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• 2CONEXPO-CON/AGG & IFPE Highlights

• F2016 FEF Conference

• FEF Keith Millis Scholarship Awards

• 2016 World ADI Conference

• ADI A North American Perspective in 2016 - Kathy Hayrynen

• Application of Differential Scanning Calorimetry for the Determination of ADI Service Temperature Limits - Karl Warsinski

• Austempering of Thin Wall Ductile Iron - Dr. Paul Sanders

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Ductile Iron News

Issue #1 - April 2017

Please stop by and visit the Ductile Iron Society Booth #455 at the 121st Metalcasting Congress in Milwaukee, WI from 10am to 6pm on Wednesday April 26th and 9am to 3pm on Thursday April 27, 2017.

CONEXPO-CON/AGG & IFPE - Las Vegas, NV:

In March, the Ductile Iron Society booth was on the road again. We once again with the help of the DIMG were exhibiting at the CONEXPO-CON/AGG & IFPE at the Las Vegas Convention in Las Vegas.

LINKS MAY NOT OPEN CORRECTLY IN CHROME BROWSER

http://www.ductile.org/back-issues/

http://www.ductile.org/

As in previous shows, there was a huge group of attendees. They were expecting well over 125,000 people. This is a great opportunity for the DIS and DIMG to talk one on one with design engineers, OEMs, and other users of ductile iron castings.


As always, there were a few folks that stopped by looking for producers of Ductile Iron and technical questions about Ductile Iron and CGI. We always have a poster in the booth with all the DIS members.

Also we handed out a small wallet size brochure that lists all the members.


Thanks to the following volunteers and companies that helped work the booth during this show. They were Dave Gilson of SinterCast, Dylan Bruins and Mark Mundell of Lethbridge Iron, Vadim Pikhovich of Magma, Mark Fields of Glidewell Foundry, Matt Schindle of Dotson Foundry, Kirk McCullough of Seneca Foundry and Bob O'Rourke of H-Bar.

2016 FEF Conference - Chicago, IL.

The 2016 College Industry Conference (CIC) for the FEF was held on November 17th and 18th in Chicago, Illinois at the Westin- Michigan Avenue. The DIS did have a tabletop display during the Career Information Session on Thursday evening.

We handed out this year's T-Shirts with the logo "Ductile Iron - Born in the USA". Once again THANKS to those sponsors who paid for the T-Shirts. They were Dura-Bar, Superior Graphite, Elkem, Cat, RMP, Applied Process, Inductotherm, Rex Heat Treat, Green Packaging, OmniSource, Foseco, Hickman, Williams & Company, ASI International, St. Mary's Foundry, ACC, Midvale, Buck Company, Neenah, ASK Chemicals & Allied Mineral Products.

Thanks also to our Treasurer Pete Guidi for his assistance in the booth. On Friday during the awards luncheon, the FEF handed out 4-$3000 scholarships to the following deserving students. They were,

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Mattie LaPrade of Virginia Tech University

Gabrielle Martin of the University of Alabama Birmingham


Nathan Peplinski of the University of Wisconsin Platteville

Connor Rittman of the University of Michigan


2016 World ADI Conference - Atlanta, GA:

The Ductile Iron Society held the 2016 World Conference on Austempered Ductile Iron (ADI) at the Westin Peachtree Hotel in Atlanta, GA from October 27-28, 2016. The turnout was not what the organizing group wanted to see, however it still was a great Conference. The attendees were presented with the top technical presentations in the field of ADI.

A big THANKS goes to Kathy Hayrynen of Applied Process for being the Technical Chairperson for the event. She work hard over the past year to make this the best ADI Conference ever. We were just hit with a bad economic downturn in the foundry business. Also, the election of a new President for the USA was about to happen and many businesses were unsure of the future. Following is a copy of the Program for that Conference.

The DIS would like to thank all the Speakers for their presentations and travel to Atlanta. We also wish to thank the Technical Chair persons and all other volunteers. Also there were a few DIS Members we wish to thank for their generous contributions to the Conference as Sponsors. They were Rex Heat Treat, THORS, Farrar Corporation, Applied Process, Magma, Larpen Metallurgical, Prohimsa Mexico, Hoosier Pattern, Capital Refractories, Lethbridge Iron, Joyworks, LLC, FasCast Incorporated, Allied Mineral and Hunter Foundry Machinery Corporation.

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Should any DIS member want a memory stick copy of the presentations, please drop a line to Jim Wood at [email protected]. If not a DIS member they are for sale for $100.00 each. They are only available until the inventory is gone.

Jim Wood DIS Executive Director 4/12/2017

Links to ADI Presentations not included on memory stick.

• ADI - A North American Perspective in 2016 - Dr. KathyHayrynen

• Application of Differential Scanning Calorimetry for theDetermination of ADI Service Temperature Limits - KarlWarsinski

• Austempering of Thin Wall Ductile Iron - Dr. PaulSanders

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NEWS BRIEFS

For Release: April 10, 2017

U.S. Manufacturing Technology Orders on Path for Strong Recovery

U.S. manufacturing technology orders increased more than expected in February, up 19.6 percent from January, according to the latest U.S. Manufacturing Technology Orders report from AMT – The Association For Manufacturing Technology. Orders were up 1.7 percent year over year.

“We anticipated an increase in orders after a soft January, but we are surprised by the strength of the February numbers,” said AMT President Douglas K. Woods. “What’s even more encouraging is the pickup wasn’t a spike related to any specific industry or region, but rather was broad-based – from Northeast to West as well as everything from aerospace to consumer products. This activity reinforces our projections for a full recovery in manufacturing technology orders by the end of the second quarter.”

While all regions reported growth, the Northeast grew by 41 percent led by the small arms and aerospace industries. Nationally, aerospace had the largest growth rate, more than doubling January’s total. There was also surprising strength reported in appliances; medical devices; and off-road and highway equipment. The February data is aligned with other key indicators of the manufacturing sector’s health. For example, every component of the March Purchasing Managers Index was up; the Federal Reserve’s manufacturing output data had its best back-to-back monthly increases in three years; and durable goods orders and housing starts climbed in February.

