Influence of solidification defects on the fatigue behaviour of heavy-section silicon solution–strengthened ferritic ductile cast irons

Mechanical and fatigue properties of heavy section solution–strengthened ferritic ductile iron (SSF-DI) castings have been examined in this contribution. Amounts of silicon varying from 3.2 to 3.55 wt% have been used. The effect of antimony on counteracting the formation of chunky graphite has been evaluated. In order to estimate the influence of solidification defects (microshrinkage porosities or degenerated graphite particles) on the fatigue strength of the investigated materials, scanning electron microscope observations of the fracture surfaces and extreme value analysis of the crack initiating defect dimension, √area, have been performed. The propagation of the fatigue crack through the material has been observed by means of microstructural analysis of the cross sections of the fracture surfaces. It has been found that the treatment with Sb is useful to avoid the formation of degenerated graphite particles. Moreover, it has been observed that the most of the fatigue life is spent in the crack initiation stage, where the microshrinkage porosities play a major role. The presence of chunky graphite affects mostly the propagation stage. Finally, mechanical and fatigue properties of SSF-DI have been compared with those obtained from traditional ductile cast iron specimens taken from the same casting geometry.