ENGINEERING RESEARCH INSTITUTE UNIVERSITY OF MICHIGAN ANN ARBOR RISERING OF DUCTILE CAST IRON PROGRESS REPORT NO. 2 RISER DIMENSIONS, FEEDING D]BTANCE, AND OTHER DATA,^_,.~~P,.. R F' ~FLI' * - *. -~.'~ t, ~ ~... Professor of Chemicai-a`d Metallurgical Engineering and Production Engineering W. A. SPIEND LER Assistant Professor of Production Engineering Project M862 THE INTERNATIONAL NICKEL COMPANY, INC. NEW YCRK, NE YORK May, 1954

/479 4002.. l^ik 12^ f

TABLE OF CONTENTS Page LIST OF FIGURES iii LIST OF TABLES iii I. SUMMARY 1 II. INTRODUCTION 1 III. PROCEDURE 6 A. Melting Practice 6 B. Molding 6 C. Inspection 6 IV, DATA II A, Risering Curve Data 1 B. Effective Feeding Distance Data (Riser Placement) 15 C, Miscellaneous Data 16 V, FUTURE WORK 20 APPENDICES 21 Appendix A Sumnmary of Analyses of all Heats 22 Appendix B Summary of Castings Made Since First Progress Report 23 ii

LIST OF FIGURES Figure Page 1 Risering Curve for Ductile Iron. 2 2a Radiograph Showing Riser Neck Shrinkage (Inadequate Riser Size). 4 2b Radiograph Showing Centerline Shrinkage (Beyond Effective Feeding Distance ). 2e Radiograph Showing Surface Shrinkage (Can be Caused by Inadequate Riser or Exceeding Effective Feeding Distance). 5 3 Castings Used for Determining Risering Curve. 7 4a Bars Used for Determining Effective Feeding Distance. 8 4b Plates Used for Determining Effective Feeding Distance.'9 5 Radiographs Showing Effect of Riser Size on Riser Neck Shrinkage. 10 6 Radiographs Showing Effect of Distance in Centerline Shrinkage.12 7 Technique for Obtaining Cooling Curves for Ductile Iron. 17 8 Cooling Curves of Different Ductile Irons, 18 9 Phase Diagram for Ductile Iron Near Eutectic. 19 LIST OF TABLES Table I 13 Table II 15 Table III 16 iii

ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN RISERING OF DUCTILE CAST IRON PROGRESS REPORT NO. 2 RISER DMENSIONS, FEEDING DISTANCE, AND OTHER DATA I. SUMMARY To obtain a sound ductile-iron casting, two principal factors must be considered, riser size and riser placement. Riser size can be calculated from Fig. 1, which provides both for sufficient feed metal in the riser and for a cooling rate enough slower than that of the casting. Riser placement depends on the effective feeding distance of a riser in a particular casting. The following formulas indicate feeding distance in simple plates and bars; the data may be projected for more complex shapes: For platest Effective feeding distance = 4.5t, where t is the thickness of the plate (applies to 1/4-to 2-inch sections). For bars: Effective feeding distance = 6 \/-, where t is the thickness of the bar (applies to 2-to -inch sections). A bar is considered as such when the width is less than 3t. These data corroborate those of Pellini for cast steel. In the category of miscelleneous data, the eutectic for the ductile irons is shown to lie near 4.4 carbon equivalent and interesting supercooling phenomena are described. II INTRODUCTION When a risering system is improperly designed, shrinkage may be enc.ntered in the casting frm one of the two distinct causes illustrated in -~. -~-~1

1.5 381 38 1.4 ~ ~ ~ ~~~_ _~ ~ 40 7 4 T l|tm | Risering Curve Ductile Iron; Total Carbon 3.6%, 1.3 I Silicon 2.5%/o 43 2-n.-di.X 3 3/4in. costing 1.2 cosg Crosshatched region isthe most 45 t\ \'^ Sefficient area for Risering to _J __ I^ complete soundness; side blind I.9 1 ~ I I I~I risers; clamped greensand molds; 48 SZ 4in. cube casting - gated into Risers, w 1.0 \ 50 Q: o *.9 ~ ~ ~ _ __ 1 _53 8 csi ^ g 2X2X6in csting ~ V 99.8 56 W 00 > > 2X6X91n. casting.7 59 W:>4 |IX3X7in. casting O.6 I I, ~ 63 0 IX4-1/2in. semicircular casting IW I |1/2X2-1/4 in. semicircular casting __l/ A __ Q _id %.5 67 e WLJ I/4 XH-1/8 in. semicircular casting A < O 4 | t | | l | 1 1 1 a} |...71 0.3 __ LEGEN D 77 *Completely sound 2 ______ ORiser shrinkage ~.2 OSurface shrinkage 83 ACenterline shrinkage.1 9~ I I I I 91 0 ___ I100 0.7 0.8 0.9 1.0 1. 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 SAc (COOLING RATE OF CASTING) VC FREEZING RATIO = SAr r (COOLING RATE OF RISER) Vr FIG. I 2

ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN Fig. 2a and bo (1) Riser-neck shrinkage (Fig. 2a) extending into the casting is caused by a riser that is too small. A riser of the proper (.larger) size freezes much later than the casting and delivers an adequate supply of liquid iron to fill the shrinkage voids in the casting* (2) Centerline shrinkage (Fig. 2b) away from the riser cannot, in general, be corrected by an increase in riser size. This type of shrinkage results from an inadequate thermal gradient across the casting. The shrinkage zone is walled off from the riser containing ample liquid metal by the rest of the casting. In the case illustrated, even a tenfold increase in riser size would not produce enough change in the thermal gradient across the entire casting to avoid the uniform solidification pattern which blocks liquid-metal flow from the riser. It is very important to notice that the remedies for these two types of shrinkage are distinctly different. For riser-neck shrinkage alarger- riser is needed, while for centerline shrinkage either an increased number of risers, chill inserts in the mold, or design changes are necessary. For completeness it should be noted that instead of these being shrinkage voids at these locations, the cope surface may be sucked in toward the hot spt by the vaccum at this point; in this case surface shrinkage partly or completely replaces the internal shrinkage. The causes and remedies are the same as those just discussed. Thsis is llustrated in Fig, 2c. The first progress report in risering of ductile iron was largely concerned with riser size and not with the feeding distance. During the past year the data on riser size have been enlarged to include a wider variety of test castings and to determine the conditions necessary for -obtaining radiographically sound castings* In the first report only careful visual inspection of sectioned castings was employed following the work of Caine, but because of the demands of the aircraft industry and others for radiographic soundness this added requirement received study. The principal effort of the year has been directed, however, toward evaluating the effective feeding distance of a riser in ductile iron, Since all castings may be considered as combinations of the simple geometrical shapes, it is logical to determine the feeding distance of risers in bars, plates, and cubes as a guide to proper riser placement in castings. It is evident from inspection that feeding distance in a cube is not a problem, since a cube is merely a very short bar. We will be concerned, therefore, with obtaining a quantitative expression for feeding distance in bars and plates. ___________________________________ 3 ______ —-________________________

Fig. 2a. Radiograph showing riser neck shrinkage (inadequate riser size) Fig. 2b. Radiograph showing centerline shrinkage (beyond effective feeding distance)

4.1~~~~~~~~~~~~~~~~~~~~1 I Differentiations~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~i~!11~',|~~~~~~~~~AD F ig. 2c. Radiograph showing surf ace shrinkage (can be caused by inadequate riser size, or exceeding effective feeding distance )

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN III. PROCEDURE A. Melting Practice The melting practice followed that described in the previous report with the exception that,015% cerium as mischmetal was added with the ferro-silicon addition. "Foundry-grade" Electromet 85% ferrosilicon (1l.5%A1) was generally used as a post-inoculant. It was necessary to break the mischmetal into small pieces. Melts were made in a 200-pound high-frequency induction furnace with a rammed mgnosite lining, heated to 2770*F, inoculated with No. 1 nickel magnesium silicon, reladled for the ferrosilicon addition, and poured at 25002590~F B. Molding 1. Riser Size. The castings used for determination of the risering curve are illustrated in Fig. 3. The dimensions were selected to provide a wide range of cooling rates, 2, Feeding Distance. The various bar and plate castings with risers are illustrated in Figs, 4a and b, and described in the tables of data. Some of these castings also provided data for the risering curve. The greensand molding practice has been described in the previous report. C. Inspection In the previous report the principal criterion of soundness was the careful visual inspection of sections through critical regions. This was more conservative than the technique Caine used in developing risering curves for steel, since the occurence of flowed metal across shrinkage voids during cuitting was minimized by sandblasting of the cut face, However, the increasing demand for radiographically sound castings prompted the use of radiographic inspection of all castings. Since the best sensitivity was obtainable with machined surfaces, the critical sections were cut out of each casting for radiographing as shown by the cross-hatched marks in Figs. 4a and b. The sensitivity is sufficient to disclose defects above 0.010 inch in size in any of the castings made. In Fig, 5 the change in riser-neck shrinkage as riser size is increased is shown by radiographs __________________________________ 6 __________________________________

u~~~~~~~~~mh.Ehhm..mhhI~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~u~~~~~~~~m~~~~~~~~m~~~~~~~~mEE~~~~~~~~~~~~~~~hI ~ ~ ~ ~:.: Fig. 5. Castings used for determining risering curve

:ii~iz~iiiiiiii i!!!i!~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~i~i —!.!!ii ~i —i!!!- i:$~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~1::::] [ Fig, 4a. Bar castings for feeding distance. ~~ i i~'""~'~'~.............~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~i: -_:iir-:i -- Fig. 4a. Bar — ca~~dPstings8~ fo fedigditac

Aw~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~4 Fig. 4b. Plate castings for feeding distance

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ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN In Fig. 6 a typical set of radiographs illustrates the appearance of centerline shrinkage as effective feeding distance is exceeded. IV. DATA The data may be divided into two principal groups for discussion: A, Risering Curve Data affecting riser size, Table I and Figs, 1, 3, and 5. B. Effective Feeding Distance Data affecting riser placement, Table II and Figs. 4 and 6. C, Miscellaneous Data, A. Risering Curve Data The application of the risering curve data shown in Fig. 1 to the calculation of the proper riser size for a given casting has been rather thoroughly discussed in the previous report, In summary, to determine whether a given riser will avoid riser-neck shrinkage in a given casting (or portion of a casting if more than one riser is used): (1) Calculate the freezing ratio of the casting to the riser. Since the cooling rate of either riser or casting is proportioned to the surfacearea / volume ratio, Surface area casting casting ~^^~ ^ ^^S Freezing ratio casting volume riser Surface area r o..f riser volume This must be greater than one for all normal cases, since the cooling rate of the riser must be less than that of the casting in order to have liquid feed metal available* (2) Calculate the volme ratio of riser to casting. In steel the volume of liquid metal in the riser must be at least 3 percent of the casting volume, since 3 percent liquid-to-solid shrinkage takes place. These two values provide the x and y axes of the graph on which the date for a given riser-casting combination indicate a sound or unsound riserneck. Conversely, the graph may be used to select the proper riser size; 11T

M~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ ro Fig. 6 adiographs showing effect of feeding distance on centerline shrinkage