(link to more info)

AMT – The Association For Manufacturing Technology 7901 Jones Branch Drive, Suite 900,

McLean, VA 22102 703-893-2900 ▪ 703-893-1151 fax ▪ www.AMT online.org

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NEWS BRIEFS


NEWS BRIEFS

For Release: April 12th, 2017

U.S. Cutting Tool 2017 YTD Consumption up 4.5% in February

February U.S. cutting tool consumption totaled $174.98 million according to the U.S. Cutting Tool Institute (USCTI) and AMT – The Association For Manufacturing Technology. This total, as reported by companies participating in the Cutting Tool Market Report (CTMR) collaboration, was up 1.1% from January’s $173.05 million and up 0.6% when compared with the total of $173.88 million reported for February 2016. With a year-to-date total of $348.02 million, 2017 is up 4.5% when compared with 2016.

These numbers and all data in this report are based on the totals reported by the companies participating in the CTMR program. The totals here represent the majority of the U.S. market for cutting tools.

“There is a feeling of optimism in the air that is backed up by the positive growth the cutting tool market data shows after the first 2 months of the year,” says Steve Stokey, President of USCTI. “Manufacturing continues to be a hot topic and continues to have a seat at the table in the new Trump administration. The strong dollar will continue to challenge our ability to export but with the US automotive and aerospace markets remaining steady, it should provide a firm foundation for growth as the other industrial sectors rebound from a weak 2016. This should bode well for cutting tool manufacturers.”

Scott Hazelton, Managing Director of Economics & Country Risk at IHS Markit adds that “The economy is enjoying improved business and consumer confidence, resulting in strong momentum in employment growth and single

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NEWS BRIEFS, Cont'd

family housing as well as a rebound in nondefense capital spending, including the important energy sector. Consumption of cutting tools is forecasted to respond with increasing growth over the year. Acceleration of growth in 2018 is expected as tax reform and infrastructure investment enhance the investment outlook.”

The Cutting Tool Market Report is jointly compiled by AMT and USCTI, two trade associations representing the development, production and distribution of cutting tool technology and products. It provides a monthly statement on U.S. manufacturers’ consumption of the primary consumable in the manufacturing process – the cutting tool. Analysis of cutting tool consumption is a leading indicator of both upturns and downturns in U.S. manufacturing activity, as it is a true measure of actual production levels.

Historical data for the Cutting Tool Market Report is available dating back to January 2012. This collaboration of AMT and USCTI is the first step in the two associations working together to promote and support U.S.-based manufacturers of cutting tool technology.

# # #

(CTMR data is also available at www.AMTonline.org.)

ISSN# 10807756

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NEWS BRIEFS, Cont'd

AMT – The Association For Manufacturing Technology represents and promotes U.S.-based manufacturing technology and its members—those who design, build, sell, and service the continuously evolving technology that lies at the

heart of manufacturing. Founded in 1902 and based in Virginia, the association specializes in providing targeted business assistance, extensive global support, and business intelligence systems and analysis. AMT is the voice that communicates the importance of policies and programs that encourage research and innovation, and the development of educational initiatives to create tomorrow’s Smartforce. AMT owns and manages IMTS – The International Manufacturing Technology Show, which is the premier manufacturing technology event in North America. The CTPG report is compiled by AMT and all data in the report is based on the totals of actual data reported by companies participating in the CTPG program.

The United States Cutting Tool Institute (USCTI) was formed in 1988 and resulted from a merger of two national associations representing the cutting tool manufacturing industry. The Institute works to

represent, promote, and expand the U.S. cutting tool industry and to promote the benefits of buying American-made cutting tools manufactured by its members. Membership includes North American manufacturers and/or remanufacturers of cutting tools, as well as tool surface treatment providers. Members, which number over 70, belong to ten product divisions: Carbide Tooling, Drill & Reamer, Metal Cutting Saw Blades, Milling Cutter, Polycrystalline Diamond & Polycrystalline Cubic Born Nitride, Substrate Materials, Surface Coating, Tap & Die, Tool Holder and All Other Tooling. A wide range of activities include a comprehensive statistics program, human resources surveys, development of product specifications and standards, and semi-annual meetings to share ideas and receive information on key industry trends.


NEWS BRIEFS

UNDERGROUND CORROSION TRAINING OFFERED AT AUCSC 2017

(Morgantown, WV) … The 62nd annual Appalachian Underground Corrosion Short Course (AUCSC 2017) will take place May 9-11, 2017 in Morgantown, WV. Detailed information and on-line registration is available at www.aucsc.com.

AUCSC offers over 100 hours of basic, intermediate, and advanced training providing attendees with technical information about the causes and prevention of corrosion on underground structures. Licensed professional engineers (P.E.’s) may earn professional development hours (PDH’s) for attending AUCSC; P.E.’s should submit proof of their completion of AUCSC courses to their state’s engineering licensing board. A NACE Technician Review Course is also offered, and AUCSC course hours may be applied towards NACE recertification requirements. NACE will offer its NACE Corrosion Exam during AUCSC 2016; please contact NACE directly for additional information regarding the exam at (281) 228-6211.

The pre-registration fee for the entire AUCSC 2017 program is $150.00 before May 1, and on-site registration is $200.00. Please visit www.aucsc.com for pre-registration and additional information, or contact AUCSC at [email protected] or (304) 293-4307.

If you would consider listing or linking our website address, www.aucsc.com, on your website it would be appreciated.

Thank you for your consideration.

