron and 10-15% lower compared to ChMN-35M cast iron. Fractographic studies show that complex alloying with molybdenum, vanadium and nickel, contributing to the refining of pearlite colonies, leads to a decrease of the size of the cleavage facets. For citation: Gabets D.A., Markov A.M., Guryev M.A., Pismenny E.A., Nasyrova A.K. The effect of complex modification on the structure and properties of gray cast iron for tribotechnical application. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2022, vol. 24, no. 4, pp. 165–180. DOI: 10.17212/1994-6309-2022-24.4-165-180. (In Russian). ______ * Corresponding author Alina Nasyrova K., Junior researcher Novosibirsk State Technical University, 20 Prospekt K. Marksa, 630073, Novosibirsk, Russian Federation Tel.: +79059376536, e-mail: nasyrova.alina98@mail.ru Introduction Low-alloyed gray cast irons are widely applied for manufacturing critical duty structures operating under wear condition at high mechanical loads [1–4]. These details are body panels, parts of brake systems, working parts of mining machines, parts of railway wagon bogies. The cast irons, from which these details are made, should not only be characterized by high strength properties, but should also provide corrosion resistance, tribotechnical properties under conditions of sliding friction, shock-friction wear. Considering
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 24 No. 4 2022 the influence of the structure on the formation of cast iron’s mechanical properties it is necessary to control its structural features including the uneven distribution of graphite inclusions in the volume of the material, the presence of chill zones which are the cause of embrittlement of cast iron, etc. Improving the structure of cast irons, reducing the amount of structural defects and increasing mechanical properties is facilitated by the alloyage with nickel, molybdenum, phosphorus, vanadium, aluminum, boron, etc. The role of alloying elements and modifying additives in the formation of the structure and complex of mechanical properties of cast irons is reflected in the works [1–10]. The shape, size and volume fraction of graphite inclusions as well as its distribution in the bulk of the material are the most significant structural features determining the level of mechanical properties of gray cast irons [2, 9, 10]. Graphite plates distributed in cast iron, on the one hand, can be considered as natural concentrators of mechanical stresses that contribute to the formation of cracks and destruction of the material, and on the other hand, graphite plates can be “pockets” where microvolumes of solid lubricant are concentrated, helping to reduce the friction coefficient and as a result increase the service life of friction pairs. Graphite distributed in gray cast iron prevents the seizing of surfaces worked as dry sliding friction units [9–14]. According to the Application standards of the Russian Railways, the main requirements for cast irons used for the manufacture of parts of railway transport, are ensuring the ultimate strength during deformation at a level of at least 350 MPa according to the tensile scheme and hardness in the range of 250–350 HB. Typical parts made from these materials should provide at least 160,000 km of mileage of railway transport. The search for technical solutions that provide the possibility of improving the mechanical properties of cast irons is an urgent task of applied importance. One of these solutions is related to the alloying of gray cast iron. Previous studies [1–14] indicate a significant effect of nickel, molybdenum and vanadium on the physical and mechanical properties of gray cast irons. The previously developed cast iron grade ChMN-35M [12] produced in correspondence with tech spec 0812-001-10036140-2014 does not fully meet the requirements for parts operating under frictional conditions. First of all we are talking about the harsh operating modes of the equipment (dry sliding friction with a high level of contact loads). It has been experimentally established that seizure centers appear under such conditions on the surfaces of parts made of ChMN-35M cast iron, the development of which results in an increase in wear intensity. The aim of this work is to study the effect of alloying elements (nickel, molybdenum, vanadium) on the structure and mechanical properties of gray cast iron intended for the manufacture of structural components operating under conditions of dry sliding friction. The level of tensile fracture resistance was the main parameter controlled during the study. Its value was not less than 450 MPa (with hardness in the range of 250–350 HB). The limiting requirement was the cost of the material provided that the minimum required level of tensile strength was guaranteed. Research methods SCh35 gray cast iron was chosen as the base material for the research. Smelting was carried out in an induction melting furnace with a crucible volume of 150 kg. Scrap 4A GOST 2787–75 weighing 100 kg was used as a charge. Samples were taken to assess the chemical composition after charge melting and carburizing of the material. Cast iron was alloyed with nickel, molybdenum and vanadium, the concentration of which was varied in the range from 0.1 to 0.8 wt. % in order to increase the strength properties. Alloying was carried out by addition the calculated amount of ferroalloys of nickel, vanadium and molybdenum directly into the SCh35 gray cast iron melt. The temperature of the melt before draining from the furnace was 1,425–1,440 °C. The mold filling time did not exceed 5 minutes [11]. An optical emission spectrometer GNR Solaris CCD Plus was used to determine the chemical composition of the studied materials. Tensile tests of the samples were performed on a universal electromechanical testing system Instron 3360 according to GOST 27208–87. Sample preparation was carried out in obedience to ISO 185–88.