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN several trial-and-error calculations (usually two are sufficient) rapidly estab lish the necessary riser size for soundness. This new graph has been established for radiographic soundness from the data of Table I, as mentioned in the procedure. TABLE I RISERING CURVE FOR 3.690C,?.5 Si DUCTILE IRON (See Appendix Pages Noted 3elow For Other Confirmatory Data) Cstg No. F.R. V.R. a.) 2-in. Dia. x 3-3/4-in, long casting (see page 23) 1 ) 2-3/4-in. Riser - completely sound 352-2 1.15 1.38 2.) 2-5/8-in. Riser - riser shrinkage 355-2 1.11 1.20 b.) 4-in. Cube casting (see page 24) 1.) 4-1/2-in. Riser - completely sound 345-4 1.13 1.12 2,) 4-3/8-in. Riser - riser shrink 348-5 1.10 11)3 c,) 2 x 2 x 6-in. Casting (see pages24 and 25) 1.) 3-in. Riser - completely sound 253-1 1.18.88 2.) 2-7/8-in. Riser - riser shrink 254-6 1.14.78 d,) 2 x 6 x 9-in. Casting (see page 35) 1.) 4-3/4-in. Riser - completely sound 363-1 1.28.78 2.) 4-5/8-in. Riser - surface shrink 364-5 125.72 e.) 1 x 3 x 7-in. Casting (see pages 25 and 26) 1.) 2-5/8-in. Riser - completely sound 256-4 1.32.68 2.) 2-1/2-in. Riser - surface shrink 257-3 1.28.59 f.) 1 x 4-1/2-in. Semicircular Casting (see page 27) 1.) 3-in. Riser - completely sound 422-4 1.41.67 2.) 2-7/8-in. Riser - riser shrink 360-2 1.30.51 g.) 1/2-in. x 2-1.4-in. Semicircular Casting (see page 31) 1.) 1-1.2-in. Riser - completely sound 363-2 1.42.67 2.) 1-3/8-in. Riser - 3/16-in. riser shrink, no centerline shrink 364-2 1.30.51 h.) 1/4-in. x 1-1/8-in. Semicircular Casting (see page 33) 1.) 3/4-in. Riser - completely sound 364-1 1.41.66 i.) 1-in. x 5-in. Semicircular Casting (see page 26) 1,) 2-7/8-in. Riser - centerline shrink 352-3 1.34.48 2.) 2-3/4-in. Riser - surface shrink 355-3 1.29.42 13

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN TABLE I (CONCLUDED) RISERING CURVE FOR 3.6%C, 2.5% Si DUCTILE IRON (See Appendix Pages Noted Below For Other Confirmatory Data) Cstg. No. F.R. V.R. j.) i-in. x 6-in. Semicircular Casting (see page 27) 1.) 3-1/4-in. Riser - centerline shrink 345-2 1.44.48 k.) 1 x 5 x 10-in. Casting (see page 27) 1.) 3-1/8-in. Riser - centerline shrinkage 357-6 1.42.48 1.) 1-in. x 4-1/2-in. x 9-in. Casting (see page 28) 1.) 3-1/4-in. Riser - centerline shrinkage 422-6 1.50.67 m.) 1/2-in. x 2-1/4-in. x 4-1/2-in. Casting (see page 31) 1.) 1-5/8-in. Riser - centerline shrinkage 364-3 1.49.66 n,) 1/2-in. x 2-1/2-in. Semicircular casting (see page 31) 1.) 1-1/2-in. Riser - centerline shrinkage 357-1 1.38 *54 0o) 1/2-in. x 3-in, Semicircular casting (see page 30) 1.) 1-5/8-in. Riser - centerline shrinkage' 348-1 1.43.47 p.) 1/2-in. x 4-in. Semicircular casting (see page 30) 1.) 1-7/8-in. Riser - centerline shrinkage 338-1 1.57.41 q,) 1/h-in. x 1-1/2-in. Semicircular casting (see page 33) 1.) 7/8-in. Riser - centerline shrinkage 363-4 1.54.60 Proper riser-neck dimensions are needed as shown by the following comparison; Effect of Neck Dimensions on Feeding Distances (3.6%C 2,5 Si) a.) 1 x 4-in. Semicircular Casting (see page 26) Cstg* No. F.R. V.R. 1.) 15/16 x 1-7/8 x 15/32-in, neck, 2-3/4-in. Riser; 3/8-in, centerline shrinkage 295-5 1.33.64 2.) 15/16 x 2-3/4 x 15/32-in. neck, 2-3/4-in. Riser; completely sound 325-1 1.34.64 In general, necks of insufficient width have been employed in platelike castings. It should be reemphasized that the above data give only the side riser dimensions needed to avoid riser-neck shrinkage, and do not govern 14_........

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN isolated centerline shrinkage, which is determined by effective feeding distance. Centerline shrinkage is avoided by proper riser placement and will now be discussed. B. Effective Feeding Distance Data (Riser Placement) As mentioned in the introduction, this problem resolves into the question "In a given bar or plate, how far will a riser feed?" It is assumed that the riser is large enough to avoid riser-neck shrinkage as calculated in Section A. To answer this question, bars and plates of different lengths and cross sections were prepared (Figs. 4a and 4b, and Table II). In the following summary, Table II, comparison of these data with those obtained by Pellini for steel is indicated. In general the data are in remarkably good agreement, as predicted in the earlier report. TABJE II FEEDING DISTANCE FOR 3.6%C, 2.5% Si DUCTILE IRON (See Appendix Pages Noted Below For Confirmatory Data) Cstg. No. F.R. V.R. a.) 2 x 2-in. Bar (see pages 33 and 34) 1i) With 4-in. riser, 10-in. length; sound 352-5 1.48 1.26 With 4-in. riser, ll-in. length; unsound 355-4 2.) With 3-in. dia.> 4-in. high riser, 9-in. length; unsound 355-5 1.25.79 b.) 4 x 4-in. Bar (see page 35) 1.) With 7-1/2; x 8-in. riser, 12-in. length; sound 353-1 1.46 1.84 With 7-1/2 x 8-ino riser, 14-in, length; unsound 349-1 c.) 1/2-in. Thick Plate (see pages 32 and 33) 1.) l/.in. x 1-1/8-in. Semicircular casting, sound 364-1 1.41.66 2.) 1/4-in. x 1-1/2-in. Semicircular casting, unsound 363-4 1.54.60 3-) l/4-in. x 1-1/4-in. Semicircular casting, sound 422-1 1.58.86 d.) 1/2-in. Thick Plate (see pages 29, 30 and 31) 1l) 1/2 x 2-1/4-in. Semicircular casting; sound 363-2 1.42.67 2.) 1/2 x 2-1/2-in. Semicircular casting, unsound 357-1 1.38.54 3.) 1/2 x 2-1/4 x 4-1/2-in. casting; unsound 364-3 1.49.66 4.) 1/2 x 4-in. Semicircular casting (3-in. Riser) sound 345-1 2.44 1.69 1/2 x 4-in. Semicircular casting (1-7/8-in. Riser) unsound 338-1 1.57.41 15

ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN TABLE II (CONCLUDED) FEEDING DISTANCE FOR 3.6%C, 2.5% Si DUCTILE IRON (See Appendix Pages Noted Below For Confirmatory Data) Cstg. No. FR. V.R. e.) 1-in, Thick Plate (see pages 25, 26, 27, and 28) 1.) 1 x 4-1/2-in. Semicircular casting; sound 422-4 1.41.67 2.) 1 x 5-ino Semicircular casting; unsound 338-2 1.39 54 3o) 1 x 4-1/2 x 9-in, casting; unsound 422-6 1.50.67 f.) 2-in. Thick Plate (see page 35) 1.) 2 x 6 x 9-ino casting - sound (6-in. Riser) 360-1 1.56 1.58 2 x 6 x 9-in, casting - sound (4-3/4-in. Riser) 363-1 1.42.78 2a) 2 x 6 x 10-ino casting - unsound (6-in. Riser) 359-1 1,54 1.42 With the availability of these data the risering of a given casting employing side blind risers may now be calculated quantitatively. Top risering should receive study in the future. The chemical analyses of all heats are given in Appendix Al and a complete tabulation of all castings made appear in Appendix B. C* Miscellaneous Data During the course of the investigation it seemed advisable to deter:mine the location of the eutectic to make certain that the analyses under study were not hypereutectic and hence subject to graphite flotation. Cooling curves were obtained using the technique illustrated in Fig. 7 for a number of heats. It is evident from Figs. 8a, b, and 9 and Table III that all the irons were hypoeutectic and that the analysis of the ferrosilicon can affect supercooling. TABLE III SUMMARY OF COOLING-CURVE DATA Heat Analysis, % Temperature, ~F Number T.C. Si C.E. Liquidus Eutectic Eutectoid Heats inoculated with foundry-grade 85% ferrosilicon containing approximately 1.50% Al, 0.50% Ca 247 3.53 1.92 4.17 2135 2110 1310 249 3.62 1.98 4.28 2150 2110 1320 253 3.50 2.48 4.33 2115 2110 1335 295 3556 2.51 4.40 none 2120 1350 16

HOT JUNCTION OF THERMOCOUPLE ~:5" D1A 10 % RHODIUM L_____, _____D1A. ~ID L- ~ 5" ~-, FUSED QUARTZ TUBE INSULATING FIRE BRICK Imm I.D0. ~~ ~~I) \2mm 0.D. l / - I Xstl C ACASTING I- i BAKED OIL SAND MOLD FIG. 7. SPECIMEN AND MOLD P FOR COLIN CURVE DET IATIN 17

2300 1I |||CARBON EQUIVALENT 2250 4.17 4.28 4.3 4.40 2250 ~ ^^^ ~ ~r^,~ ~ H-~-INOCULATED WITH 0.55 % SI. ---- WITH 0.75 % SI. 2200 22^0C~Tl ~ T ~ ~ ^ ~~~~PLUS CERIUM 2150,s 2100 2050. \ HEAT 247 \ HEAT 249 \ HEAT 253 \ HEAT 295 2000 - ~19501 —' "' — - 5 MINUTES 19 50 FIG. 8A, COOLING CURVES OF HEATS INOCULATED WITH FOUNDRY-GRADE FERROSILICON. 2300 - -~ - CARBON \ EQUIVALENT 2250 \ 4.21 1 14.21 1 1 4.35 2200 2150 ~~~~ 2100 2050 HEAT 238 HEAT 244 HEAT 236 2000 4000 ~ _____ ~-5 MINUTES 1950 - FIG. 8B. COOLING CURVES OF HEATS INOCULATED WITH LOW-AL FERROSILICON 18

0 ____ ____ _ HEAT NUMBER.. 21540 EAT 2 1T I I I 2140 I'' P LIQUIDUS 2130 OF ^Q2120 __(HEAT 295 "LONLY ONE ARREST 2110 EUTECTIC _ TEMPERATURE EUTECTIC COMPOSITION 210 FOR 3.0" DIA. CYLINDER, 3.0" HIGH 4.10 4.20 4.30 4.40 CARBON EQUIVALENT ( C + SI. ) FIG. 9. COMPOSITE PLOT OF LIQUIDUS AND SOLIDUS TEMPERATURES TO LOCATE EUTECTIC COMPOSITION, AND EUTECTIC TEMPERATURE. 19

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN TABLE III (CONCLUDED) SUMMARY OF COOLING-CURVE DATA Heat Analysis,. Temperatures, ~F Number T.C. Si C.E..Liquidus Eutectic Eutectoid Heats inoculated with lo - aluminum ferrosilicon 236 3,70 1.95 4.35 2105F 2080F 1320F 238 3.60 1,82 4.21 2150 2080 1310 244 3.65 1.68 4.21 2.150 2080 1310 V. FUTURE WORK For further understanding of ductile-iron risering and to insure maximum utility of the data already obtained, the following research seems indicated. (1) Apply these, risering data to test castings under laboratory conditions and evaluation of results. (2) Establish risering curve for top risers, insulated and uninsulated. (3) Determine whether any shift in risering curve or feeding distance is encountered when the ferrosiliconmagnesium.cerium alloy, now in common use, is employed. In general much lower chilling tendency has been noted with this inoculant, and the higher graphitization may decrease shrinkage. (4) Examine risering conditions in very light (1/8-inch) sections such as are encountered in piston rings and other potential automotive uses. 20

