New ductile cast iron digital grades for automotive components

This research paper demonstrate that new cast iron grade materials can be developed aided by an expert digital twin (manufacturing twin) and the model predictive controls developed aided by artificial intelligent tools. High yield strength material and high machinability grades were developed by expert analysis of the industrial manufacturing data of anchors and housings monitored for more than one year.

The well-known EN GJS-550 high strength standard material grade, commonly used for safety components, is substituted by the new HS420/250 grade which presents a yield strength higher than 420 MPa, elongation higher than 7 % and hardness below 250 HB. This 13.5 % of increment in yield strength open new design opportunities of lightweight components in cast iron. Additionally, the high machinability cast iron grade developed is able to improve significantly the tools life of the casting with intensive machining operations, meanwhile high automotive quality standards are fulfilled.