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 24 No. 4 2022 The hardness of cast irons was determined according to GOST 24648–90 on a hardness testing machine ITRB-3000. Microstructural studies were carried out on a metallographic microscope Carl Zeiss Axio Observer Z1m in accordance with ISO 945–75 using the «Thixomet Pro» software [15–26]. The microhardness of the samples was evaluated according to ISO 6507–1:2005 on a microhardness testing machine MN-6 at a load of 0.2452 N. An array of indents from diamond pyramid in the amount of 15×15 was applied to the surface of each of the weakly etched samples. Indents located on the ferrite/ pearlite, ferrite/graphite boundaries as well as on the graphite plates were not taken into account. The evaluation of tribotechnical properties under dry friction conditions was carried out according to the “shaft-block” scheme on a friction machine 2168 UMT. Friction pairs “the material under study – steel 30CrMnSiA (0.28–0.34 % C, 0.8–1.1 % Cr, 0.8–1.1 % Mn, 0.9–1.2 % Si) / 20MnL (0.15–0.25 % C, 1.2–1.6 % Mn, 0.2–0.4 % Si) / 09Mn2Si (< 0.12 % C, 1.3–1.7 % Mn, 0.5–0.8 % Si)” were studied. Impact bending tests were carried out on a pendulum impact tester Metrocom in accordance with ISO 83–76. Samples with a U-shaped stress concentrator 2 mm deep cut on a Sodick AG400L electric spark wire machine were used for testing. SCh35 cast iron and its closest analogue ChMN-35M cast iron were used as a reference material for mechanical characteristics [12]. Results and discussion Experiments for choosing optimal concentration of alloying additives were carried out to develop the chemical composition of SChKM-45 cast iron with increased complex of mechanical properties. In accordance with the results of the studies, concentration of nickel providing the required level of hardness (at least 250 HB) is 0.4–0.7 wt. %. In this case the ultimate strength exceeds 450 MPa (Fig. 1) [11, 27]. A similar conclusion can be drawn regarding the amount of molybdenum. The addition of more than 0.7 wt. % of molybdenum is not rational due to a significant increase in the level of hardness (more than 350 HB) and material embrittlement. In this case, the ultimate strength increases to a lesser extent (Fig. 2) [11, 27]. Concentration of vanadium which ensures the requirements for the level of hardness and ultimate strength is in the range from 0.2 to 0.4 wt. %. With the addition of this element in an amount of less than 0.2 wt. % level of ultimate strength does not reach 450 MPa. The excess of the vanadium content of more than 0.4 wt. % is accompanied by chilling of cast iron and the appearance of islands of skeletal eutectic. It should be emphasized that an increase in the vanadium content does not lead to an increase in the ultimate strength of the material (Fig. 3), but the cost of the material increases. The noted circumstance is one of the factors that significantly limit the efficiency of the alloyed alloy [11, 27]. a b Fig. 1. Effect of nickel concentration in SChKM-45 gray cast iron containing 0.45 wt.% of molybdenum and 0.34 wt.% of vanadium: a – on hardness; b – on ultimate strength
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 24 No. 4 2022 a b Fig. 2. Effect of molybdenum concentration in SChKM-45 gray cast iron containing 0.52 wt.% of nickel and 0.38 wt.% of vanadium: a – on hardness; b – on ultimate strength a b Fig. 3. Effect of vanadium concentration in SChKM-45 gray cast iron containing 0.6 wt.% of molybdenum and 0.55 wt.