APPENDICES

ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN APPENDIX A SUMMARY OF ANALYSES OF ALL HEATS Heat No. T.C. Si Mn P Mg Date Cast 236 3.70 1.95.28.021 June 9, 1953 238 3.60 1,82.25.027 June 12, 1953 244 3,65 1,68.24.027 June 19, 1953 247 3 53 192.27.023 June 25, 1953 249 3.62 1.98.31.026 June 30, 1953 251 3.65 1.83.30.025 July 8, 1953 253 3.50 2.48.22 038 July 20, 1953 254 3.57 2.69 o31,030 July 23, 1953 256 3.44 2.38.24.034 July 28, 1953 295 3.56 2.51.32.035.067 Sept. 11, 1953 325 3.59 2.44.23.040.080 Oct. 23, 1953 338 3.54 2.66.34.013.075 Nov. 12, 1953 345 3.60 2.66.31.013.082 Nov. 19, 1953 348 3.47 2.62.30.042.080 Nov. 27, 1953 349 3.64 2.76.26 o034.090 Nov. 27, 1953 352 3.62 2.58.19.060.080 Dec. 5, 1953 353 3^61 2.45.18.035.070 Dec. 12, 1953 354 3.61 2.46.19.035.080 Dec. 12, 1953 355 3.60 2.59.18.027.090 Dec. 19, 1953 357 3^57 2.41.17.022.070 Jan. 9, 1954 359 3.62 2.51.22.027.110 Jan. 16, 1954 360 3.56 2.38.29.027.070 Jan. 26, 1954 363 3.58 2.69.23.029.090 Feb. 12, 1954 364 3 72 2,70.22.024.080 Feb. 13, 1954 422 3,64 2.72.20.022.084 Apr. 5, 1954 22

ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN APPENDIX B SUMMARY OF CASTINGS MADE SINCE FIRST PROGRESS REPORT High - 3.9C, 2.5 Si Int - 3.6C, 2.5 Si Low - 3.6C, 1.8 Si Riser Neck Heat and Diameter and Dimensions, Restraint Casting Carbon Soundness Height, in. in.. - ~ Number Equivalent 2-in.-Diameter x 3-3/4-in.-Long Casting 2-3/8 1-5/16 half circle Clamped 220-6 Low Riser shrink x 7/16 2-5/8-in. * 2-3/8 1-7/8 half circle Clamped 236-6 Low Riser shrink x 7/16. 2-5/8-in. * 2-1/2 1-7/8 half circle Clamped 238-6 Low Riser shrink x 7/16. 2-1/4-in. * 2-5/8 7/8 x 1-3/4 x 7A6 Clamped 244-6 Low Riser shrink rounded and padded 2-3/16-in. * 2-5/8 7/8 x 1-3/4 x 7A6 Clamped 249-6 Low Uncertain; halves X-rayed 2-3/4 15/16 x 1-7/8 x Clamped 251-6 Low Uncertain; 7/16 halves X-rayed 2-5/8 7/8 x 1-3/4 x 7/16 Clamped 254-5 Int. Centerline rounded and padded shrink 3/8-in. 2-1/2 7/8 x 1-3/4 x 7/16 Clamped 256-6 Int. Centerline rounded and padded shrink 1/4-in. 2-3/4 15/16 x 1-7/8 x Clamped 295-6 Int. Centerline 15/32 shrink 3/16-in. 2-3/4 1 x 2 to 2-3/4 x Clamped 252-2 Int. Completely 3/8 side blind sound; X-ray 2-5/8 1 x 2 to 2-5/8 x Clamped 355-2 Int. 3/16-in. riser 3/8 side blind shrink; X-ray * Heats inoculated with lQw-aluminum ferrosilicon, 23

ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN APPENDIX B (CONTImNED) Riser Neck Heat and Diameter and Dimensions, Restraint Casting Carbon Soundness Height, in. in. Number Equivalent 4-in.-Cube Casting 4-3/8 1-7/16 x 2-7/8 x Clamped 220-7 Low Riser shrink 11/16 2-13/16-in. * 4-3/8 1-7/16 x 2-7/8 x Clamped 236-7 Low Riser shrink 11/16 1-1/4-in. * 4-1/2 1-1/2 x3 x 3/4 Clamped 238-7 Low Surface shrink at neck * 4-1/2 1-1/2 x 3 x 3/4 Clamped 244-7 Low Surface shrink at neck * 4-1/2 1-1/2 x 3 x 3/4 Clamped 295-7 Int. Surface shrink 1/8-in. 4-1/2 1-1/2 x 3 x 3/4 Clamped 325-4 Int. Surface shrink 4-5/8 1-5/8 x 3-1/8 x Clamped 338-4 Int. Surface shrink 3/4 4-1/2 2 x 4 x 3/4 Clamped 345-4 Int. Completely sound; X-ray 4-3/8 2 x 4 x 3/4 Clamped 348-5 Int. Riser shrink 5/8-in.; X-ray 2 x 2 x 6-in. Casting 3-1/8 1-1/16 x 2-1/8 x Clamped 220-5 Low Riser shrink 17/32 13/16-in. * 3-1/8 1-1/16 x 2-1/8 x Clamped 236-5 Low Riser shrink 17/32 1-3/16-in. * 3-1/4 1-1/16 x 2-1/8 x Clamped 238-5 Low Surface shrink 17/32 1/32-in. * 3-1/8 1-1/16 x 2-1/8 x Clamped 249-5 Low Uncertain 17/32 ~ Heats inoculated with low-aluminum ferrosilicon. ___________________________________ 24 _____________

