Agricultural Applications of Austempered Ductile Iron

Kristin R. Brandenberg
Kathy L. Hayrynen, Ph.D.
Applied Process Inc. Technologies Div.- Livonia, Michigan, USA

ABSTRACT

Austempering is a high performance heat treat process

that, when applied to ferrous materials, produces
components that have properties superior to those
processed by conventional means. Due to its high
strength-to-weight ratio as well as its increased wear
resistance, Austempered Ductile Iron and Carbidic
Austempered Ductile Iron are well suited for agricultural
applications from suspension to ground-engaging
components.

INTRODUCTION

Austempering is an isothermal heat treat process that

can be applied to ferrous materials to increase strength
and wear resistance. Figure 1 shows an isothermal (I-
T) diagram for cast iron with both the Austempering
(green line) and the quench and tempering (red line)
processes outlined. Austempering in cast iron consists Figure 1: Schematic I-T Diagram illustrating the
of Austenitizing followed by rapidly quenching to a Austempering (green) and Quench & Tempering
temperature above the Martensite start temperature, (red) Processes.
where the material is then transformed isothermally to
form Ausferrite, (acicular ferrite in carbon stabilized Carbidic Austempered Ductile Iron (CADI) is a ductile
austenite). The quench & temper process consists of cast iron containing carbides, (either thermally or
Austenitizing and then rapidly quenching below the mechanically induced) that is subsequently
Martensite start temperature. The Martensite that forms Austempered to produce an Ausferritic matrix with an
is very hard and brittle; and subsequently must undergo engineered amount of carbides. This process creates
a tempering process to acquire the desired combination components that have high wear resistance
of strength and toughness. characteristics.

Because Austempering is an isothermal process, it Agricultural equipment demands the same increasing
offers advantages versus quench & tempering. Since performance measures of other off-highway equipment.
the formation of Ausferrite occurs over minutes or hours Components are driven to be low cost and high
at a single temperature, distortion is minimized and performance, to handle high stress applications, and last
cracking does not occur. Meanwhile, the formation of longer under high wear conditions. With the proven
Martensite occurs immediately as the metal temperature strength and wear resistance of ADI, agricultural
drops below the Martensite start temperature. Because components can handle higher loads and tougher wear
cooling is achieved at different rates in various sections, situations than other competitive materials.
this is a non-uniform transformation, which can result in
significant distortion and/or cracking. SUSPENSION AND DRIVELINE COMPONENTS
Suspension components are an ideal candidate for
agricultural applications, such as the new suspension
systems on tractors. The different grades of ADI,
(achieved through a variation in the Austempering produce a light-weight, hollow design. This 145 lb.
temperature and time), can create a range of properties casting not only cost less to manufacture, but weighed
as seen in Table 1. Grades 1 and 2 ADI can withstand significantly less than the proposed forging.
the dynamic loading on suspension and driveline
components.

Table 1: ASTM A897/897M - 90 Property table for ADI

Tensile Yield Impact Typical
Elong
Grade Strength Strength Energy Hardnes
(%)
(MPa/Ksi) (MPa/Ksi) (J/ft-lb) s (HBW)
100 /
1 850 / 125 550 / 80 10 269 – 321
75
1050 /
2 700 / 100 7 80 / 60 302 – 363
150
1200 /
3 850 / 125 4 60 / 45 341 – 444
175
1400 / 1100 /
4 1 35 / 25 366 – 477
200 155
1600 / 1300 /
5 N/A N/A 444 - 555
230 185

The tensile and yield strength of ADI increases with Figure 3: ADI Control Arm for AWD Tractor (courtesy
increased Brinell hardness as shown in Figure 2. of John Deere)

Wheel hubs are a popular application for ADI across

various industries. ADI provides the strength required for
the application, and often a weight savings due to its
improved strength-to-weight ratio compared to other
materials.

Figure 2 : Typical Properties of Austempered Ductile

Iron as a function of Brinell Hardness.