Frank Rampton, AUCSC Publicity Chairman

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Austempering of Thin Wall Ductile Iron

Dr. Paul Sanders Michigan Technological University

Acknowledgements

• Michigan Tech: Alex Reinl, Steph Tankersley, Ale Almaza Perales, Russ Stein

• Grede: Jay Solomond • LIFT

Stiffness vs. Cost

4

Austempering

• Mechanical properties of steel

• Castability of ductile iron • Possible to eliminate

carbides in thin sections

www.totalmateria.com

Mechanical Properties

Fras 2014 Thin Wall Ductile Iron Castings as Substitutes for Aluminum Alloy Castings

A) Relative strength B) Yield strength C) Stiffness D) Fatigue strength E) High temp strength F) Damping capacity

A) B)

C) D)

E) F)

Thin Wall DI vs. Aluminum

Fras 2014 Thin Wall Ductile Iron Castings as Substitutes for Aluminium Alloy Castings

Nodule Count and Strength vs. Wall Thickness

K. M. Ibrahim, 2013. Effect of cast wall thickness, composition and austempering temperature on microstructure and properties of ductile cast iron

Wall Thickness vs. Toughness

K. M. Ibrahim, 2013. Effect of cast wall thickness, composition and austempering temperature on microstructure and properties of ductile cast iron

Mechanical Property

Correlations

• Convert hardness to strength and elongation – Applied in this

work; will discuss later

– ADI vs conventional Robert J. Warrick, 2000. Austempered Ductile Iron Castings for Chassis Applications. ADI Castings for Chassis Applications SAE 2000 Paper

Select process for balance of strength and toughness

10

Austempering Process

Hayrynen, Kathy. "The Production of Austempered Ductile

Iron." World Conference on ADI (2002).

Standard ADI Grades per ASTM A897/A897M-15

11

Austempered Properties

Grade Tensile Strength* (Mpa)

Yield Strength* (Mpa)

Elongation* (%)

Impact Energy* (J)**

Hardness (HBW)

Grade 1 900-650-09 900 650 9 100 269-341

Grade 2 1050-750-07 1050 750 7 80 302-375

Grade 3 1200-850-04 1200 850 4 60 341-444

Grade 4 1400-1100-02 1400 1100 2 35 388-477

Grade 5 1600-1300-01 1600 1300 1 20 402-512 * Minimum Values **Unnotched Charpy Tests

Target Grade 1.6

Thin Wall Casting at Michigan Tech Developed pattern to assess cooling rate effects

Finger mold design 3D printed pattern

4”

12

Casting Thin Plates • Standard 4512, 5506, 7003 • Utilization of 3D-printed patterns • Replicate vertical molding to cast plates from 2 - 6 mm

Finger casting Chem bond molds

13

MAGMASOFT Process Modeling

• Temperature • Cooling Rate • Fill Time • Carbides • Ferrite and Pearlite

14

Temperatures Fill Time

Cooling Rate Air Entrapment

MAGMASOFT Modeling Correlation

5506 Grade DI • Ferrite • Pearlite • Carbides

Grede-Brewton Production Tooling

Diff Case with Finger Pattern

16

Ram Swing

Fingers

Grede-Brewton Production Tooling

Diff Case with Finger Mold

17

Ram Swing

Chemistry and Pouring Details

18

Grede 4512 DI

Element Wt%

C 3.7

Si 2.6

Cu 0.29

Mn 0.46

Mg 0.038

S 0.006

CE 4.5

Grede DISAMATIC Process • Pour Time: 6 seconds • Pour Temp: 2460°F • Casting Weight: 10.5 lbs

Grede-Brewton Production Castings

4512 DI

19

20

ADI Hardness and Tensile Specimens

ADI 4512 fingers from Grede - Brewton

ADI Mechanical Properties

21

Thickness(mm)

UTS(Mpa)

Yield(Mpa)

Elong(%) Comments

6 1040 880 3.3 1 small inclusion6 1068 873 5.3 1 small inclusino4 1086 931 3.6 1 very small inclusion4 1033 882 2.0 1 small inclusion3 1000 717 2.0 1 small inclusion

2.5 944 689 1.1 2 very small inclusionsADI Grade 1.6 1000 700 8 www.appliedprocess.com

22

Inclusions on ADI Fracture Surfaces

ADI from 4512 fingers from Grede - Brewton

6 mm

Mechanical Properties

* Inclusions present in samples

** Robert J. Warrick, 2000. Austempered Ductile Iron Castings for Chassis Applications. ADI Castings for Chassis Applications SAE 2000 Paper

Material UTS (MPa) YS (MPa) %Elong Source

DI-5506 552 379 6 Handbook (CES)

DI-7003 689 483 3 Handbook (CES)

ADI Grade 1 900 650 9 www.appliedprocess.com

ADI Grade 2 1050 750 7 www.appliedprocess.com

ADI from 4512 1050 880 2.5* Grede - Brewton

ADI from 4512 900 600 9 Hardness Conversion**

Brinell Hardness Results

24

BH

N

Section Thickness (mm)

Carbides present

Young’s Modulus – Ultrasonic Testing

25

As-Cast Grede Fingers

26

4 mm

2 mm

4512

4512

Comparison – 4512 DI vs ADI

27

2.5 mm

4512

2.5 mm

ADI from 4512

ADI Heat Tinting – 2 Trial Images

28

Phase Identification •Unreacted austenite Light Blue •Reacted (↑C austenite) Purple •Ferrite Beige •Eutectic carbide White/Cream •Martensite Dark Blue 75 Microns 75 Microns

4512 DI from Grede – 6 mm thickness

Reduce Cooling Rate

Cooling rate significantly reduces as section thickness increases

30

QUESTIONS?

www.oemoffhighway.com

For additional information, please contact:

• Paul Sanders• 1400 Townsend Dr ,Houghton, MI 499341• 906 487 2339• 906 487 2934• [email protected]• www.mtu.edu/materials/department/faculty/sanders/

RETURN TO DI NEWS

mailto:[email protected]

Contact:Penny Brown, AMT, 703-827-5275

[email protected]

For Release: April 10, 2017

U.S. Manufacturing Technology Orders on Path for Strong Recovery

U.S. manufacturing technology orders increased more than expected in February, up 19.6 percent

from January, according to the latest U.S. Manufacturing Technology Orders report from AMT – The

Association For Manufacturing Technology. Orders were up 1.7 percent year over year.