% of nickel: a – on hardness; b – on ultimate strength The result of the experiments to determine the optimal chemical composition for an alloy with a complex of high properties is the development of gray cast iron grade SChKM-45 alloyed with nickel, molybdenum and vanadium. The authorship of the development is entrenched by the RF patent for the invention No. 2733940 [13]. The chemical composition of alloys SCh35, ChMN-35M and SCHKM-45 is presented in Table 1. Mechanical properties of SChKM-45 cast iron compared to basic SCh35 cast iron and developed earlier ChMN-35M cast iron are presented in Table 2. The properties of alloyed gray cast irons are largely determined by the structure of its metal matrix, the shape and distribution of graphite inclusions. Comparative analysis results of the structure of cast irons analyzed in this work are presented in Table 3 [11]. Ta b l e 1 Chemical composition of SCh35, ChMN-35M and SChKM-45 cast irons Cast iron grade Mass fraction of elements, % Fe – balance С Si Mn Мо Ni V Cr Cu S P SCh35 2.92 1.45 0.88 – – – 0.04 0.03 0.04 0.01 ChMN-35M 2.85 1.39 0.86 0.82 0.75 – 0.05 0.03 0.03 0.02 SChKM-45 2.65 1.35 0.89 0.45 0.52 0.34 0.05 0.03 0.03 0.02
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 24 No. 4 2022 Ta b l e 2 Mechanical properties of SCh35, ChMN-35M and SChKM-45 cast irons Cast iron grade Ultimate tensile strength, MPa, at least Brinell hardness, HB from to SCh35 345–365 272 288 ChMN-35M 362–395 277 319 SChKM-45 470–505 268 321 Cast iron SCh35 is characterized by the formation of graphite inclusions with a length of ~ 10–200 µm. The shape of graphite is lamellar, partially swirling (Fig. 4, a) [28, 29]. The structure of ChMN-35M cast iron is characterized by a uniform distribution of graphite inclusions with the size of ~ 10–150 µm (Fig. 4, b) [11, 27]. Simultaneous alloying of cast iron with molybdenum and vanadium contributes to the formation of the corresponding solid solutions mainly in the α-phase, which contributes to a higher degree of graphitization; at the same time the melt volumes enriched in molybdenum and vanadium are characterized by an increased number of crystallization centers [28]. Thereby with an increase in the degree of alloying, the size of graphite inclusions decreases. The length of graphite inclusions observed in SChKM-45 cast iron (10–110 μm) is approximately two times less than in SCh35 gray cast iron. The shape of the inclusions in SChKM-45 cast iron is lamellar, partially swirling (Fig. 4, c). The main structural component of the metal matrices of all three cast iron grades is lamellar perlite. Its content ranges from 92 vol. % in ChMN-35 cast iron up to 100 vol. % in SCh35 cast iron. The pearlite fraction in the SChKM-45 alloy is ~ 86 vol. %. Thereby the result of alloying elements addition into cast irons is an increase of the fraction of the ferrite in the structure [1, 2, 10, 31]. The effect of molybdenum on the volume fraction of ferrite is more significant since it is more soluble in the α-phase compared to vanadium. It is also noted that thermodynamic stability of ferrite can be increased by alloying with molybdenum and vanadium [31, 32]. Structural features of the metal matrix analyzed by light microscopy are shown in Fig. 5. Ferrite precipitated in ChMN-35 and SChKM-45 cast irons is mainly localized near graphite inclusions. The reason for this phenomenon is the presence of nickel and molybdenum in alloys, the complex effect of which leads to the same effect as a decrease in the cooling rate of the melt. Thus a ferrite rim is formed along the edges of graphite inclusions in these cast irons [32, 33]. Ferrite observed in ChMN-35 cast iron is predominantly Ta b l e 3 Structural parameters of SCh35, ChMN-35M and SChKM-45 cast irons Characteristic of microstructure according ISO 945–75 Cast iron grade SCh35 ChMN-35M SChKM-45 Shape of graphite inclusions, scale 1A, ×100 vermicular vermicular vermicular Length of graphite inclusions, scale 1Б, ×100 60–120 µm 30–60 µm 30–60 µm Distribution of graphite inclusions, scale 