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RECOMMENDATIONS FOR OBTAINING SAMPLES OF CASTING PARTS – MECHANICAL CHARACTERISTICS
RECOMMENDATIONS
FOR OBTAINING
SAMPLES OF
CASTING PARTS –
MECHANICAL
CHARACTERISTICS
15/04/2013 Rev.: 01
FUNDICIONES FUMBARRI-DURANGO
RECOMMENDATIONS FOR OBTAINING SAMPLES OF CASTING PARTS – MECHANICAL CHARACTERISTICS
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RECOMMENDATIONS FOR OBTAINING SAMPLES OF CASTING PARTS – MECHANICAL CHARACTERISTICS
Table of Contents
1. INTRODUCTION .................................................................................... 2
2. TERMS & DEFINITIONS ......................................................................... 2
3. UNE-EN 1561:2011 “FOUNDING – GREY CAST-IRONS” ......................... 3
4. UNE-EN 1563:2011 “FOUNDING – SPHEROIDAL GRAPHITE CAST-IRONS” ................................................................................................... 8
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1. INTRODUCTION
This manual has been put together to clarify the methods that should be used to
obtain samples of material (commonly known as specimens), representing the cast
parts’ mechanical and metallographic characteristics, whether Grey or Spheroidal
casting.
The material’s mechanical characteristics can be assessed in machined specimens
made from: independent samples, samples attached to the part, samples included
in the part and/or samples cut from the part.
Due to the size and type of the parts cast at Fumbarri, whenever a material’s
mechanical characteristics are going to be assessed, we recommend you use the
samples included in the part, as they are the ones that best represent the parts’
characteristics.
There are currently two standards that set the methodology for defining samples,
and these standards are as follows: UNE-EN 1561:2011 “Founding - Grey Cast-
irons” and UNE-EN 1563:2011 “Founding – Spheroidal Graphite Cast-irons”.
2. TERMS AND DEFINITIONS
- Casting sample: An amount of cast material that represents the casting
material, including independent samples, attached samples and samples
included in the part. The specimen to be tested will be obtained from these
samples through machining.
- Independent samples: Sample cast in an independent sand mould under
the representative manufacturing conditions and type of material.
- Sample attached to the part: Sample cast in the mould along with the
part, with a common filling system.
- Sample included in the part: Sample that is directly joined to the casting
part. At Fumbarri we recommend this system to obtain samples.
- Deciding wall thickness: The wall thickness that is representative of the
casting parts, and which is defined by determining the size of the casting
samples for which the mechanical properties are applied.
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3. UNE-EN 1561:2011 “Founding – Grey Cast-irons”
3.1 Tensile and HB hardness characteristics of grey cast-iron, measured in
machined specimens using casting samples. NAME OF MATERIAL DECIDING WALL THICKNESS mm
Minimum Tensile
Strength MPa
HB Hardness Symbolic Numerical > ≤
EN-GJL-250 (GG25)
5.1301
50 100 220
160 to 220
100 200 200
*
EN-GJL-300 (GG30)
5.1302
50 100 260
180 to 240
100 200 240
*
* For deciding wall thicknesses of t>100mm, the casting types are not classed according to their hardness. As the
deciding thickness increases, the hardness decreases. For further details on hardness, please see the UNE-EN 1561:2011
standard “Founding – Grey Cast-irons”.
3.2 Definition of samples for tensile testing DECIDING WALL THICKNESS mm Type 1 Sample
included in part
See Figure 1
Diameter of the tensile specimen > ≤
50 100 30 mm (A)
20
100 200 50 mm (B)
32
Figure 1. Type 1 - Sample included in the part:
A
B
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3.3 Additional information on the mechanical and physical characteristics of
the casting samples with a crude casting diameter of 30 mm.
Characteristic Symbol SI Unit
Name of material
EN-GJL-250 EN-GJL-300
Tensile strength Rm MPa 250 to 350 300 to 400
Conventional yield strength at 0.1% Rp0.1 MPa 165 to 228 195 to 260
Lengthening A % 0.8 to 0,3 0.8 to 0.3
Compressive strength MPa 3.01 x Rm
2.87 x Rm
Conventional yield strength at 0.1% compression
MPa 325 390
Bending strength MPa 1.66 x Rm 1.60 x Rm
Shear strength MPa 290 345
Torsional strength MPa 1,36 x Rm
Modulus of elasticity E GPa 103 to 118 108 to 137
Poisson’s Ratio V - 0.26
Flexural fatigue strength MPa 0.46 x Rm
Repeated alternate tensile / compression strength
MPa 0.34 x Rm
Torsional fatigue strength MPa 0.38 x Rm
Fracture toughness KIc MPa.m1/2 20 19
Density P t/m3 7.2 7.3
Specific heat capacity Between 20ºC and 200ºC Between 20ºC and 600ºC
C J/(kg.K) 460 535
Linear expansion coefficient Between -100ºC and + 20ºC Between 20ºC and 200ºC Between 20ºC and 400ºC
α µm/(m.K)
10.0 11.7 13.0
Thermal conductivity At 100ºC At 200ºC At 300ºC At 400ºC At 500ºC
A
W/(m.K)
48.5 47.5 46.5 45.0 44.5
47.5 46.0 45.0 44.0 43.0
Resistivity P Ω.mm2/m 0.73 0.70
Coercitivity H0 A/m 560 to 720
Maximum permeability µ µH/m 220 to 330
Loss due to hysteresis at B=1T J/m3 2500 to 3000
1 MPa equals 1 N/mm2
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3.4 Placing the sample in the part
The sample will be stuck to the model, on the working side, and in a
horizontal position (good side). It should never be placed on the bottom
of the bases or inside the drawers, or in a vertical position, as the
material’s characteristics can be altered by the mould filling process.
