PSI - Issue 18

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2019) 000–000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2019) 000–000

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

ScienceDirect

Procedia Structural Integrity 18 (2019) 46–62

25th International Conference on Fracture and Structural Integrity Assessment of the fatigue strength of thick-walled nodular cast iron with Dross Christoph Bleicher* a , Rainer Wagener a , Heinz Kaufmann a , Ralf Tschuncky b , Fabian Weber b , Philipp Hettich c , Steffen Buchmüller c , Hans W. Berg c a Fraunhofer Institute for Structural Durability and System Reliability LBF, Bartningstrasse 47, 64289 Darmstadt, Germany 25th International Conference on Fracture and Structural Integrity Assessment of the fatigue strength of thick-walled nodular cast iron with Dross Christoph Bleicher* a , Rainer Wagener a , Heinz Kaufmann a , Ralf Tschuncky b , Fabian Weber b , Philipp Hettich c , Steffen Buchmüller c , Hans W. Berg c a Fraunhofer Institute for Structural Durability and System Reliability LBF, Bartningstrasse 47, 64289 Da stadt, Germany b Fraunhofer Institute for Nondestructive Testing IZFP, Campus E3 1, 66123 Saarbrücken, Germany c BMB Gesellschaft für Materialprüfung mbH, Wannenäckerstrasse 63/1, 74078 Heilbronn, Germany b Fraunhof r Institute for Nondestructive Testing IZFP, Campus E3 1, 66123 Saarbrücke , r c BMB Gesellschaft für Materialprüfung mbH, Wannenäckerstrasse 63/1, 74078 Heilbronn, Germany Abstract Dross in large castings made of nodular cast iron reduces the quasi-static and the fatigue strength of the materials significantly, which causes afford to remove the Dross or to reject the complete component, if a secure assessment of the component’s lifetime cannot be performed. The aim is thus to find appropriate methods to determine the quasi-static and cyclic material behavior of Dross and to set up an assessment concept for components affected by Dross with the help of non-destructive testing. For this purpose, cast blocks made of EN-GJS-400-15 were casted with Dross. These blocks were investigated with different NDT methods to achieve information about the position and the characteristics of Dross present. Afterwards fatigue and tensile specimens were removed from the blocks taken from the Dross and the baseline material, which were tested under strain control to determine the cyclic strain based material behavior. Additionally, all fatigue specimens were investigated concerning their Dross distribution with X-ray computer tomography and partly also with magnetic particle inspection to correlate the NDT and the destructive test results with the forms of Dross detected. Further, a fatigue assessment concept including these research results was developed to assess large cast components with Dross. Abstract Dross in large castings made of nodular cast iron reduces the quasi-static and the fatigue strength of the materials significantly, which causes afford to remove the Dross or to reject the complete component, if a secure assessment of the component’s lifetime cannot be performed. The ai is thus to find appropriate methods to determine the quasi-static and cyclic material behavior of Dross and to set up an assessment concept for components affected by Dross ith the help of non-destructive testing. For this purpose, cast blocks made of EN-GJS-400-15 were casted with Dross. These blocks were investigated with different NDT methods to achieve information about the position and the characteristics of Dross present. Afterwards fatigue and tensile specimens were removed from the blocks taken from the Dross and the baseline material, which were tested under strain control to determine the cyclic strain based material behavior. Additionally, all fatigue specimens were investigated concerning their Dross distribution with X-ray computer tomography and partly also with magnetic particle inspection to correlate the NDT and the destructive test results with the forms of Dross detected. Further, a fatigue assessment concept including these research results was developed to assess large cast components with Dross.

© 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo.

Keywords: nodular cast iron; Dross; defects; thick walled Keywords: nodular cast iron; Dross; defects; thick walled

2452-3216 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. 2452-3216 © 2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. * Corresponding author. Tel.: +49 6151 705 8359; fax: +49 6151 705 214. E-mail address: christoph.bleicher@lbf.fraunhofer.de * Corresponding author. Tel.: +49 6151 705 8359; fax: +49 6151 705 214. E-mail address: christoph.bleicher@lbf.fraunhofer.de

2452-3216  2019 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. 10.1016/j.prostr.2019.08.139