1В, ×100 reticular equilibrium equilibrium Type of the structure of the metal base of cast iron, scale 5, ×500 lamellar pearlite lamellar pearlite lamellar pearlite Number of graphite inclusions, scale 1Г, ×100 ≤ 3 % 3–5 % 5–8 % The content of pearlite and ferrite in the structure of cast iron. % scale 6А, row 1, ×100 perlite ≥ 98 % ferrite ≤ 2 % perlite 90–94 % ferrite 6–10 % perlite 80–90 % ferrite 10–20 % Perlite dispersion distance between cementite plates ≥ 1.6 µm distance between cementite plates 1.3–1.6 µm distance between cementite plates 0.8–1.3 µm
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 24 No. 4 2022 a b c Fig. 4. Distribution of graphite in: a – SCh35; b – ChMN-35M; c – SChKM-45 (number 1 denotes graphite) alloyed with molybdenum according to the energy dispersive analysis. Vanadium is also recorded in the ferrite of SChKM-45 cast iron along with molybdenum. Nickel is evenly distributed over the volume of the studied materials. The result of alloying with molybdenum and nickel is an increase in the dispersion of lamellar pearlite. The reasons for this effect are reflected in [31–33]. The interlamellar distance is 2.2 µm and corresponds to PD1.6 in SCh35 cast iron.Alloying cast iron with molybdenum and nickel leads to a decrease of interlamellar distance to ~ 1.4–1.5 µm (PD1.4). Perlite observed in SChKM-45 cast iron alloyed with molybdenum, nickel and vanadium is characterized by an even higher level of perlite dispersion (PD1.0) [30, 34–36]. The results of measuring the microhardness of the volumes of structurally free ferrite and lamellar pearlite in the analyzed cast irons are presented in Table 4. A comparative analysis of obtained data allows to conclude that with an increase in the degree of alloying the microhardness of single structural components of the metal matrix increases [37, 38]. Structural analysis established that small amounts of primary cementite are present in SChKM-45 cast iron, the particle size of which is in the range from ~ 8 to ~ 35 μm (see Fig. 4, e). Works [31, 32] describe similar effect. The values of the friction coefficient and the weight wear of the friction pair elements were chosen as criteria characterizing the tribological properties of the analyzed materials. The test results of the samples are presented in Table 5. The obtained data testify the high tribological properties of SChKM-45 cast iron. The wear amount of samples from this alloy is approximately 1.3–1.8 times lower compared to SCh35 cast iron and 1.1–1.2 times lower compared to ChMN-35M cast iron. The efficiency of complex alloyed SChKM-45 cast iron used in friction pairs with steels 30CrMnSiA, 20MnL and 09Mn2Si was confirmed [39, 40–42]. The fractographic research data shown in Figs. 6 allow to conclude that the fracture of all specimens is brittle. The brittleness of the investigated alloys conditioned by the presence of graphite inclusions sharply
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 24 No. 4 2022 Fig. 5. The structure of metal matrices in cast irons: a, b – SCh35; c, d – ChMN-35M; e, f – SChKM-45 (number 1 denotes graphite, 2 – pearlite, 3 – ferrite, 4 – cementite) а b c d e f Ta b l e 4 Average values of microhardness of structural components in SCh35, ChMN-35M and SChKM-45 alloys Microhardness Cast iron grade SCh35 ChMN-35M SChKM-45 Ferrite 195 235 270 Perlite 290 315 370 reduces the sensitivity of gray cast irons to stress concentrators. The fractures of samples made of SCh35 cast iron (Fig. 6, a) and ChMN-35M cast iron (Fig. 6, b) both in the zones of initiation and in the zones of crack propagation are the same. The destruction predominantly occurs according to the transcrystalline mechanism with an insignificant fraction of the intercrystalline component [11, 27, 39].