Figure 3 shows the lower control arm on the

independent front suspension of the new John Deere
8020 series large-row crop tractor. This part was Figure 4 : ADI Planetary Gear Wheel Hub for Tractor
originally conceived as a steel forging. However, the Axles (courtesty of Dana Corporation)
strength of ADI and the near-net shape sand casting
created the possibility of a low-cost, high performance Axles can also be converted from a steel assembly to a
component. The ductile iron casting was cored to one-piece ADI casting for use in agricultural equipment.
Figure 5 : ADI Off-Highway Drive Axles

WEAR APPLICATIONS
Austempered Ductile Iron has increased contact fatigue
strength and wear resistance than comparable
materials. Figure 6 Compares the allowable contact
stress behavior of ASTM Grades 2 and 5 ADI, (ASTM
1050-700-07 and 1600-1300-00).
Figure 7 : Comparison of Contact Fatigue Strengths
of ADI with Those of Conventional Irons and Steels.

Figure 8 : Pin Abrasion Test Results, Comparing

Volume Loss at Equivalent Hardness Levels.
Figure 6 : Contact Fatigue (90% Confidence Limits)
From the ASME Gear Research Institute
Ground engaging applications withstand heavy wear,
thus, ADI is a suitable material for these applications.
Figure 7 demonstrates that the contact fatigue Figures 9 and 10 show ripper points and plow points
properties of various grades of ADI are comparable to that have been successful applications of ADI. Other
gas nitrided steels and can be competitive with wear applications include tillage points, seed boots, and
carburized and hardened steel. sway limiters. The higher wear resistance of ADI
increases the life of these components. In addition, they
Figure 8 illustrates that ADI has improved abrasion are less expensive than Abrasion Resistant White Irons.
resistance when compared to other materials. ADI
experiences less volume loss at similar hardness levels,
resulting in a component with improved wear
characteristics in a high stress environment.
Figure 9: Various Ripper Points (courtesy ADI
Engineering)

Figure 11: Bending Fatigue Strength of Various

Types of ADI compared to as-cast ductile iron and
various steels.

Figure 12 shows the allowable stress for Grade 2 and

Grade 5 ADI in a single tooth bending test.

Figure 10: ADI Plow Points (courtesy of Carroll Ag)

GEARS
Increased contact and bending fatigue strengths, as well
as noise reduction make ADI well suited for gear and
sprocket applications. Figure 11 shows a comparison of
tooth root bending fatigue of several ferrous materials.
This data shows that ADI is very competitive with cast
and through-hardened steels. When shot peening is
utilized, the increase in compressive stresses on the
surface can make ADI comparable to gas nitrided and
case carburized steels in tooth root bending fatigue.

ADI is used for gear and gear housing applications in

many industries, including agricultural equipment. Often Figure 12: Single Tooth Bending Fatigue for ADI.
times the ADI casting can be cast to near-net shape.
Austempered gears are used in diesel engine Noise is becoming an important design consideration for
applications across many industries, for their strength, many applications, including agricultural equipment.
noise reduction and ease of manufacture. Ductile Iron is intrinsically quieter than aluminums and
steels due to the presence of graphite. However, when
ductile iron is Austempered, there is an even greater
reduction in noise. Figure 13 shows the decrease in
decibel level (dB) in a hypoid gear and pinion application the insertion of a steel tube for application of anhydrous
when the components were made from ADI instead of ammonia. The steel tube was set into the green sand
steel. mold and the iron was cast around the tube, which
eliminated a costly machining attachment and/or welding
Support brackets, gears, PTO components and many procedure as well as protected the tube from wear.
other parts can benefit from the noise reduction in
Austempered Ductile Iron. ADI engine mounting
brackets can help dampen the vibrations in the engine
compartment.

