Effect of Casting Shakeout Temperature on Residual Stresses of Hypoeutectic High Chromium Iron Alloys Using Hole-Drilling Method

Attention on residual stress (RS) development, magnitude, and distribution on abrasive wear materials, i.e., high chromium (Cr) iron alloys, has been minimal, even though these materials are prone to tearing or inferior mechanical properties because of distortion during manufacturing processes, such as casting and heat treatment, leading to premature failure of cast components. Identification of the source and succeeding management of RS provides an opportune possibility to enhance the product quality. In the current study, the as-cast hypoeutectic irons of ASTM A532, Type A, Class III, 25% Cr, i.e., sample A (S/A) and sample B (S/B), were cast at 1384 and 1390 degrees Celsius (oC) and allowed to solidify and cool for approximately 1645 and 1295 minutes (mins), respectively. Thus, the shakeout temperatures of S/A and S/B cast products were established to be approximately 60 and 180oC respectively. Resultant RS and macrohardness were determined at ambient temperatures using the hole-drilling method (HDM) and Brinell hardness (BH) tester machines, respectively. Higher hardness values of 600BHN were established on S/B compared to 526BHN for S/A. In addition, casting shakeout at higher temperatures, i.e., 180oC on S/B, yielded higher magnitudes of RS distribution compared to 60oC shakeout for S/A.