Influence of Austenite Stability on the Machinability of Different Grades of Austempered Ductile Iron (ADI) During Dry Turning Machining

Abstract This work evaluated the machinability characteristics of three different austempered ductile irons using three machinability indicators: cutting force, tool wear, and surface roughness. Additionally, this paper addresses the interplay among the production conditions of ADIs, microstructural development, the TRIP effect arising from transformations of the retained austenite into martensite, and the machinability behavior of ADIs. Various characterization studies including hardness measurement, X-ray diffraction analysis, light and electron microscope were used. Machinability results indicated that the increase in cutting force is always associated with a corresponding increase in the martensite content when the cutting depth was increased from 0.5 to 2.0 mm. Such correlation is more evident with ADI grade austempered at high austempering temperature, 375 °C (ADI-375). It was noticed that although ADI-375 has only 0.46% martensite in the structure before machining, this ratio increases with the highest depth of cut of 2.0 mm to reach about ~ 23% martensite with a corresponding increase in the cutting force. Ferrite content and morphology have a great impact on the overall surface finish of each grade as it leads to deteriorating the surface characteristics of the investigated alloys. This could explain the highest roughness values across all processing experiments obtained in the ADI grade austenitized in the intercritical region (IADI), which mainly contains the highest ferrite content. Tool wear and chip characteristics were also studied in this work.