The main objective of the present research project is to develop a new generation of low cost high performance ductile cast iron for light weight design of automotive components. This will be accomplished by the use of improved ferrosilicon based foundry alloys for a general refinement of the ductile iron microstructure in combination with balanced additions of micro alloying elements for precipitation strengthening of the ferrite matrix. The target yield strength is 550Mpa or higher with a minimum ductility of 12% (elongation at fracture) . Provided successful results, weight savings of more than 10% for suspension components and 30% for gear parts are possible, corresponding to an estimated total weight reduction of 120 mill. kg per year and a resulting reduction in fuel consumption of 0.6 mill. liters per 100km.
The major project outputs are a new family of high strength ductile cast iron for light weight application, new microalloyed foundry ferroalloys, prototypes of automobile crankshaft components and power transmission gears, life cycle assessment incorporating environmental issues and mathematical process models developed to predict the properties of new cast irons.
Funding SchemeCSC - Cost-sharing contracts
09596 Freoberg (Sachs)
LE11 3TU Loughborough