Experimental and Numerical Analysis of Thermal Fatigue of Grey Cast Iron Ingot Mould

This article presents the results of experimental studies and numerical calculations that were conducted to analyse the phenomena that occur during the operation of an ingot mould that is designed for casting steel ingots. The studies were conducted on an experimental stand in a foundry on an ingot mould that was designed to make ingots that weigh up to six tons; they consisted of determining the temperature of the ingot mould and measuring the displacements of its walls during filling with steel and cooling. These studies were used to create and verify a numerical model that was used to determine the temperatures, displacements, deformations, and stresses in ingot mould walls during the operating cycle using the FEM method. Microstructure studies of ingot cast iron that was subjected to thermal fatigue were also conducted on a laboratory stand; the temperature changes and test times were the same as those used under the normal operating conditions of the ingot mould. Cast iron samples were subjected to heating and cooling cycles within a range of 0 to 60 cycles; then, tensile tests were performed to determine their stress-strain curves. As a result of the conducted tests, a great influence was found of the number of cycles on decreases in the values of the modulus of elasticity and tensile strength-especially within a range of 0 to 10 cycles. A relationship was also found between the changes in these values and the image of the cast iron microstructure. Based on images of the cast iron microstructure after being subjected to different numbers of thermal fatigue cycles, the mechanism of the crack initiation and propagation was determined. The influence of the changes in the strength of the cast iron and the stress state that was determined by the FEM method on the durability of the tested type of ingot mould was analysed. The obtained research results will be useful for introducing design changes that are aimed at increasing the fatigue durability of ingot moulds.