ENGINEERING RESEARCH INSTITUTE -UNIVERSITY OF MICHIGAN APPENDIX B (CONTINUED) Riser Neck BIHeat and Diameter and Dimensions, Restraint Casting Carbon Soundness Height, in. in, Number Equivalent 3 1 x 2 x 1/2 Clamped 253-1 Int. Completely sound; X-ray 3-1/8 1-1/16 x 2-1/8 Clamped 253-2 Int. Not inspected x 17/32 2-7/8 1 x 2 x 1/2 Clamped 254-6 Int. Riser shrink 3/8-in. 3 1 x 2 x 1/2 End Clamped 325-2 Int. Centerline Blind shrink 1.0 in. 1 x 3 x 7-in, Casting 2-1/2 7/8 x 1-3/4 x Clamped 220-4 High Riser shrink 7/16 1-1/8-in. * 2-1/2 7/8 x 1-3/4 x Clamped 236-4 High Riser shrink 7/16 1-1/16-in. * 2-5/8 7/8 x 1-3/4 x Clamped 238-4 Low Riser shrink 7/16 1-1/16-in. * 2-3/4 15/16 x 1-7/8 x Clamped 244-5 Low Riser shrink 15/32 1.0-in. * 2-3/4 15/16 x 1-7/8 x Clamped 251-5 Low Completely 15/32 sound; X-ray 2-5/8 7/8 x 1-3/4 x Clamped 249-4 Low Riser shrink 7/16 1-1/4-in.; X-ray 2-1/2 7/8 x 1-3/4 x Clamped 247-4 Low Riser shrink 7/16 1-3/4-in. X-ray 2-1/2 7/8 x 1-3/4 x Clamped 254-4 Int. Riser shrink 7/16 1-3/16-in.; X-ray *Heats inoculated with low-aluminum ferrosilicon. 25

ENGINEERING RESEARCH INSTITUTE UNIVERSITY OF MICHIGAAN APPENDIX B (CONTINUED) Riser Neck Heat and Diameter and Dimensions, Restraint Casting Carbon Soundness Height, in. in. Number Equivalent 2-5/8 7/8 x 1-3/4 x Clamped 256-4 Int. Completely sound 7/16 9x9 Flask X-ray 2-5/8 7/8 x 1l3/4 x Clamped 256-5 Int. Completely 7/16 13 x 13 sound; X-ray Flask 2-1/2 1 x 2-1/2 x 3/8 Clamped 257-3 Int. 1/16-in. surface 9x9 Flask shrink I x 4-in. Semicircular Casting 2-3/4 15/16 x 1-7/8 Clamped 295-5 Int. fRiser zone 1-1/4 x 15/32 in. Centerline shrink 3/8-in) X-ray 2-3/4 15/16 x 2-3/4 Clamped 325-1 Int. Completely x 15/32 sound; X-ray 1 x 5-in. Semicircular Casting 3 1 x 3 x 1/2 lamped 338-2 Int. (Riser zone 5/8in. Centerline 1-3/4 in3 X-ray 2-7/8 1 x 2-7/8 x 7/16 Clamped 352-3 Int. (Riser zone 1-1/4 in. Centerline shrink 5/8-inj X-ray 2-3/4 1 x 2-3/4 x 7/16 Clamped 355-3 Int. Riser zone 1-1/2 in, Centerline 3/8-in, surface shrink 3/32-in. 2-7/8 1 x 2-7/8 x 3/8 Weighted 357-4 Int. Surface shrink 3/32-in. 2-7/8 i x I to 2-7/8 Clamped 357-5 Int. Riser zone 1-1/4 x 3/8 Knock-off in. Centerline shrink 5/8-in. 26

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN APPENDIX B (CONTINUED) Riser Neck Heat and Diameter and Dimensions Restraint Casting Carbon Soundness Height, in. in. Number Equivalent 1 x 6-in, Semicircular Casting 3-1/4 1 x 3-1/4 x 9/16 Clamped 345-2 Int. Riser zone 11/2-in. Centerline shrink 13/4-in] X-ray 1 x 5 x 10-in. Casting 3-1/8 I x 3-1/8 x 3/8 Clamped 357-6 Int. Riser zone 1-1 in. Centerline shrink 1.0 inf X-ray 1 x 4-1/2-in. Semicircular Casting 2-7/8 1 x 2-7/8 x 3/8 Clamped 360-2 Int. 5/16-in. Riser shrink 3 1 x 3 x 3/8 Clamped 363-3 Int. Surface shrink due to too thick gate, riser froze over, not X-rayed 3 1 x 3 x 3/8 Clamped 364-4 Int. 9/16-in. Riser zone 1/16-in. Centerline slrink Atmospheric pressure core failed. 3 1 x 3 x 3/8 Clamped 422-3 Int. Surface shrink (Riser froze over) 3 1 x 3 x 3/8 Clamped 422-4 Int. Completely sound 3 1 x 3 x 3/8 Weighted 422-5 Int. Riser zone 5/8in; Centerline 3/8-in. 3-1/8 1 x 3 x 3/8 Clamped 422-2 Int. Not inspected *7

ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN APPENDIX B (CONTINUED) Riser Neck Heat and Diameter and Dimensions, Restraint Casting Carbon Soundness Height, in. in. Number Equivalent 1 x 4-1/2 x 9-~n.: Casting 3-1/4 1 x 3-1/4 x 3/8 Clamped 422-6 Int. Riser zone 1-in. Centerline 1/8in. 3/4 x 4 x 7-in. Casting 2-1/8 3/4 x 1-1/2 x Clamped 220-3 High Riser shrink 13/8 1/2-in. Surface shrink 3/32-in.* 2-1/8 3/4 x 1-1/2 x Clamped 236-3 High Riser shrink 13/8 3/4-in. Surface shrink 3/64-in.* 2-1/4 3/4 x -1/2 x Clamped 238-3 Low Riser shrink 13/8 7/8-in. * 2-3/8 13/16 x 1-5/8 x Clamped 244-4 Low Riser shrink 113/32 15/16-in. Surface shrink 3/64 in. * 2-./k 3/4 x 1-1/2 x Clamped 247-3 Low Riser shrink 3/8 3/8-in. 2-3/8 13/16 x 1-5/8 x 13/32 Clamped 249-3 Low Centerline padded shrink; X-ray 2-1/2 7/8 x 1-3/4 x Clamped 251-3 Law Completely 7/16 padded sound; X-ray 2-1/2 3/4 x 1-3/4 x Clamped 251-4 Low Centerline 7/16 shrink; X-ray 2-1/4 3/4 x 1-1/2 x Clamped 254-3 Int. Riser zone 1 in. 3/8 Centerline shrink; X-ray *Heats inoculated with low-aluminum ferrosilicon. __________________________________ 28

