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The aim of the project is to establish an innovative strength verification for the use of components made of ausferritic cast iron with nodular graphite (ADI), in which the locally acting stresses determined from geometry and external loads are compared with the local strengths present in the component and evaluated in a damage calculation. In cooperation with the Institute of Mechanical Plant Engineering and Structural Durability (IMAB) at Clausthal University of Technology, thick-walled components and components with large wall thickness transitions made of ADI are to be characterized with regard to their microstructure, quasi-static and cyclic properties. The local microstructures in ADI components are to be predicted using process simulation and, for the first time, a material model is to be created by selecting suitable microstructure parameters, which allows the local fatigue strength in the component to be predicted. As a result, even incompletely ausferritized components with inhomogeneous microstructures can be evaluated with regard to their fatigue strength. The results of the microstructure and property simulation are linked to the post-processor for service life estimation.
The direct benefit is that the concept and the tools created for it enable SMEs in particular with one-off productions and small series to evaluate the fatigue strength of components despite inhomogeneous microstructures without experimental effort. The service life concept can significantly reduce the time and cost of component development and optimize component geometries in a targeted manner towards lightweight construction. The possible reduction in the use of expensive alloying elements such as nickel or molybdenum, particularly in the manufacture of thick-walled components, can not only save material costs of up to 30%, but also avoid grain boundary increases caused by Mo and thus achieve improved mechanical properties. The competitiveness of components made of ADI is thus increased compared to its alternatives, allowing existing business areas to be expanded.
Duration: 01.01.2021 - 30.04.2023
Project partner:
- Institute for Mechanical Plant Engineering and Structural Durability at Clausthal University of Technology
- Iron foundry Hans Dhonau e.K.
- Josef Brechmann GmbH & Co. KG
- Buchholz & Cie. foundry GmbH
- Kessler & Co. GmbH Leipzig
- RWP GmbH
- Magna International Inc.
- ADI Technik GmbH
- Roll foundry & chilled casting plant Quedlinburg GmbH
- Hawle Guss GmbH
Funding: Federal Ministry for Economic Affairs and Energy
Responsible: Patrick Lachart