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 24 No. 4 2022 Ta b l e 5 Results of tribotechnical tests No. Friction pair (hob – shaft) Friction coefficient Weight wear, g Total wear, g Hob Shaft 1 SCh35 – 0.3C-Cr-Mn-Si(high quality) 0.11–0.13 0.11 0.84 0.95 2 ChMN-35M – 0.3C-Cr-Mn-Si(high quality) 0.10–0.12 0.15 0.45 0.60 3 SChKM-45 – 0.3C-Cr-Mn-Si(high quality) 0.10–0.12 0.10 0.43 0.53 4 SCh35 – 0.2C-Mn(cast) 0.11–0.13 0.24 0.86 1.10 5 ChMN-35 – 0.2C-Mn(cast) 0.11–0.12 0.23 0.60 0.83 6 SChKM-45 – 0.2C-Mn(cast) 0.12–0.12 0.22 0.58 0.80 7 SCh35 – 0.09C-2Mn-Si 0.13–0.14 0.40 0.45 0.95 8 ChMN-35M – 0.09C-2Mn-Si 0.11–0.12 0.24 0.66 0.90 9 SChKM-45 – 0.09C-2Mn-Si 0.11–0.12 0.20 0.55 0.75 a b c Fig. 6. Structure of fractures of cast irons after impact bending tests: a – SCh35; b – ChMN-35M; c – SChKM-45 The fractures shown in Fig. 6 have a characteristic facet structure. A morphology analysis shows that graphite inclusions played a significant role in the initiation and development of cracks. Microcracks extending deep into the material were fixed at the points where the graphite plates came to the surface. The structure of fracture surfaces of ChMN-35M is more uniform. The size of the cleavage facets is approximately 1.5 times smaller compared to SCh35 cast iron, which is explained by the more dispersed structure of the cast iron metal base [11]. The arrows in Fig. 6 indicate characteristic fracture zones of the transcrystalline mechanism of the material. The formation of fracture zones of this type can be explained by the strength properties of the
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 24 No. 4 2022 metal matrix of ChMN-35M cast iron as well as by the increased level of relaxation properties of the material alloyed with molybdenum and nickel. However alloying cast iron with molybdenum and nickel does not have a significant effect on the overall picture of destruction. Complex alloying of SChMN-45 cast iron with molybdenum, nickel and vanadium accompanied by an increase in the dispersion of the pearlite structure leads to a significant refinement of the cleavage facets (Fig. 6, c). Approximately 30 % of the fracture surface is formed by the mechanism of intercrystalline fracture. The sensitivity of SChMN-45 cast iron to the presence of stress concentrators is also less noticeable which indicates the decisive role of graphite inclusions of lamellar morphology in the manifestation of the mechanisms of crack initiation and development [11, 27, 39]. Conclusions 1. Complex alloying with molybdenum, nickel and vanadium provides the hardness of SChMN-45 gray cast iron at the level of 295 HB and the ultimate strength during tests according to the tensile scheme at the level of 470–505 MPa, which exceeds the values corresponding to SCh35 gray cast iron (290 HB and 365 MPa, respectively). 2. The addition of nickel (0.4–0.7 wt. %), molybdenum (0.4–0.7 wt. %) and vanadium (0.2–0.4 wt. %) into gray cast iron leads to a decrease in the interlamellar distance in pearlite by 2 times and a decrease in the length of graphite inclusions. These changes explain the increase in the strength properties of alloyed cast iron in comparison with the SCh35 cast iron. 3. Alloying of gray cast iron with molybdenum and vanadium provides an increase in the microhardness of ferrite grains decorating graphite inclusions by about 1.4 times. This factor has an additional effect on the level of strength properties of the materials under study. 4. Cast iron alloyed with nickel, molybdenum and vanadium is characterized by a higher complex of tribotechnical properties compared to serial gray cast iron. The total wear of shafts made of SChMN-45 cast iron is approximately 1.3–1.8 times lower compared to SCh35 cast iron and 1.1–1.2 times lower compared to ChMN-35M cast iron. Analysis of the research results testify to the efficiency of using SChMN-45 cast iron in friction pairs with counter bodies made of steels 30CrMnSiA, 20MnL and 09Mn2Si. 5. Significant refinement of cleavage facets at fractures of dynamically fractured specimens recorded by the method of fractographic studies of the complexly alloyed SChMN-45 cast iron indicates an increased level of energy consumption for the process of destruction of the material compared to unalloyed cast iron. The chemical composition of cast iron providing the required parameters of mechanical properties (ultimate strength 450–505 MPa, hardness 265–330 HB) includes: 2.3–2.8 % C, 1.3–1.5 % Si , 0.6–1.0 % Mn, 0.4–0.7 % Mo, 0.2–0.4 % V, 0.4–0.7 % Ni. Such cast iron can contain no more than 0.3 % Cr, 0.3 % Cu, 0.2 % P, 0.1 % S. References 1. Bagesh B., Rahul K., Anil K.S. Effect on the mechanical properties of gray cast iron with variation of copper and molybdenum as alloying elements. International Journal of Engineering Research and Technology, 2014, vol. 3 (5), pp. 81–84. 2. Sujith B., Mukkollu S.R., Harish B.B., Leman Z. Effect on the mechanical properties of grey cast iron with variation of molybdenum and as – cast alloying elements. Universal Journal of Mechanical Engineering, 2020. vol. 8 (6), pp. 298–304. DOI: 10.13189/ujme.2020.080602. 3. Razaq A., Zhou J., Hussain T., Tu Z., Yin Y., Ji X., Xiao G., Sen X. Effect of alloying elements W, Ti, Sn on microstructure and mechanical properties of gray iron 220. China Foundry, 2019, vol. 16, pp. 393–398. DOI: 10.1007/s41230-019-9035-4. 4. Ankamma K. Effect of trace elements (boron and lead) on the properties of gray cast iron. Journal of the Institution of Engineers (India): Series D, 2014, vol. 95, pp. 19–26. DOI: 10.1007/s40033-013-0031-3. 5. Ma Y., Li X., Liu Y., Zhou S. Effect of Ti-V-Nb-Mo addition on microstructure of high chromium cast iron. China Foundry, 2012, vol. 9 (2), pp. 148–153.
