Modeling and Simulation of the Gray-to-White Transition during Solidification of a Hypereutectic Gray Cast Iron: Application to a Stub-to-Carbon Connection Used in Smelting Processes

Abstract

This work reports on experimental and numerical results of the gray-to-white transition (GWT) during solidification of a hypereutectic gray cast iron (GCI) in a casting test using a stub-to-carbon (STC) connection assembly. Since in this process non-uniform cooling rates are produced, the mechanical properties are expected to spatially vary due to the development of different microstructures along the thimble. The twin aims of this work were to (1) experimentally validate the GWT prediction capabilities of the microstructural model proposed earlier by the authors in the rodding process of a hypereutectic GCI-STC, and (2) estimate, from the numerically obtained microstructure and ultimate tensile strength (UTS), the local hardness of the alloy after the numerical predictions of the microstructure were experimentally validated. To this end, the final microstructure at different points of the thimble and the hardness profile along its radial direction were measured for validation purposes. Moreover, this rodding process was simulated using an extension of a thermal microstructural model previously developed by the authors and the GWT was superimposed on that simulation. The computed results encompass cooling curves, the evolution of gray and white fractions, eutectic radii and densities and, in addition, the hardness profile. A detailed discussion of the experimental and numerical results is presented. Finally, the computed GWT was found to adequately reproduce the experimental data.