“We anticipated an increase in orders after a soft January, but we are surprised by the strength of the

February numbers,” said AMT President Douglas K. Woods. “What’s even more encouraging is the pickup

wasn’t a spike related to any specific industry or region, but rather was broad-based – from Northeast to

West as well as everything from aerospace to consumer products. This activity reinforces our projections

for a full recovery in manufacturing technology orders by the end of the second quarter.”

While all regions reported growth, the Northeast grew by 41 percent led by the small arms and

aerospace industries. Nationally, aerospace had the largest growth rate, more than doubling January’s total.

There was also surprising strength reported in appliances; medical devices; and off-road and highway

equipment. The February data is aligned with other key indicators of the manufacturing sector’s health.

For example, every component of the March Purchasing Managers Index was up; the Federal Reserve’s

manufacturing output data had its best back-to-back monthly increases in three years; and durable goods

orders and housing starts climbed in February.

U.S. Manufacturing Technology Orders a statistical program of AMT

(more)

AMT – The Association For Manufacturing Technology7901 Jones Branch Drive, Suite 900, McLean, VA 22102703-893-2900 ▪ 703-893-1151 fax ▪ www.AMTonline.org

Orders for February 2017 totaled $300.51 million, up from January’s $251.36 million. USMTO is a reliable

leading economic indicator as manufacturing companies invest in capital metalworking equipment to increase

capacity and improve productivity.

# # #

The United States Manufacturing Technology Orders (USMTO) report

These numbers and all data in this report are based on the totals of actual data reported by companies participating in the USMTO program. This report, compiled by AMT – The As-

sociation For Manufacturing Technology, provides regional and national U.S. orders data of domestic and imported machine tools and related equipment. Analysis of manufacturing

technology orders provides a reliable leading economic indicator as manufacturing industries invest in capital metalworking equipment to increase capacity and improve productivity.

About AMT – The Association For Manufacturing Technology

AMT represents U.S.-based builders and distributors of manufacturing technology – the advanced machinery, devices, and digital equipment that U.S. manufacturing relies on to be pro-

ductive, innovative, and competitive. Located in McLean, VA, near the nation’s capital, AMT acts as the industry’s voice to speed the pace of innovation, increase global competitiveness

and develop manufacturing’s advanced workforce of tomorrow. With extensive expertise in industry data and intelligence, as well as a full complement of international business opera-

tions, AMT offers its members an unparalleled level of support. AMT also produces IMTS – The International Manufacturing Technology Show, the premier manufacturing technology

event in North America.

IMTS – International Manufacturing Technology Show

The largest and longest running manufacturing technology trade show in the United States is held every other year at McCormick Place in Chicago, Ill. IMTS 2018 will run Sept. 10-15.

IMTS is ranked among the largest trade shows in the world. Recognized as one of the world’s preeminent stages for introducing and selling manufacturing equipment and technol-

ogy, IMTS attracts more than 114,000 visitors from every level of industry and more than 112 countries. IMTS is owned and managed by AMT – The Association For Manufacturing

Technology. www.IMTS.com

(USMTO data is also available at www.AMTonline.org.) ISSN# 10807756

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FEB 17 (P) PreviousMonth

%Change

Year AgoMonth

%Change

YTD 17 (P) YTD 16(R) % Change

YTD

National

Regional


February 2017

$ = millions of dollars P – preliminaryR – revised* – percent change greater than 1,000%Totals may not match due to rounding

288.37 243.92 18.2% 287.46 0.3% 532.28 556.35 -4.3% 12.15 7.44 63.2% 7.97 52.4% 19.59 23.75 -17.5% 300.51 251.36 19.6% 295.43 1.7% 551.87 580.11 -4.9% 64.85 46.09 40.7% 43.64 48.6% 110.94 100.07 10.9% 1.61 1.10 46.2% D D 2.71 D D 66.46 47.19 40.8% D D 113.65 D D 27.44 27.06 1.4% 43.45 -36.8% 54.50 82.20 -33.7% 2.55 0.47 438.0% 1.10 130.6% 3.02 D D 29.99 27.53 8.9% 44.55 -32.7% 57.52 D D 72.96 58.39 24.9% 82.56 -11.6% 131.35 144.47 -9.1% 4.75 5.35 -11.1% 2.79 70.1% 10.10 6.62 52.6% 77.71 63.74 21.9% 85.35 -9.0% 141.45 151.09 -6.4% 45.90 42.55 7.9% 49.64 -7.5% 88.45 95.39 -7.3% 1.86 0.30 525.2% 0.72 159.2% 2.16 D D 47.76 42.85 11.4% 50.35 -5.2% 90.61 D D 27.39 21.19 29.3% 19.73 38.8% 48.59 33.54 44.9% D D * D D D D D D D D D D D D D 49.83 48.63 2.5% 48.45 2.9% 98.46 100.69 -2.2% D D 130.1% 2.09 D D D D D D 3.0% 50.54 D D D D

Metal Cutting Metal Forming & Fabricating

Total

Northeast Metal Cutting Metal Forming & Fabricating

TotalSoutheast


TotalNorth Central-East


TotalNorth Central-West


TotalSouth Central


TotalWest


Total

Note on fields marked D: Due to a change in survey participants the year over year comparison number for Metal Forming and Fabricating is not an accurate reflection of the data. We have adjusted the data for the past 12 months to take this change into consideration. The new chart reflects a consistent year over year comparison of the data at the current participation level.