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 24 No. 4 2022 6. Vadiraj A., Tiwari S. Effect of silicon on mechanical and wear properties of aluminium-alloyed gray cast iron. Journal of Materials Engineering and Performance, 2014, vol. 23, pp. 3001–3006. DOI: 10.1007/s11665-014- 1040-6. 7. Hassani A., Habibolahzadeh A., Sadeghinejad S. Comparison of microstructural and tribological effects of low vanadium-low titanium additions to a gray cast iron. Journal of Materials Engineering and Performance, 2013, vol. 22, pp. 267–282. DOI: 10.1007/s11665-012-0229-9. 8. Hassani A., Habibolahzadeh A., Sadeghinejad S. Influence of vanadium and chromium additions on the wear resistance of a gray cast iron. International Journal of Minerals, Metallurgy, and Materials, 2012, vol. 19, pp. 602–607. DOI: 10.1007/s12613-012-0601-7. 9. Rana R. High-performance ferrous alloys. Switzerland, Springer, 2021. 624 p. ISBN 978-3-030-53824-8. DOI: 10.1007/978-3-030-53825-5-5. 10. Pero-Sanz Elorz J.A., Fernandez Gonzalez D., Verdeja L.F. Physical metallurgy of cast irons. Switzerland, Springer, 2018. 343 p. DOI: 10.1007/978-3-319-97313-5-5. 11. Gabets D.A., Markov A.M. Issledovanie vliyaniya legiruyushchikh elementov na strukturu i svoistva serykh chugunov, rabotayushchikh v usloviyakh udarno-friktsionnogo iznosa [Study of the in? uence of alloying elements on the structure and properties of gray cast iron operating under conditions of shock-friction wear]. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2019, vol. 21, no. 1, pp. 70–81. DOI: 10.17212/1994-6309-2019-21.1-70-81. 12. Gabets A.V., Gabets D.A. Chugun [Cast iron]. Patent RF, no. 2562554, 2015. 13. Gabets D.A., Markov A.M. Chugun [Cast iron]. Patent RF, no. 2733940, 2020. 14. Gabets D.A., Markov A.M., Gabets A.V., Chertovskikh E.O. Otsenka vliyaniya legiruyushchikh dobavok na strukturu i mekhanicheskie svoistva serykh chugunov [Evaluation of the influence of alloying on the structure and mechanical properties of gray cast irons]. Polzunovskii vestnik = Polzunov Bulletin, 2018, no. 4, pp. 189–195. 15. Vander Voort G.F. Color metallography. ASM Handbook. Vol. 9. Metallography and Microstructures. ASM International, 2004, pp. 493–512. DOI: 10.1361/asmhba0003752. 16. Kazakov A.A., Ryaboshuk S., Lyubochko D., Chigintsev L. Research on the origin of nonmetallic inclusions in high-strength low-alloy steel using automated feature analysis. Microscopy and Microanalysis, 2015, vol. 21 (3), p. 1755. DOI: 10.1017/s1431927615009551. 17. Kazakov A., Kovalev P., Ryaboshuk S. Metallurgical expertise as the base for determination of nature of defects in metal products. CIS Iron and Steel Review, 2007, no. 1–2, pp. 7–13. 18. Kazakov A. Kiselev D. Industrial application of Thixomet. Metallography, Microstructure, and Analysis, 2016, vol. 5, pp. 294–301. DOI: 10.1007/s13632-016-0289-6. 19. Vander Voort G.F. Computer-aided microstructural analysis of specialty steels. Materials Characterization, 1991, vol. 27 (4), pp. 241–260. DOI: 10.1016/1044-5803(91)90040-B. 20. Ivanov S.G., Guriev A.M., Zemljakov S.A., Guriev M.A., Romanenko V.V. Osobennosti metodiki podgotovki obraztsov dlya avtomaticheskogo analiza karbidnoi fazy stali Kh12F1 posle tsementatsii v vakuume s primeneniem programmnogo kompleksa «Thixomet PRO» [Features of the method of preparation of samples for automatic analysis of the carbide phase of steel X12F1 on the program complex “Thixomet PRO” after carbonization in vacuum]. Polzunovskiy vestnik = Polzunov Bulletin, 2020, no. 2, pp. 165–168. DOI: 10.25712/ ASTU.2072-8921.2020.02.031. 