Effect of misch metal inoculation on microstructure, mechanical and wear properties of hypoeutectic gray cast irons

Alloyed gray cast irons were made with and without misch metal inoculation (0.1%). The mechanical and wear properties were compared with conventional gray cast iron used for a typical clutch application in heavy commercial vehicles. Alloyed gray iron without misch metal showed higher volume fraction of pearlite (89%) and lower flake graphite (11%). Misch metal inoculated gray irons showed higher volume of flake graphite (15%) with 85% pearlite as matrix. Alloyed gray irons produced tensile strength from 300 to 344 MPa and hardness in the range of 221–247 VHN. Misch metal inoculation has slightly increased the graphite volume (40–60%) with corresponding decrease in strength and hardness (9–13%) in alloyed gray irons. The specific wear rates of all alloyed gray irons are significantly lower (<34%) compared to unalloyed base at two different sliding speeds (1.6 m/s and 2.5 m/s). The friction coefficient is less than 0.4 for alloyed gray irons as against 0.5–0.7 for unalloyed base gray iron at both the sliding speeds. This is attributed to the presence of alloying additives within the matrix which resists adhesive and abrasive wear loss. Among the inoculated alloyed gray irons, the alloy with lower S content (0.08%) showed higher wear rate at higher sliding speed due to lower graphite flake density compared to higher S containing iron (0.12%). This indicates that the wear rate is influenced by the amount of graphite which is released into the interface during sliding to provide lubrication and reduce wear. Inoculation with rare earth misch metal has a positive influence over graphite morphology in gray iron.