Net New Orders for U.S. Consumption

Total National Orders (Thousands of Dollars)

METAL CUTTING METAL FORMING & TOTAL ORDERS MACHINES FABRICATING MACHINES DATE Units Value Units Value Units Value

REGIONAL

2016 FEB 1,743 $295,427 1,692 $287,456 51 $7,9712016 MAR 2,269 $394,539 2,227 $384,505 42 $10,0342016 APR 1,674 $288,801 1,627 $277,050 47 $11,7512016 MAY 1,729 $288,925 1,685 $283,489 44 $5,4362016 JUN 1,899 $333,749 1,826 $318,827 73 $14,9222016 JUL 1,469 $258,774 1,432 $245,855 37 $12,9182016 AUG 1,989 $329,549 1,948 $318,502 41 $11,0472016 SEP 2,838 $517,059 2,787 $504,377 51 $12,6822016 OCT 1,994 $348,357 1,950 $325,248 44 $23,1092016 NOV 2,080 $344,834 2,027 $333,764 53 $11,0702016 DEC 2,645 $425,175 2,594 $416,856 51 $8,3192017 JAN 1,588 $251,358 1,529 $243,916 59 $7,4412017 FEB 1,743 $300,513 1,690 $288,368 53 $12,146 Average 1,974 $336,697 1,924 $325,247 50 $11,450

Northeast Region (Thousands of Dollars)


2016 FEB 337 D 333 $43,637 4 D2016 MAR 417 $89,994 410 $88,553 7 $1,4412016 APR 345 D 344 $55,755 1 D2016 MAY 336 $54,894 323 $53,429 13 $1,4662016 JUN 422 $85,403 403 $77,874 19 $7,5292016 JUL 273 $49,597 268 $48,794 5 $8032016 AUG 330 D 327 $56,384 3 D2016 SEP 508 $95,973 497 $94,210 11 $1,7632016 OCT 381 $57,099 370 $54,988 11 $2,1112016 NOV 374 $64,557 363 $59,886 11 $4,6712016 DEC 502 D 496 $82,156 6 D2017 JAN 319 $47,192 309 $46,092 10 $1,1002017 FEB 364 $66,461 358 $64,852 6 $1,609 Average 378 $65,484 369 $63,585 8 $1,899



February 2017

Southeast Region (Thousands of Dollars)


2016 FEB 296 $44,551 288 $43,446 8 $1,1042016 MAR 295 D 292 $38,470 3 D2016 APR 189 $36,620 178 $29,273 11 $7,3482016 MAY 220 D 215 $33,024 5 D2016 JUN 207 D 204 $37,271 3 D2016 JUL 217 D 213 $43,676 4 D2016 AUG 360 $67,115 353 $64,940 7 $2,1752016 SEP 383 D 378 $80,837 5 D2016 OCT 211 D 210 $45,408 1 D2016 NOV 245 D 240 $31,902 5 D2016 DEC 309 D 308 $42,590 1 D2017 JAN 194 $27,531 185 $27,058 9 $4732017 FEB 185 $29,988 176 $27,442 9 $2,547 Average 255 $43,444 249 $41,949 5 $1,495

North Central-East Region (Thousands of Dollars)


2016 FEB 394 $85,354 376 $82,559 18 $2,7952016 MAR 550 $104,204 536 $98,791 14 $5,4132016 APR 343 $68,239 325 $65,882 18 $2,3572016 MAY 366 $66,307 354 $65,169 12 $1,1382016 JUN 457 $85,442 444 $84,902 13 $5402016 JUL 335 $52,283 322 $49,957 13 $2,3262016 AUG 460 $84,539 445 $77,517 15 $7,0232016 SEP 724 $130,389 707 $123,797 17 $6,5922016 OCT 513 $109,381 492 $90,583 21 $18,7982016 NOV 511 $82,926 494 $79,961 17 $2,9652016 DEC 628 $97,961 616 $95,255 12 $2,7062017 JAN 356 $63,738 328 $58,391 28 $5,3472017 FEB 424 $77,710 409 $72,957 15 $4,754 Average 466 $85,267 450 $80,440 16 $4,827




February 2017

North Central-West Region (Thousands of Dollars)

South Central Region (Thousands of Dollars)




2016 FEB 283 $50,353 276 $49,635 7 $7182016 MAR 421 $76,024 409 $73,758 12 $2,2662016 APR 308 $52,613 297 $51,309 11 $1,3042016 MAY 309 $62,869 300 $62,084 9 $7852016 JUN 337 $54,518 327 $53,289 10 $1,2292016 JUL 268 $56,729 257 $48,854 11 $7,8752016 AUG 331 D 327 $53,173 4 D2016 SEP 497 $84,357 490 $82,401 7 $1,9562016 OCT 377 $64,104 369 $62,450 8 $1,6542016 NOV 380 $86,291 374 $85,451 6 $8402016 DEC 425 $75,313 409 $72,737 16 $2,5762017 JAN 259 $42,850 251 $42,552 8 $2982017 FEB 246 $47,756 233 $45,895 13 $1,861 Average 342 $62,143 332 $60,276 9 $1,867


2016 FEB 124 D 118 $19,731 6 D2016 MAR 129 D 127 $25,560 2 D2016 APR 156 D 154 $21,058 2 D2016 MAY 133 D 129 $17,111 4 D2016 JUN 135 $20,667 117 $18,754 18 $1,9122016 JUL 106 D 105 $14,106 1 D2016 AUG 143 D 139 $18,294 4 D2016 SEP 187 D 185 $22,725 2 D2016 OCT 136 D 136 $15,945 0 D2016 NOV 178 D 175 $18,545 3 D2016 DEC 233 D 227 $36,524 6 D2017 JAN 145 D 144 $21,193 1 D2017 FEB 188 $28,301 181 $27,394 7 $908 Average 153 $21,688 149 $21,303 4 $385


February 2017



West (Thousands of Dollars)


