Wescast Industries Inc.

Brantford, United States

Wescast Industries Inc.

Brantford, United States
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Li D.,Natural Resources Canada | Sloss C.,Wescast Industries Inc.
72nd World Foundry Congress, WFC 2016 | Year: 2016

High-alloy graphitic irons include ferritic high-silicon molybdenum irons (referred to as SiMo) and austenitic high-nickel irons (referred to as Ni-resist). The high alloy contents greatly influence the eutectic carbon content and the constituents of these cast irons. This paper highlights some examples of the latest developments in SiMo and Ni-resist irons produced for automotive exhaust components with section thickness < 20 mm (3/4''). The graphite shapes of SiMo typically consist of spheroidal graphite (SG), compacted graphite (CG), and the recently-developed mixed graphite (MG) with medium graphite nodularity. MG iron constitutes a new class of cast iron that can improve manufacturability and material properties as compared to CG and SG irons. © 2016, The WFO (The World Foundry Organization Ltd). All rights reserved.


Li D.,Natural Resources Canada | Sloss C.,Wescast Industries Inc.
Materials Science and Engineering A | Year: 2017

This letter attempts to comment on the article by Chen et al. [Mater. Sci. Eng. A 688 (2017) 416] in the aspects of microstructure and tensile properties of ductile iron with niobium additions. © 2017


Wu X.,National Research Council Canada | Quan T.,Wescast Industries Inc | Sloss C.,Wescast Industries Inc
SAE Technical Papers | Year: 2013

Strain-controlled low-cycle fatigue (LCF) experiments were conducted on ductile cast iron at total strain rates of 1.2/min, 0.12/min and 0.012/min in a temperature range of RT 800°C. An integrated creep-fatigue (ICF) life prediction framework is proposed, which embodies a deformation mechanism based constitutive model and a thermomechanical damage model. The constitutive model is based on the decomposition of inelastic deformation into plasticity and creep mechanisms, which can describe both rate-independent and rate-dependent cyclic responses under wide strain rate and temperature conditions. The damage model takes into consideration of i) plasticity-induced fatigue, ii) intergranular embrittlement, iii) creep and iv) oxidation. Each damage form is formulated based on the respective physical mechanism/strain. The overall damage accumulation follows a nonlinear interaction mechanism that represents the nucleation and propagation of a surface crack in coalescence with internally distributed damages (cracks/voids). For ductile cast iron (DCI), the model predicates that the room temperature deformation and LCF life are primarily driven by cyclic plasticity; but at 400°C, albeit the deformation is mainly plasticity, its LCF is limited by intergranular embrittlement. When the temperature is increased above 600°C, rate-dependent stress-strain behaviour manifests due to creep, and the synergetic interaction of creep with oxidation dominates the LCF process. As a result of such interaction, a crossover-behaviour between room temperature and high-temperature (>600°C) strain-life relationships may occur, as observed in the experiments. The model prediction corroborates with the LCF test results and fractographic observations on the test coupons, which further substantiates the validity of the model. Copyright © 2013 NRC Canada.


Li D.,Wescast Industries Inc. | Sloss C.,Wescast Industries Inc.
SAE International Journal of Materials and Manufacturing | Year: 2010

There is a wide spectrum of cast ferrous heat resistant alloys available for exhaust component applications such as exhaust manifolds and turbocharger housings. Generally speaking, the ferrous alloys can be divided into four groups including: ferritic cast irons, austenitic cast irons, ferritic stainless steels, and austenitic stainless steels. Selection of a suitable alloy usually depends on a number of material properties meeting the requirements of a specific application. Ferritic cast irons continue to be an important alloy for exhaust manifolds and turbocharger housings due to their relatively low cost. A better understanding of the alloying effects and graphite morphologies of ferritic cast irons are discussed and their effect on material behavior such as the brittleness at medium temperatures is provided. The nickel-alloyed austenitic cast irons, also known as Ni-resist, exhibit stable structure and improved high-temperature strength compared to the ferritic cast irons. Austenitic cast irons with varying nickel contents were evaluated in terms of microstructure stability, heat treatment, oxidation and thermal fatigue resistance. For the most demanding applications requiring even higher elevated- temperature strength, creep, and fatigue resistance, ferritic or austenitic stainless steels may be selected. The chemical composition, microstructures, and properties of cast stainless steels are reviewed. Synthesizing this information on material behavior provides a guide to aid in the selection of ferrous alloys for high temperature applications. © 2010 SAE International.


