2015 03-30-produits-de-demain-sont-coules-cabanne

Rio Tinto Iron & Titanium SIRRIS – Gent – Mars 2015 - PM.Cabanne

Energie Eolienne et Nouvelle Fonte GS au Si

PM.Cabanne – Sirris – mars 2015

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Energie Eolienne.

Nouvelle Fonte GS au Si.

Compatibilité ?

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Wind Mill energy: evolution!


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2006

Wind Mill energy: evolution of capacity!


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2009



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2012



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2014



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2006

Wind Mill energy: evolution of capacity by country!


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2009



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2012



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2014



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Wind Mill energy: Europe!


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Wind Mill energy: Belgium!

Belgium = 2.5% of new capacity in 2014 and in

Europe


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Wind Mill energy: Belgium! Belgium = 141 MW new offshore capacity in 2014 for a

total of 1 725 MW in Europe


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Wind Mill energy: size! Evolution of size by country and during last years

Europe and Offshore


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Wind Mill energy: size and weight! Evolution of rotor hub weight versus power!


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Wind Mill energy: size and weight! Evolution of nacelle and co weight versus power!


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Wind Mill energy: size and weight and DI!

2 MW ~ 35 T of DI

4 MW ~ 80 T of DI

From 15 to 20 T of ductile iron

per MW

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Wind Mill energy: future for DI!

15 to 20 T of DI per MW ~789 000 T in 2015

~1 009 000 T in 2017


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Wind Mill energy: future for DI!

15 to 20 T of DI per MW ~ 1 400 000 T in 2022


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Wind Mill energy and Ductile Iron in 2017

15 to 20 T of DI per MW

57 685 MW of new installed capacity in 2017

1 009 487 Tons of Ductile Iron

> 434 000 Tons for Asiatic countries

~325 000 Tons for Europe

> 80% in ferritic grade with impact at low temperature

But how much in new Ductile Iron? PM.Cabanne – Sirris – mars 2015

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New Ductile Iron Grades:


New Iso Standard and new

“Solid Solution Strengthened Ferritic

Spheroidal Graphite Cast Iron”

EN 1563:2010

New Ductile Iron Grades:


New Grades


The new Family of Ductile iron

0

5

10

15

20

25

300 500 700 900 1100 1300 1500

Allo

ngem

ent

-Elo

ngat

ion

-%

Résistance à la Rupture -- Tensile Strength -- Mpa


New Grades: Why & How?

Recently (2009 – 2010), the European commission for DI standard, recommended and officialised new grades for DI!

Leaded by Nordic Foundries and Machining experts (Volvo, Componenta, …), these new grades would have good machinability with great mechanical characteristics!

EN-GJS-450-18, 500-14 and 600-10

Ductile Iron « 600-10 » developed by Fiat 30 years ago, didn’t request any structural specifications versus new Iso grades which ask for:

a minimum ferrite level at 95%

a maximum level of pearlite at 5%

and no more than 1% of Carbides !!!

And or with a Silicon between 3.2 et 4.3%! PM.Cabanne – Sirris – mars 2015

New Grades: why Silicon?

Silicon increases the hardness of ferrite!

More the hardness of ferrite is,

More it is difficult to break it!

Same tensile strength but higher Yield Strength!

Silicon is one of the best ferrite’ promoter!

Huge elongation


Silicon increases

the hardness of

ferrite!

The harder the ferrite is, the harder it is to break

it!

BUT: level of Silicon is limited

New Grades: why Silicon?


New Grades: but what could be the resilience?

Silicon has a very bad effect on « transition » temperature. Silicon is a brittle element mainly at low temperature!!!!!

So, these new grades will NEVER replace ferritic grades with impact at low temperature like 350-22-LT et 400-18-LT.


Like a normal « ferrito-pearlitic » DI ! That was confirmed and initiated by Swedish Engineers

New Grades: what is resilience at different temperatures?