METAL CUTTING METAL FORMING &TOTAL ORDERS MACHINES FABRICATING MACHINES

DATE Units Value Units Value Units Value

2016 FEB 309 $50,536 301 $48,448 8 $2,0882016 MAR 457 D 453 $59,372 4 D2016 APR 333 D 329 $53,772 4 D2016 MAY 365 D 364 $52,672 1 D2016 JUN 341 $50,364 331 $46,737 10 $3,6272016 JUL 270 D 267 $40,468 3 D2016 AUG 365 $48,729 357 $48,194 8 $5342016 SEP 539 D 530 $100,407 9 D2016 OCT 376 D 373 $55,874 3 D2016 NOV 392 $58,848 381 $58,018 11 $8302016 DEC 548 D 538 $87,594 10 D2017 JAN 315 D 312 $48,630 3 D2017 FEB 336 D 333 $49,829 3 D

Average 380 $58,670 375 $57,694 6 $977

February 2017

Return to DI NEWS

ADI – A North American Perspective in 2016

Kathy L. Hayrynen Applied Process Companies

World Conference on Austempered Ductile Iron, Oct. 27-28, 2016 The Westin – Peachtree Plaza, Atlanta, GA

A look back at 2002 in NA


What’s next in the USA? • Continued growth in Ductile Iron production • More steel and aluminum conversions

– Aggressive FEA modeling • Increased exploitation Carbidic ADI (CADI) • High integrity, 3mm wall ADI components • Increasing fatigue performance:

– Surface treatments • More possibilities for ADI gears if we can:

– Increase bending fatigue – Reduce gear noise

• VERY large ADI components • Grade 800 ADI? (intercritical ADI)

2016 Perspective: Today’s Discussion

• Innovations in applications of ADI continue, but constraints of NDAs limit what can be discussed in most instances;

• High integrity 3mm wall castings are not yet readily available;

• Large ADI Components – now a reality; • CADI usage continues to increase, especially in

the agricultural sector;


2016 Perspective: Today’s Discussion

• Gears – Standards work with AGMA – Noise Study at OSU

• Intercritical ADI (Grade 800 or Grade 750) • Other Developments

– Alloy developments – Surface hardening – Heavy section Properties


The ADI Market in North America


Estimated North American ADI Market Distribution (2002)

Railroad Equipment

13%

General Manufacturing

13%

Construction & Mining13% Heavy Vehicle

25%

Light Vehicle25%

Agricultural Equipt.

13%


Heavy Vehicle

Railroad Equipment

Agricultural Equipment

General Manufacturing

Construction & Mining

Large ADI Components


Size constraints exist because of equipment constraints.

2.1m x 2.4m Integral Salt Quench Batch Furnace (10 ton capacity)

ADI Gears


ADI Gear Development Needs . . .


Database Development

Inclusion into ANSI/AGMA/ISO Gear Standards

Gear Research Institute Results


Gear Noise Terminology

• Gear Whine – tonal sound related to the gear mesh frequency that is calculated by taking the product of the number of teeth multiplied by the shaft speed;

• Gear Rattle – generated when gear teeth come out of contact and then impact


OSU / AP Gear Noise Study

• Objective – Design a test where there is no difference in

microgeometries of the gear sets. • The only difference in results should be due to modulus

differences and possibly damping between the gears.


Predicted Noise Results (LDP model – gear whine excitation metric)


• ADI gears 1 – 4 dB at low frequencies;

• ADI gears 1-3 dB noisier above notch;

• Differences drop at highest torque.

Ref: An Experimental and Analytical Comparison of Noise Generated by Gears of ADI and Steel Materials – D. Houser, S. Shon, K. Hayrynen and J. Lefevre, AGMA Fall Technical Meeting October 2016, Paper 16FTM18

Summary of Results


Load (Nm) TR1, avg TR2, avg TR4, avg 82 -2.07 -2.12 -1.92

143 -1.20 -0.83 -0.83 199 -1.22 -0.67 -1.57 302 -0.90 -0.73 -1.17

*Negative implies ADI is quieter than steel

TR1: Closest microphone to gearbox (1 meter)

TR2: Farthest microphone from gearbox (2 meters)

TR4: Accelerometer located at the center of the gearbox top plate

Ref: An Experimental and Analytical Comparison of Noise Generated by Gears of ADI and Steel Materials – D. Houser, S. Shon, K. Hayrynen and J. Lefevre, AGMA Fall Technical Meeting October 2016, Paper 16FTM18

What did we learn about gear noise?

• Experimental results from this study indicate ADI gears are consistently from 1 to 2 dB quieter than 8620 steel gears, a value that is undetectable by the human ear and within limits of noise level measurement accuracy.


ANSI/AGMA 6014-B15 Gear Power Rating for Cylindrical Shell and

Trunnion Supported Equipment


Applicability This standard provides a method to determine the power rating of gear sets with spur and helical conventional pinions and spur self-aligning pinions for cylindrical grinding mills, kilns, coolers, and dryers. The formulas are applicable to steel, ductile iron (spheroidal graphitic iron), and austempered ductile iron (ADI) with machined spur, single helical, double helical, or herringbone gear teeth.

Intercritical ADI


Austenitizing Temperature

for ADI and IADI

TADI > TIADI The austenite carbon content for temperature TADI is greater than the austenite carbon content for temperature TIADI.

TADI

TIADI

ASTM A897/897M-06 Grades of ADI

Grade Tensile

Strength (MPa / Ksi)

Yield Strength

(MPa / Ksi) Elongation

(%)

Impact Energy

(Joules / lb.-ft.)

