APPLICATIONS OF ADI

In late September, the 2002 World Conference on ADI was held in Louisville, KY. Experts from around the world convened to discuss the latest information about ADI. This paper summarizes some of the many examples of applications of ADI that were presented.

ADI DEVELOPMENTS IN NORTH AMERICA

The growth of the ADI market in North America has been impressive over the past 30 years according to John Keough. This was attributed to an interesting set of properties exhibited by this material along with a unique set of economic and technical circumstances, which deliver the material for prices well below those of steel and aluminum castings, weldments and forgings. 

It was estimated that ADI production in North America could approach 200,000 tons per year by the end of this decade and exceed 300,000 tons per year by 2020. The market sectors for ADI in North America included: heavy and light vehicle, railroad equipment, agricultural equipment, construction and mining equipment along with numerous general manufacturing components. Figure 1 summarizes the estimated US market distribution of ADI applications.

Figure 1 - Estimated US Market Distribution of ADI Applications (Courtesy of Applied Process Technologies Division)

ADI APPLICATIONS AT FARRAR CORPORATION

Farrar Corporation has successfully converted a number of components to ADI. According to Don Reimer, their customers are taking advantage of the near net shape technology of the casting process as well as the unique properties of ADI. 

Figure 2 shows a side link pusher dog for overhead conveying equipment that was converted from a steel forging. This ADI component was a significant cost savings for the end user because the lubricating hole could be cast in rather than machined into a forging

Figure 2: A side link pusher dog for overhead conveying equipment. (Courtesy of Farrar Corp.)

Since this initial successful program, Farrar has continued with additional conversions to ADI in overhead conveyor systems along with numerous construction equipment applications. Figure 3 shows another ADI component in trenching equipment.

Figure 3 - ADI gear in trenching Equipment. (Courtesy of Farrar Corporation)
AN ADI ALTERNATIVE FOR A HEAVY DUTY TRUCK LOWER CONTROL ARM

Daimler Chrysler Corporation's experience with the development of lower control arm for a heavy duty Dodge Ram pickup truck was chronicled by Phil Seaton. While the use of aluminum for substitution of ductile iron seems to be the emphasized for weight reduction purposes, the use of ADI is being considered because it has 3 times the strength of aluminum and 2.3 times the stiffness.

Figure 4 shows both the stamped steel welded design along with the ADI alternative that was considered for this application. The final results showed a reduction in weight of 4 pounds per vehicle in addition to a significant reduction in tooling costs for the ADI control arm. However, the steel component was chosen over ADI because the ADI component was not ready in time for mandatory vehicle testing. Although ADI was not chosen in this instance, Seaton was confident that the advantages of using ADI were clearly demonstrated by this exercise.

Figure 4 - The stamped steel welded (left view) and the ADI (right view) lower control arms for a heavy duty Dodge Ram pickup truck. (Courtesy of Intermet Corporation and Daimler Chrysler Corporation.)

AGRICULTURAL APPLICATIONS OF ADI

Applications ranging from gears to suspension and driveline components for agricultural applications were featured by Kristin Brandenberg of Applied Process Technologies Division. Once again, the near net shape aspects of using a casting along with the properties of ADI such as strength to weight ratio, toughness and wear resistance were listed as reasons for conversions. 

Figure 5 shows the lower control arm on the independent front suspension for a John Deere 8020 series large-row crop tractor. This 145 lb. casting not only cost less to manufacture, but weighed significantly less than the proposed forging. 

Figure 5 - ADI Control Arm for AWD Tractor (courtesy of John Deere)

Carbidic ADI (CADI) which consists of ausferrite with a controlled volume fraction of carbide present was also discussed for its growing interest for agricultural applications. This material shows improved wear performace over ADI along with impact properties that can be several times that of abrasion resistant irons. Figure 6 shows a CADI plow point that has been in production since the early 1990's.

Figure 6 - ADI Plow Point (Courtesy of Carroll Ag)

THIN WALL ADI IN ARGENTINA

The use of ADI for thin-wall, high strength parts was explored by Martinez et al. It was pointed out that the casting process for producing thin wall components is more complicated and that casting quality is paramount for success in this type of a program. The production of a hollow connecting rod (Note Figure 7.) for an innovative two cylinder engine that generates 55 hp at 5500 rpm was shown. The thickness of the main portions of the part were as small as 3 mm which allowed for a weight reduction of 600 gms for a steel forging to a 400 gm ADI connecting rod.

Figure 7 - A hollow connecting rod developed in Argentina. (Courtesy of INTEMA, Argentina)

These connecting rods were assembled in prototype engines and were extensively tested in service with excellent results. This new engine with the hollow connecting rods has been presented in several national and international expositions in Argentina.

SUMMARY

ADI has become a material of choice for applications for a number of reasons that include the following:

• High strength to weight ratio
• Toughness
• Wear resistance
• Near net shape casting advantages

The applications of ADI featured in this article represent only a small sample of those presented at the 2002 World Conference on ADI. Additional information can be found in the conference proceedings.

FOR MORE INFORMATION

Copies of the Proceedings of the 2002 World Conference on ADI cosponsored by the DIS and AFS can be purchased on-line from the American Foundry Society at www.afsinc.org.