21. Kazakov A.A., Kiselev D.V., Andreeva S.V., Chigintsev L.S., Golovin S.V., Egorov V.A., Markov S.I. Razrabotka metodiki kolichestvennoi otsenki mikrostrukturnoi poloschatosti nizkolegirovannykh trubnykh stalei s pomoshch’yu avtomaticheskogo analiza izobrazhenii [Development of technique for quantifying microstructural banding of low-alloy pipe steels using automatic image analysis]. Chernyye metally = Ferrous Metals, 2007, no. 7–8, pp. 31–37. 22. Kazakov A.A., Kiselev D. Industrial application of Thixomet image analyzer for quantitative description of steel and alloys microstructure. Microscopy and Microanalysis, 2015, vol. 21 (3), p. 457. DOI: 10.13140/ RG.2.1.2204.0720. 23. Kazakov A.A., Lyubochko D.A., Ryaboshuk S.V., Chigintsev L.S. Issledovanie prirody nemetallicheskikh vklyuchenii v stali s pomoshch’yu avtomaticheskogo analizatora chastits [Investigation of the nature of nonmetallic inclusions in HSLA steels using an automatic particle analyzer]. Chernyye metally = Ferrous Metals, 2014, no. 4 (988), pp. 37–42.
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 24 No. 4 2022 24. Kazakov A.A., Kiselev D.V., Andreeva S.V., Myasnikov A.A., Golovin S.V., Egorov V.A. Razrabotka metodiki kolichestvennoi otsenki zagryaznennosti nizkolegirovannykh trubnykh stalei nemetallicheskimi vklyucheniyami s pomoshch’yu avtomaticheskogo analiza izobrazhenii [Development of a method for quantifying the contamination of low-alloy pipe steels with non-metallic inclusions using automatic image analysis]. Chernyye metally = Ferrous Metals, 2007, no. 7–8, pp. 24–31. 25. Vander Voort G.F., Pakhomova O., Kazakov A. Evaluation of normal versus non-normal grain size distributions. Materials Performance and Characterization, 2016, vol. 5 (5), pp. 521–534. DOI: 10.1520/ MPC20160001. 26. Kazakov A.A., Kazakova E.I., Geller G.V. Otsenka kachestva mikrostruktury tiksotropnykh materialov [Evaluation of the quality of the microstructure of thixotropic materials]. Tsvetnyye metally, 2007, no. 10, pp. 110– 118. (In Russian). 27. Gabets D.A., Markov A.M., Gabets A.V. Issledovanie vliyaniya khimicheskogo sostava i struktury na mekhanicheskie svoistva chuguna ChMN-35M [Investigation of chemical composition and material structure influence on mechanical properties of special cast iron]. Aktual’nye problemy v mashinostroenii = Actual Problems in Mechanical Engineering, 2017, vol. 4, no. 4, pp. 100–107. (In Russian). 28. Girshovich N.G. Kristallizatsiya i svoistva chuguna v otlivkakh [Crystallization and properties of cast iron in castings]. Moscow, Mashinostroenie Publ., 1966. 562 p. 29. Chigarev V.V., Rassokhin D.A., Loza A.V. Izmenenie struktury i svoistv litogo metalla legirovaniem v otlivkakh iz chuguna i stali [Modification of the structure and properties of cast metal by means of alloying in castings, made of iron and steel]. Vestnik Priazovskogo derzhavnogo tekhnicheskogo universiteta. Seriya: Tekhnicheskie nauki = Reporter of the Priazovskyi State Technical University. Section: Technical sciences, 2010, vol. 21, pp. 61–66. (In Russian). 30. Semenov V.I., Chaikin A.V. Fazovye i strukturnye izmeneniya v chugune posle modifitsirovaniya [Phase and structural changes in cast iron upon inoculation]. Metallurgiya mashinostroeniya = Metallurgy of Machinery Building, 2006, no. 5, pp. 14–18. 