Experimental and Modeling Study of Fluidity in Ductile Iron (GGG40)

Abstract Ductile irons (spheroidal graphite cast irons, SGI) are widely used in automotive and energy systems due to their high strength, ductility, and excellent machinability. The casting quality of these alloys largely depends on the flow and filling behavior of the molten metal, namely its fluidity. In this study, the effects of pouring temperature, filling time, and metallurgical quality on the fluidity of GGG40 ductile iron were investigated through both experimental and numerical approaches. Experimental trials were conducted at pouring temperatures of 1350 °C, 1400 °C, and 1450 °C; metallurgical quality levels of 10%, 50%, and 90%; and filling times of 5 s and 10 s. The fluidity lengths were measured and statistically evaluated. The results revealed that increasing the pouring temperature and metallurgical quality significantly improved fluidity, while shorter filling times allowed the molten metal to travel longer distances before solidification. Modeling studies performed using a commercial casting simulation software showed strong correlation with the experimental data. Microstructural examinations indicated that higher pouring temperatures and improved metallurgical quality led to a more homogeneous distribution of graphite nodules and an increased ferrite fraction in the matrix. The findings provide valuable insights into the influence of process parameters on the fluidity behavior of ductile iron and offer critical design data for enhancing casting quality and productivity in industrial foundry applications.