Like a normal « ferrito-pearlitic » DI ! That was confirmed and initiated by Swedish Engineers

New Grades: what is resilience at different temperatures?

Problems for Wind Mill application:

No impact resistance at low temperature

Impossible to use these grades for safety casting.


New Grades: which Advantages?

Better machinability: as the structure is uniform (« only » ferrite and graphite) the machining tools don’t meet alternating hardness (ferrite + carbide) as for ferrito-pearlitic grade (500-7 & 600-3)

Better toughness: closer and closer to carbon steel!

For a same tensile, the yield strength is greater: for engineering department this advantage will allow a decrease of casting section/thickness a lower weight!

A better elongation versus tensile strength: a casting with a good deformation before fracture is well appreciate by engineering department. Future development for automotive!

The high level of Si (ferritic and graphitic promoter) would allow more detrimental elements. Has to be confirmed!


New Grades: which Advantages?

Better machinability: as the structure is uniform (« only » ferrite and graphite) the machining tools don’t meet alternating hardness (ferrite + carbide) as for ferrito-pearlitic grade (500-7 & 600-3)

Better toughness: closer and closer to carbon steel!

For a same tensile, the yield strength is greater: for engineering department this advantage will allow a decrease of casting section/thickness a lower weight!

The high level of Si (ferritic and graphitic promoter) would allow more detrimental elements.

Advantages for Wind Mill application:

Better toughness

Weight reduction:

Full ferritic structure with “lower” quality of charge material – potential low price for castings!


Carbon level has to “be under control” to avoid:

Graphite Flotation, exploded nodules, Chunky graphite, …

The new Iso accepts a certain level of no spherical graphite shape: 20% of form III!

But: the standard does not specify any characteristic for thickness bigger than 60 mm!

New Grades: which Problems?

From IfG:

New Grades: some results?


Carbon level has to “be under control” to avoid:

Graphite Flotation, exploded nodules, Chunky graphite, …

The new Iso accepts a certain level of no spherical graphite shape: 20% of form III!

But: the standard does not specify any characteristic for thickness bigger than 60 mm!


Wind Mill application:

Thickness of the castings and graphite shape problem will be a huge challenge for the foundries and the designers:

No realistic at that time!

Some windmill manufacturers requested trial about the new DI but with no results at that time!


Problems due to Silicon:

Diagram Fe-C-Si:

in theory, “eutectic step” is at higher temperature and “eutectic point” is at lower Carbon



Problems due to Silicon:

With C= 3.3 and

Si=4.8% =

similar attitude for solidification than SiMo iron

= around 100°C for solidification

interval

New Grades: which problems?


Serial castings for trucks and tractors: a certain amount of Sb is well recommended to avoid chunky graphite!!!

New Grades: some results?


Composition: Si ~3.8% C ~3%

New Grades: first results from our R&D in Sorel?


Composition: Si ~3.8% C ~3%



Risering would be different: more risers = lower casting yield

Isolated heavy sections will request independent riser!

Feeding distance is close to zero!


R² = 0,7854

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1,200

0,00 1,00 2,00 3,00 4,00 5,00 6,00

Solid

e sh

rinka

ge in

%

Silicon %

Solide Shrinkage in %

R² = 0,616

0,000

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1,000

1,200

3,50 4,00 4,50 5,00 5,50

Solid

e sh

rinka

ge in

%

Silicon %

Solide Shrinkage in %



Redesign of pattern-plates!

Investigation and study have to be done



AB1C

a

c dr

a

C AB2

D E




Gating design will have to be recalculated for a better distribution

of the liquid.

Redesign of pattern-plates!

Worth yield = higher production cost


MERCI

THANKS

PM.Cabanne SORELMETAL Febru

ary 2015

2015 03-30-produits-de-demain-sont-coules-cabanne

Technology

Transcript of 2015 03-30-produits-de-demain-sont-coules-cabanne