31. Furrer D.U., Semiatin S.L., eds. ASM Handbook. Vol 22B. Metals process simulation. ASM International, 2010. 695 p. DOI: 10.31399/asm.hb.v22b.9781627081979. 32. ASM Handbook. Vol. 4. Heat Treating. ASM International, 1991. 2173 p. DOI: 10.31399/asm. hb.v4.0871703793. 33. Viswanathan S., Apelian D., Donahue R.J., DasGupta B., Gywn M., Jorstad J.L., eds. ASM Handbook. Vol. 15. Casting. ASM International, 1998. 2002 p. DOI: 10.31399/asm.hb.v15.9781627081870. 34. Komarov O.S., Rozenberg E.V., Urbanovich N.I. Osobennosti modifitsirovaniya razlichnykh tipov zhelezouglerodistykh splavov [Features modifying various types of iron-carbon alloys]. Lit’e i metallurgiya = Foundry Production and Metallurgy, 2015, vol. 79, no. 2, pp. 24–28. 35. Boulifaa M.I., Hadji A. Effect of alloying elements on the mechanical behavior and wear of austempered ductile iron. Mechanics and Industry, 2015, vol. 16 (3), p. 304. DOI: 10.1051/meca/2015002. 36. Larin T.V., Astashkevich B.M., Trankovskaya G.R. Vliyanie vanadiya, medi, alyuminiya na iznosostoikost’ i friktsionnye svoistva fosforistogo chuguna dlya tormoznykh kolodok [Influence of vanadium, copper, aluminum on the wear resistance and frictional properties of phosphorous cast iron for brake pads]. Vestnik nauchnoissledovatel’skogo instituta zheleznodorozhnogo transporta = Vestnik of the Railway Research Institute, 1986, no. 8, pp. 40–42. 37. Belyakov A.I., Petrov L.A., Kaminskij V.V., Akhunov T.A., Ershov V.P. Poluchenie chuguna s sharovidnym grafitom «LS protsessom» [Making spheroidal graphite cast iron by the LS-process]. Liteinoe proizvodstvo = Foundry. Technologies and Equipment, 1997, no. 5, pp. 20–21. 38. Kornienko E.N., Bikulov R.A. Tyazhelaya ligatura dlya polucheniya vysokoprochnogo chuguna [Heavy master alloy for producing ductile iron]. Zagotovitel’nyye proizvodstva v mashinostroyenii = Blanking productions in mechanical engineering, 2009, no. 2, pp. 3–5. 39. Gabets D.A., Markov A.M., Gabets A.V. Spetsial’nyi modifitsirovannyi chugun marki ChMN-35M dlya tyazhelo nagruzhennykh detalei telezhki gruzovogo vagona [Special modified ЧМН-35М cast iron for heavily loaded parts of a freight car bogie]. Tyazheloe mashinostroenie = Russian Journal of Heavy Machinery, 2016, no. 1–2, pp. 23–26. (In Russian).
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 24 No. 4 2022 40. Vijeesh V., Prabhu K.N. Review of microstructure evolution in hypereutectic Al-Si alloys and its effect on wear properties. Transactions of the Indian Institute of Metals, 2014, vol. 67 (1), pp. 1–18. DOI: 10.1007/s12666013-0327-x. 41. Zhi X., Xing J., Fu H., Gao Y. Effect of fluctuation and modification on microstructure and impact toughness of 20 wt.% Cr hypereutectic white cast iron. Materialwissenschaft und Werkstofftechnik, 2008, vol. 39 (6), pp. 391– 393. DOI: 10.1002/mawe.200700219. 42. Borshch B.V., Gabets A.V., Sukhov A.V., Filippov G.A. Povyshenie iznosostoikosti friktsionnykh detalei iz serogo chuguna [Increased wear resistance of friction parts made of gray cast iron]. Stal’ = Steel in Translation, 2014, no. 1, pp. 66–68. (In Russian). Conflicts of Interest The authors declare no conflict of interest. 2022 The Authors. Published by Novosibirsk State Technical University. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).
RkJQdWJsaXNoZXIy MTk0ODM1