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

Attention on residual stress development, magnitude, and distribution on abrasive wear materials, such as high chromium 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 residual stress provides an opportune possibility to enhance product quality. In the current study, the as-cast hypoeutectic irons of ASTM A532, Type A, Class III, 25% Cr, i.e., sample A and sample B, were cast at 1384 and 1390 degrees Celsius and allowed to solidify and cool for approximately 1645 and 1295 minutes, respectively. Thus, the shakeout temperatures of sample A and sample B products were established to be approximately 60 and 180°C, respectively. Resultant residual stress and macrohardness were determined at ambient temperatures using the hole-drilling method and Brinell hardness tester machines, respectively. Higher hardness values of 600 BHN were established on sample B compared to 526 BHN for sample A. In addition, casting shakeout at higher temperatures, i.e., 180°C on sample B, yielded higher magnitudes of residual stress distribution compared to 60°C shakeout for sample A.