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3.5 Errors in samples
For Grey Cast-iron, only the geometry of the previously shown sample
should be applied, as otherwise the specimen obtained will not be
representative of the material’s characteristics. A common error is to
use samples for Spheroidal Cast-iron in Grey Cast-iron.
ERROR: Spheroidal casting specimen placed on a Grey casting base.
It is a common error to place samples inside the drawers or in a vertical position.
This should be avoided, as the filling process or the residue deposits from the
polystyrene combustion are left inside the specimens, making them invalid for the
purpose in question, which is to represent the part's characteristics and its
deciding thickness.
ERROR: Spheroidal casting specimen placed on a Grey casting base, inside a
drawer.
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ERROR: Spheroidal casting specimen placed on a Grey casting base, in a vertical
position.
4. UNE-EN 1563:2011 “Founding – Spheroidal Graphite Cast-irons”
4.1 Tensile and HB hardness characteristics of spheroidal cast-iron,
measured in machined specimens using casting samples.
NAME OF MATERIAL DECIDING WALL THICKNESS mm
CONVENTIONAL YIELD STRENGTH
AT 0.2% Rp0.2 MPa Min.
TENSILE STRENGTH
Rm MPa Min.
LENGTHENING A %
Min.
HARDNESS HB
Symbolic Numerical > ≤
EN-GJS-400-18-LT (GGG40.3) LOW TEMPERATURE
5.3103 30 60 230 380 15
130 to 175 60 200 220 360 12
EN-GJS-400-18 (GGG40.3) AMBIENT
TEMPERATURE
5.3105
30 60 250 390 15
60 200 240 370 12
EN-GJS-400-15 (GGG40)
5.3106 30 60 250 390 14
135 to180 60 200 240 370 11
EN-GJS-500-7 (GGG50)
5.3200 30 60 300 450 7
170 to 230
60 200 290 420 5 150 to 230
EN-GJS-600-3 (GGG60)
5.3201 30 60 360 600 2
190 to 270
60 200 340 550 1 180 to 270
EN-GJS-700-2 (GGG70)
EN-GJS-700-2-L (GGG70L)*
5.3300 30 60 400 700 2
225 to 305
60 200 380 650 1 210 to 305
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4.2 Definition of samples for tensile testing DECIDING WALL THICKNESS mm Type of Sample
included in the part
See Figure 5
Diameter of the tensile specimen
> ≤
30 60 C 14
60 200 D 14
TYPE OF SAMPLE
DECIDING THICKNESS
OF THE PART
a b
Max. C
Min. h
Lt
C 30 to 60 40 30 20 40 to 65 150
D 60 to 200 70 52.5 35 65 to 105 150
Figure 5. Samples included in the part - Types C & D
Part
D
C
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4.3 Additional information about the characteristics of spheroidal casting.
Characteristic Unit EN-GJS-400-18 EN-GJS-500-7 EN-GJS-600-3 EN-GJS-700-2
EN-GJS-700- 2L
Shear strength MPa 360 450 540 630
Torsional strength MPa 360 450 540 630
Modulus of elasticity E (tensile & compressive
strength) GN/m2 169 169 174
176
Poisson’s Ratio v ----- 0.275 0.275 0.275 0.275
Fatigue limit (rotating bending) without notch
(Ø10.6 mm) MPa 195 224 248
280
Fatigue limit (rotating bending) with notch (f10.6
mm) MPa 122 134 149
168
Compressive strength MPa 700 800 870 1000
Fracture toughness MPa.√ 82 63 38 30
Thermal conductivity at 300ºC
W/(K.m) 36.2 35.2 32.5 31.1
Specific heat capacity from 20ºC to 500ºC
J/(kg.K) 515 515 515 515
Linear expansion coefficient from 20ºC to 400ºC
µm/(m.K) 12.5 12.5 12.5 12.5
Density Kg/dm3 7.1 7.1 7.2 7.2
Maximum permeability µH/m 2136 1596 866 501
Loss due to hysteresis J/m3 600 1345 2248 2700
Resistivity µΩ.m 0,50 0.51 0.53 0.54
Main mould structure Ferrite Ferrite-Pearlite Pearlite-Ferrite Pearlite
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4.4 Placing the sample in the part
The sample will be stuck to the model, on the working side, and in a
horizontal position (good side). It should never be placed on the bottom
of the bases or inside the drawers, or in a vertical position, as the
material’s characteristics can be altered by the mould filling process.
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4.5 Errors in samples
For Spheroidal Cast-iron, only the geometry of the previously shown
sample should be applied, as otherwise the specimen obtained will not
be representative of the material’s characteristics.
Never place the samples inside the drawers or in a vertical position, as
the residue deposits from the polystyrene combustion would be left in
the specimens, altering the material’s characteristics.
Samples stuck to copies or profiles should not be placed, as this would
cause hot spots that may lead to contraction defects (shrinkages).
ERROR: Specimen placed in the part’s vertical position and in the profiling zone.
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ERROR: Specimen placed in a vertical position and inside a drawer.
ERROR: The sample is not according to standard measurements and is placed in the
profiling zone.
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ERROR: The sample is placed in the copy zone.
ERROR: The sample is placed in the copy zone. Signed:
Ignacio Martínez Del Agua
Quality Manager
Fundiciones Fumbarri-Durango