Typical Hardness

(BHN)

110-70-11 750-500-11 750 / 110 500 / 70 11 110 / 80 241-302

130-90-09 900-550-09 900 / 130 550 / 90 9 100 / 75 269 – 341

150-110-07 1050-750-07 1050 / 150 750 / 110 7 80 / 60 302 – 375

175-125-04 1200-850-04 1200 / 175 850 / 125 4 60 / 45 341 – 444

200-155-02

1400-1100-02

1400 / 200 1100 / 155 2 35 / 25 388 – 477

230-185-01

1600-1300-01

1600 / 230 1300 / 185 1 20 / 15 402 - 512

Mixed Microstructure Grades of ADI per ASTM A897/897M-16

GR 750-500-11 GR 110-70-11

UTS [MPa / ksi]

750 / 110

Yield Strength [MPa / ksi]

500 / 70

% Elongation 11

Typical Brinell Hardness (HBW)

241 - 302

Grade 750 ADI

Presenter

Presentation Notes

Grade 750 consists of a mixture of proeutectoid ferrite and ausferrite. It can be found in a stand alone table in ASTM A897/897M.

ASTM A897/897M-16 Grades of ADI

Grade

Tensile Strength

(MPa / ksi)

Yield Strength

(MPa / ksi)

Elongation (%)

Typical Hardness

(HBW)

1 900 / 130 650 / 90 9 269 – 341

2 1050 / 150 750 / 110 7 302 – 375

3 1200 / 175 850 / 125 4 341 – 444

4 1400 / 200 1100 / 155 2 388 – 477

5 1600 / 230 1300 / 185 1 402 - 512

Presenter

Presentation Notes

This table shows the details of the ASTM ADI Standard.

Alloy Developments for ADI


Microsegregation Low vs... High Nodule Count

Presenter

Presentation Notes

This slide graphically depicts the relative microsegregation of the various alloys: Si is highest near the nodules and lowest at the cell boundary. Cu (and Sn and Sb) segregate in layers at the graphite metal interface and produce a C barrier. Ni does not segregate significantly and can be added up to several percent. Mn, Mo, Cr, Ti, V, W and all other carbide formers segregate significantly at the cell boundaries. (This is where you will find the carbides). If more, smaller nodules are present, the micro-segregation is mitigated (dotted line red graphic).

Suggested Chemical Composition Ranges

Manganese Max Section > 13mm 0.35% max +/- 0.05% Max Section < 13mm 0.60% max +/- 0.05% Copper (only as needed) 0.80% max +/- 0.05% Nickel (only as needed) 2.00% max +/- 0.10% Molybdenum (only as needed) 0.30% max +/- 0.03%

Presenter

Presentation Notes

Note: Cu, Ni and Mo are added ONLY to increase the hardenability of the iron, not to influence the austempered properties. The most important measure is NOT the mean composition….but the range. The ranges shown here represent good, industrial practice and are easily achievable with proper attention.

The Case for Mn • Relatively inexpensive alloying element; • Relatively potent hardenability agent; • Segregates to LTF – delays formation of

ausferrite.

• Challenge – find a way to mitigate segregation tendencies - control of nodule count

• Can a semi-quantitative relationship between Mn level and nodule count be developed?


Low (0.31 Mn) vs High (0.61 Mn)


What about Nickel?

• Advantages – No deleterious segregation issues; – Increased toughness; – Low temperature properties; – Increased corrosion resistance.

• Disadvantage – Cost


Low Temperature Properties

• The target – V-notch Charpy at -40°

• 8 ft-lb (11 J)


CVN Results vs Ni Content


Surface Hardening


Welding produces a HAZ


Hardfacing ADI


Ref: A. Lundquist and T. Sheets, Hardfacing ADI

• A comparison of welding after and before austempering is shown.

• No HAZ if welding is done prior to austempering

• Additional work is focused on testing the weld media/metal bond.

Hardened area

Base material Base material

Wear resistant cladding

Dilution Zone

Heat affected Zone (hardened)

Micrograph of Laser Cladding on ADI Grade 5, Main Alloys: 0.5Mn, 0.91Cu

Laser Cladding

• Low heat affected zone. • Dilution (mixing) of powder

and base material at the interface creating a true metallurgical bond.

• One step process. • No masking required. • Ability to create very thick

coatings (0.025”). • Greater flexibility in powder

choices. • Completely dense coatings

with no porosity.

Ref: Kondex Corporation, www.kondex.com

Galling Properties of ADI


Galling Threshold Testing Details

Test method per ASTM D5707-05

Test environment replicated that for an automotive hypoid gear set.

Presenter

Presentation Notes

This is a schematic of the SRV apparatus fixture for the galling threshold testing. It was a pin on disk test. The block temperature was 75°C, stroke length of 1mm or total sliding distance of 2mm per cycle. Cycle frequency of 50 Hz. Average sliding speed was 0.1 m/sec. Tests concluded when the specimens seized, which was indicated by a measured stroke length of 0mm or when the coefficient of kinetic friction dramatically increased by 0.3 for 30 seconds. If seizure was not complete, the test continued and galling onset was later determined from the collected data and inspection of the wear scar. Recent research has shown that frictional criteria can be used as a necessary condition to establish the presence of galling

Galling Test Friction and Load vs... Time

Presenter

Presentation Notes

This chart compares the coefficients of friction for the ferrous materials in self-mated tests. It also indicates at what point in the test cycle each material galled by the sharp rise in friction. Note Gr. 900 ADI did not gall. Bear in mind that the right hand axis is in terms of load and does not take into account the wear scar size and, thus, does not give an accurate representation of the contact stress for each test. The point to take away from this is that Grade 900 endured a higher load than the other materials and still had a very small wear scar.

Material

Volume Loss (mm3)

Hardness (HRC)

Galling Threshold

(MPa)

Grade 900 ADI (GR 1) 10.9 30 1527+

Grade 1050 ADI (GR 2) 10.7 40 894

Grade 1600 ADI (GR 5) 9.4 52 941

C/A 8620 Surface 10.6 54 512

C/H 8620 Surface 10.6 60 882

SAE 660 Bronze 70.1 27(HRB) 311+

A Comparison of Galling Resistance

Test method per ASTM D5707-05

Presenter

Presentation Notes

Results are for self-mated tests i.e. GR 1 ADI was tested on GR 1 ADI. 660 Bronze is SIGNIFICANTLY softer than all of the other materials. (The Rockwell B hardness test uses a ball indenter and 27 HRB is too soft to correlate to any reading on the HRC scale.) A comparison between the size of the wear scar for Grade 1 ADI and bronze speaks to this value (comparative wear in a high stress environment). The wear scar on self-mated ADI was ~1 mm2 whereas the self-mated bronze specimen had an average wear scar of 6.5 mm2. Due to the geometry of the specimen tip, the relative volume loss (comparing Gr. 1 and bronze) is much, MUCH greater than 1:6.5.

