IJMC/FEF Student Research Competition

Abstract Research has been extensively conducted on cast irons to understand their solidification behavior and corresponding mechanical properties. Variations in the composition (for example, carbon contents) and microstructure of cast irons with different thicknesses have been studied. However, the kinetics of other solute elements, such as copper (Cu), have not been comprehensively investigated. This study aims to compare simulated and experimental results of wedge castings produced from cast iron containing 0.25% Cu, with a focus on their mechanical performance and microstructural correlations. The influence of copper in 2-mm thickness sections is analyzed in terms of composition, thermal conditions, microstructure, and mechanical properties. Flow and solidification behavior are validated using MAGMA simulations, while the phase evolution along solidification is modeled using a CALPHAD-based numerical package. The as-cast structures with Cu and without Cu addition are compared through experimental characterization including arc emission spectrometry, tensile testing, Rockwell hardness testing, and optical microscopy. This study provides a foundation for future research aimed at optimizing cast iron properties through tailored processing techniques and compositional adjustments, advancing beyond the approaches explored in previous studies.