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN APPENDIX B ( CONTINUED) Riser Neck Heat and Diameter and Dimensions, Restraint Casting Carbon Soundness Height, in. in. Number Equivalent 2-3/8 13/16 x 1-5/8 Clamped 256-3 Int. Riser zone 1-1/2 x 13/32 padded in.; X-ray Less centerline than 254-3 3/4 x 4-in. Semicircular Casting 2-3/8 3/4 to 13/16 x Clamped 295-4 Int. Riser zone 9/161-5/8 x 13/32 in.; X-ray Centerline shrink 15/16-in. 2-3/8 3/4 x 2-3/8 x Clamped 357-2 Int. ~Riser zone 2.0 5/16 in. Centerline 1/2-in} X-ray. 1/2 x 4 x 7-in. Casting 1-5/8 1/2 x 1-1/8 x Clamped 220-2 High Unsound * 1/4 1-5/8 1/2 x 1-1/8 x Clamped 236-2 High Centerline 1/4 shrink * 1-3/4 1/2 x 1-1/8 x Clamped 238-2 Low Centerline 1/4 shrink * 1-7/8 5/8 x 1-1/4 x Clamped 244-2 Low Centerline 5/16 shrink * 1-5/8 9/16 x 1-1/8 x Clamped 247-2 Low Riser shrink 9/32 padded 1/2-in. into casting 1-3/4 9/16 x 1-1/8 x Clamped 249-2 Low Riser zone 19/32 padded 1/4-in. Centerline 13/16-in. 1-7/8 5/8 x 1-1/4 x Clamped 251-2 Low Slight cente-Line 5/16 padded shrink; X-ray *Heats inoculated with low-alminum ferrosilicon. 29___________________

ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN APPENDIX B (CONTINUED) Riser Neck Heat and Diameter and Dimensions, Restraint Casting Carbon Soundness Height, in, in. Number Equivalent 1-3/4 5/8 x 1-1/4 x Clamped 254-2 Int. Centerline 5/16 padded shrink; X-ray 1-7/8 5/8 x 1-1/4 x Clamped 256-2 Int. Centerline 5/16 padded shrink; X-ray 1/2 x 4-in, Semicircular Casting 1-7/8 1/2 to 5/8 x Clamped 295-3 Int. (Riser zone 11-1/4 x 5/16 5/8-in. Centerline 3/4-in. X-ray 1-7/8 1/2 x 1-7/8 x Clamped 338-1 Int. fRiser zone 15/16 3/4-in. Centerline 3/4-in3 X-ray 3 1/2 x 3 x 5/16 Clamped 345-1 Int. Completely sound; X-ray 1/2 x 3-in. Semicircular Casting 1-5/8 1/2 x 1-5/8 x Clamped 348-1 Int. CRiser zone 1-in. 7/32 Centerline 1/4inj X-ray 1-5/4 1/2 x 1-3/4 x Clamped 352-1 Int. (Riser zone 7/87/32 in. Centerline 3/8-in3 X-ray * 1-3/4 1/2 x 1-3/4 x Clamped 355-1 Int. {Riser zone 7/87/32 in. Centerline 1/2-in3 X-ray ** *Inoculated with 0.75% Si. **Inoculated with 0.55% Si. 30

ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN APPENDIX B (CONTINUED) Riser Neck Heat and Diameter and Dimensions Restraint Casting Carbon Soundness Height, in.. in.. Number Equivalent 1/2 x 2-1/2-in. Semicircular Casting 1-1/2 1/2 x 1-1/2 x Clamped 357-1 Int. Riser zone 9/169/32 in, Centerline shrink 7/16-in3 X-ray 1/2 x 2-1/4-in. Semicircular Casting 1-1/2 1/2 x 1-1/2 x Clamped 363-2 Int. Completely 1/4 sound 1-3/8 1/2 x 1-3/8 x Clamped 364-2 Int. 3/16-in. Riser 1/4 shrink no cen- terline shrink 1/2 x 2-1/4 x 4-1/2-in. Casting 1-5/8 1/2 x 1-5/8 x Clamped 364-3 Int. 3/4-in. Riser 1/4 zone; 3/16-in. centerline 3/8 x 4 x 7-in. Casting l-1/4 3/8 x 7/8 x 3/16 Clamped 220-1 High Riser plus centerline shrink 1-5/8-in. into casting * 1-1/4 3/8 x 7/8 x 3/16 Clamped 236-1 High Riser zone 1/2in. Centerline 2-3/8-in. * 1-3/8 3/8 x 7/8 x 3/16 Clamped 238-1 Low Sound riser zone with centerline shrinkage * 1-1/2 1/2 x 1 x 1/4 Clamped 244-1 Low Sound riser zone padded. with centerline shrink * *Heats inaculated with low-aluminum ferrosilicon.....___..__ ________________________ 3.1 _____ ____________________________31