Heavy Section ADI


How is section size addressed in ADI standards?

• ASTM doesn’t address; • SAE – up to 50 mm (2-inches); • ISO – up to 100 mm (4-inches);


What’s ahead for 2030?

• Inclusion of ADI in materials text books and design databases;

• ADI is a “standard” material; • Thin wall ADI; • Si-Solution Strengthened ADI; • And a lot of other surprises.


Thank You

• Angella Sell and Terry Lusk, Applied Process • Stephen Gladieux and Chad Kelsey • Rob Logan, Catherine Hartung and Doug

White – ELKEM • John Keough and Justin Lefevre, Joyworks LLC • Don Houser and Sam Shon – OSU



• Kathy L. Hayrynen• 12202 Newburgh Rd, Livonia, MI 48150• 734-464-8000• [email protected]• www.appliedprocess.com


RETURN TO DI NEWS

Application of Differential Scanning Calorimetry for the Determination of ADI Service Temperature Limits

Karl WarsinskiSt. Marys Foundry, Inc. / Michigan Technological

University

World Conference on Austempered Ductile Iron, Oct. 27‐28, 2016 The Westin – Peachtree Plaza, Atlanta, GA

Project Background

• ADI for railroad wheels– Lighter– Better wear characteristics– Noise damping

• Limited by on‐tread braking– Steel wheels can fail due to overheating– How does ADI compare?


ADI Stability

• Several studies from mid‐90s through early 2000s– Isothermal aging, dilatometry, XRD, etc.– Limited alloy scope– Conclusion: Don’t approach austempering temperature

• DIS Research Project #28– Low alloy iron– Exposure time = 1000 hours– ADI did not maintain mechanical properties for exposures at T > (Taustemper – 200°F)


Kinetics Groundwork• Effect of treatment parameters

– 5 heat treatments of same composition– Determine effective activation energy (EA) for decomposition via Kissinger method (DSC)

• Alloying effects – Produce and test alloy variations– Can we “move the needle” significantly?– HT#1 used for all alloys*


What is DSC?• Measures temperature differences between a sample and an inert reference during heating


• Deflections/peaks indicate phase changes

• Onset = Start of Transformation

• Peak = Maximum rate

How does this help us?• Peak position shifts

with heating rate when phase changes are thermally activated

• Peak position and heating rate can be used to determine activation energy (EA)


Experimental Alloys


Alloy C Si Ni Cu Mo Co Mn P S Mg

AP‐5506 3.56 2.55 0.02 0.48 <0.01 ‐ 0.28 0.027 0.013 0.034

H151201A 3.52 2.45 1.508 0.46 0.003 ‐ 0.160 0.017 0.005 0.017

H160126A 3.48 2.48 0.041 0.769 0.007 0.011 0.273 0.017 <.001 0.040

H160126B 3.50 2.53 0.045 0.479 0.197 0.010 0.276 0.015 <.001 0.035

H160127A 3.42 2.57 0.045 0.476 0.007 0.466 0.245 0.017 <.001 0.037

H160127B 3.41 2.56 0.054 0.48 0.009 2.359 0.34 0.016 <.001 0.041

Casting Geometry• AP‐5506 – 1” Y‐blocks,

Received in heat treated condition– Samples cut via cooled

abrasive saw, wire EDM

• Michigan Tech alloys – ¾”Ø cylinders, 7.5” tall– Turned to ½”Ø before heat

treating– Turned to sub‐size tensile

samples (1/4” gage, 3/8” grip)– DSC samples machined from

grip end remainder


Heat Treatments

UTS Yield Elongation Austempering

Grade/HT# MPa MPa % Temp. (C) Time (min)

1 900 650 9 382 106

2 1050 750 7 356 135

3 1200 850 4 313 182

4 1400 1100 2 282 217

5 1600 1300 1 260 240

All samples austenitized at 896°C for 122 minutes.


DSC Parameters

• N2 or Ar atmosphere• Vacuum and backfill 3x• Stabilize at 100°C• Ramp from 100‐600°C

– 5, 10, and 20°/min scans

• Alumina crucibles• ~170mg Samples

– (4.5mmØ x 3mm typical)


Analysis


Effect of Treatment Temperature


-11.0-10.8-10.6-10.4-10.2-10.0-9.8-9.6-9.4-9.2-9.0

2 2.1 2.2 2.3 2.4

Ln(ϕ

/T^2

)

1000/Tonset

Grade 1Grade 2Grade 3Grade 4Grade 5

Activation Energy By Treatment Temp.

45

50

55

60

65

70

75

250 300 350 400

Activ

ation En

ergy, K

J/mol

Austempering Temperature, °C


Effect of Alloy Additions(HT#1)


60.00

65.00

70.00

75.00

80.00

85.00

90.00

95.00

0 0.5 1 1.5 2 2.5

Activ

ation En

ergy (K

J/mol)

% Alloy

Ni

Cu

Mo*

Co*

Further WorkNear Term:• Additional scans to improve regressions• Test existing alloys with varying heat treatments

Recommended:• Fill in additional alloy levels• Develop predictive model for activation energy based on composition and heat treatment temperature


AcknowledgementsThis project was supported by the National University Rail (NURail) Center ‐ a

US DOT RITA University Transportation Center

Project ID: NURail2012‐MTU‐R01

Sample ADI (AP‐5506) was provided by Applied Process, Inc.



Karl [email protected]

Paul Sanders, [email protected]


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