Li D.,Wescast Industries Inc.
International Journal of Materials Research | Year: 2010

It is well known that ferritic cast irons with 4 to 5 wt.% Si provide good service and low cost in many elevated-temperature applications. In terms of cast iron microstructures, both spheroidal graphite and compacted graphite cast irons are currently used to produce engine exhaust manifolds and turbocharger housings. Between the two graphite morphologies, the mixed graphite microstructure has been proposed and evaluated in the aspects of molten metal treatment, solidification characteristic, microstructural stability, standard tensile testing, long-term hot oxidation and thermal cycling testing. The effects of graphite morphologies on the material properties are presented. The samples with mixed graphite structure showed an improved ductility at medium temperatures and thermal fatigue resistance. © 2010 Carl Hanser Verlag, Munich, Germany.


Patent
Wescast Industries Inc. | Date: 2011-06-23

An exhaust gas heat recovery system may include a housing, a valve member, and a heat exchanger. The housing may include an inlet, an outlet, a first exhaust gas pathway in communication with the inlet and outlet, and a second exhaust gas pathway in communication with the inlet and outlet. The valve member may be disposed within the housing and may be movable between first and second positions. In the first position, the valve member may allow fluid flow through the first exhaust gas pathway and substantially prevent fluid flow through the second exhaust gas pathway. In the second position, the valve member may allow fluid flow through the second exhaust gas pathway. The heat exchanger may be in communication with the second exhaust gas pathway and may include a conduit containing a fluid in thermal communication with exhaust gas when the valve member is in the second position.


Patent
Wescast Industries Inc. | Date: 2013-02-18

An exhaust manifold including a manifold body made of a first material and at least one heat shield insert provided inside the manifold body and made of a second material. The first material is a low cost material and the second material is a higher grade, temperature-resistant material. The manifold body includes a plurality of runners, collector and an outlet. The shield insert is preferably provided in the collector region adjacent to the outlet. The heat shield insert may have a curved sheet configuration or a tubular configuration depending on applications. The heat shield properly insulates the manifold body from the exhaust gas to protect the manifold body. The exhaust manifold, which is made from a combination of different materials, provides a more cost-effective solution in high temperature applications.


Patent
Wescast Industries Inc. | Date: 2010-10-13

A component of an exhaust system may convey exhaust gas between one or more inlets and one or more outlets and may include at least one fluid path in thermal communication with the exhaust gas. The fluid path may be defined by an external surface of the component and a cover plate attached to the external surface. The fluid path may be connected to a coolant source.


Patent
Wescast Industries Inc. | Date: 2014-07-23

A turbocharger system may include a turbine housing and a tongue insert. The turbine housing may include an inlet, an outlet, and a gas pathway between the inlet and outlet. The gas pathway may include a volute portion and an inlet portion extending approximately tangent to the volute portion. The turbine housing may be formed from a first material. The tongue insert may be received in the turbine housing and may at least partially define the volute portion and the inlet portion. The tongue insert may be formed from a second material that is more heat resistant than the first material.


Patent
Wescast Industries Inc. | Date: 2014-02-26

An exhaust gas heat recovery system may include a housing, a valve member, and a heat exchanger. The housing may include an inlet, an outlet, a first exhaust gas pathway in communication with the inlet and outlet, and a second exhaust gas pathway in communication with the inlet and outlet. The valve member may be disposed within the housing and may be movable between first and second positions. In the first position, the valve member may allow fluid flow through the first exhaust gas pathway and substantially prevent fluid flow through the second exhaust gas pathway. In the second position, the valve member may allow fluid flow through the second exhaust gas pathway. The heat exchanger may be in communication with the second exhaust gas pathway and may include a conduit containing a fluid in thermal communication with exhaust gas when the valve member is in the second position.

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