ENGINEERING RESEARCH INSTITUTE * UNIVERSITY OF MICHIGAN APPENDIX B (CONTINUED) Riser Neck He at and Diameter and Dimensions, Restraint Casting Carbon Soundness Height in, in. Number Equivalent 1-1/4 7/16 x 7/8 x Clamped 247-1 Low Riser shrink 7/32 padded 9/16-in. into casting 1-3/8 7/16 x 7/8 x Clamped 249-1 Low Sound riser zone 7/32 with centerline shrink; X-ray 1-3/8 1/2 x 1 x 1/4 padded Clamped 254-1 Int. Sound riser and edge zones with centerline shrink; X-ray 1-1/2 1/2 x 1 x 1/4 Clamped 256-1 Int. Sound riser and padded edge zones with centerline shrink; X-ray 3/8 x3 x 6-in. Casting 1-1/2 1/2 x 1 x 1/4 Clamped 244-3 Lw Sound riser and padded edge zones with centerline shrink * 3/8 x 4-in. Semicircular Casting 1-5/8 3/8 to 9/16 x Clamped 295-2 Int. {Riser zone 11-1/8 x 9/32 3/8-in. Centerline 1-1/2-inj X-ray 1/4 x 4 x 7-in. Casting 1 3/8 x 3/4 x Clamped 251-1 Low Riser zone 3/43/16 padded in. Centerline shrink 2-11/16in. X-ray *Heats inoculated with low-aluminum ferrosilicon. 32

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN APPENDIX B (CONTINUED) Riser Neck Heat and Diameter and Dimensions, Restraint Casting Carbon Soundness Height, in. in. Number Equivalent 1/4 x 4-in. Semicircular Casting 1-1/4 1/4 to 7/16 X Clamped 295-1 Int. Riser zone 17/8 x 7/32 3/8-in. Centerline shrink 21/8-in. X-ray 1/4 x 1-1/2-in. Semicircular Casting 7/8 1/4 x 7/8 x 3/16 Clamped 363-4 Int. Riser zone 3/16in. Centerline shrink 7/16-in, 1/4 x 1-1/8-in. Semicircular Casting 3/4 1/4 x 3/4 x 3/16 Clamped 364-1 Int. Completely sound 1/4 x 1-1/4-in. Semicircular Casting 7/8 1/4 x 7/8 x 3/16 Clamped 422-1 Int. Completely soun 2 x 2 x 8-in. Casting 4 1-3/8 x 2-3/4 x Clamped 254-7 Int. Completely sound; 11/16 padded X-ray 4 2 x 2 to 2-3/4 x 11/16 Clamped 338-3 Int. Atmospheric pressure. core broke, riser froze over, surface shrink. 4 2 x 2 to 2-3/4 Clamped 345-3 Int. Completely x 11/16 sound; X-ray 2 x 2 x 9-in. Casting 3-in. Dia. 2 x 2 x 0 Clamped 251-7 Low Unsound 3-3/4-in. High (open) 33

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN APPENDIX B (CONTINUED) Riser Neck Heat and Diameter and Dimensions, Restraint Casting Carbon Soundness Height, in. in. Number Equivalent 4 2 x 2 to tan- Clamped 348-4 Int. Completely gent x 11/16 sound; X-ray Mold tilted 4 2 x 2 to tan- Clamped 352-4 Int. Completely gent x 11/16 sound; X-ray 3-in. Dia. 2 x 2 to tan- Clamped 355-5 Int. Riser zone 44-in. Lgki gent x 9/16 1/8-in. Center(Blind) line 3/8- in. X-ray 2 x 2 x 10-in. Casting 4 1-3/8 x 2-3/4 Clamped 256-7 Int. Completely x 11/16 padded sound; X-ray 4 1-3/8 x 2 to 2- Clamped 325-3 Int. (Riser zone 33/4 x 11/16 3/8-in. Centerline shrink 31/2-in3 X-ray 4 2 x 2 to tan- Clamped 352-5 Int. Completely gent x 11/16 sound; X-ray 2 x 2 x 11-in. Casting 4 2 x 2 to tan- Clamped 355-4 Int. Riser zone 5-in. gent x 11/16 Centerline shrink 1/4-in.} X-ray 2 x 2 x 12-in. Casting 4 1-3/8 x 2-3/4 Clamped 253-4 Int. {Riser zone 4x 11/16 padded 7/8-in. Centerline 3-5/8-inJ X-ray 2 x 2 x 14-in. Casting 4 1-3/8 x 2-3/4 Clamped 253-3 Int. -Riser zone 5-1/2 x 11/16 padded in. Centerline 34 4-15/16-inX- y

ENGINEERING RESEARCH INSTITUTE ~ UNIVERSITY OF MICHIGAN APPENDIX B (CONCLUDED) Riser Neck Heat and Diameter and Dimeonions, Restraint Casting Carbon Soundness Height, in, in. Number Equivalent 4 x 4 x 14-in. Casting 7-1/2-in, 4 x 4 to tan- Clamped 349-1 Int. {Riser zone 6Dia.8-in. gent x I 1/4-in. CenterHigh line shrink 2l/4-in3 X-ray 4 x x 12-in. Casting 7-1/2-in. 4 x 4 to tan- Clamped 353-1 Int. Completely Dia. 8-in, gent x 1 soundl X-ray of High 3/4-in, thick center slice. 2 x 6 x 12-in. Casting 6 2 x 6 x 5/8 Clamped 354-1 Int. {iser zone 33/4-in. Centerline 1-1/4-inj X-ray 2 x 6 x 10-in. Casting 6 2 x 6 x 5/8 Clamped 359-1 Int. (Riser zone 0.0in. Centerline shrink 7-3/4-in3 X-ray 2x 6 x 9-in. Casting 6 2 x 6 x 5/8 Clamped 360-1 Int. Completely sound; X-ray 4-3/4 2 x 4-3/4 x 5/8 Clamped 363-1 Int. Completely sound 4-5/8 2 x 4-5/8 x 5/8 Clamped 364-5 Int. Surface shrink.... 3~...............________

UNIVERSill Y OF MIWHIAN 3 9015 02826 3146