Figure 15: ADI Anhydrous Ammonia Knife with cast-

in steel tube (courtesy of Gothic Millhouse)

MANUFACTURABILITY – ADI offers an opportunity for

increased manufacturability since rough machining can
be done prior to heat treatment. In the as-cast condition,
Figure 13: Decibel readings of a steel hypoid gear the material is much easier to machine, resulting in a
and pinion set compared to an ADI hypoid gear and cost reduction. Though many applications can be heat
pinion set. treated after final machining, finish machining after heat
treatment increases the strength characteristics of ADI,
UNIQUE SOLUTIONS giving it superior bending fatigue strength when
As a cast product, ADI can offer other unique design compared to parts austempered after machining.
solutions for various applications. In the case of Figure Figure 16 compares the relative machinability of several
14, this knotter gear was designed, cast, Austempered ferrous materials. Note that ductile iron in a ferritic or
and put into service with minimal machining required pearlitic condition is easier to machine than 30 Rc 4140
prior to heat treatment. steel or Grade 1 ADI. If ductile iron is machined prior to
heat treatment, one can gain the advantage of better
machinability. Furthermore, machining of ductile iron
and ADI results in a compact, discontinuous chip that is
easily handled and is fully recyclable.

Figure 14: ADI Hay Baler Knotter Gear

Figure 16: Relative Machinability of Several Ferrous
In the case of Figure 15, this anhydrous ammonia knife
Materials
was made more cost effectively with ADI, but required
LOW TEMPERATURE CONSIDERATIONS –
ADI exhibits un-notched Charpy impact values that are
up to three times higher that those reported for
conventional ductile iron, but lower than those of forged
steel. Because of the notch sensitivity of cast iron, it is
difficult to directly compare ADI to steel. Fracture
toughness is perhaps a better means of comparision. It
has been found that when valid comparisions like
fracture toughness are made, the toughness of ADI is
much greater than conventional ductile iron and
equivalent or superior to competitive cast and forged
steels.

At lower temperatures, ADI maintains a rather high

percentage of its room temperature toughness. Figure
17 shows that ADI retains nearly 70-80% of its room
temperature toughness at –40°C. Figure 18 further
illustrates how the fracture toughness of ADI does not
significantly vary in low temperature applications.

Figure 18: Fracture Toughness of ADI vs. varying

180
test temperature conditions5.
160

140
CARBIDIC AUSTEMPERED DUCTILE IRON
Impact Energy (J)

120 Carbidic ADI or CADI consists of an ausferritic

100
microstructure that contains a controlled volume fraction
of carbides. It is produced by austempering ductile iron
80 that contains carbides. These carbides can be
60
introduced by using several methods which include:

40 -As-Cast Carbides
20 Grade 1 ADI -Internal (chemical or inverse) chill
Grade 1.5 ADI -Surface chill (limited depth, directional)
0
-100 -80 -60 -40 -20 0 20 40 60
-Mechanically Introduced Carbides
-Cast-in, crushed MxCy carbides
Temperature (°C)
-Cast-in, engineered carbides (shapes)
-Welded
Figure 17: Impact transition curves for ADI Grades -Hardface weldment
1.0 and 1.5. (It should be noted that ASTM does not -Weldment with MxCy grains
recognize a Grade 1.5 ADI. This nomenclature is
used to refer to ADI that is produced by heat treating Figure 19 shows a CADI microstructure with as-cast
in the temperature zone between a Grade 1 and carbides that was Austempered at 700°F. The volume
Grade 2 in order to optimize ductility, impact and fraction of carbide in the matrix after austempering was
fatigue properties.) 18%. Figure 20 shows the same base iron as Figure
19 except that the material has now been austempered
at 500°F. Note the change in the microstructural scale
of the ausferrite. The heat treatment parameters for
making CADI can be controlled in order to produce
Ausferrite with different ferrite/austenite ratios and
microstructural fineness.
 Pin Abrasion Results

20
As-Cast Irons

As-cast ductile iron

Q&T Ductile Iron
ADI
15
ADI - interrupted quench

Volume Loss, cm3 (x103)

Ni-Hard
Carbidic ADI
ADI Abrasion Resistant
10
Irons
CADI - 5%

Austempered Steel
CADI - 18% Q&T Steel
Q&T 4140
5 Ni-Hard

As-cast Gray Iron

Abrasion
Resistant AGI
Irons
0
20 25 30 35 40 45 50 55 60 65

Hardness, Rc

Figure 21: Abrasive wear resistance of CADI vs.

several other materials. All results were obtained
Figure 19: CADI with a 700°F ADI matrix. (These experimentally with the exception of High-Chromium
carbides were produced as-cast by alloying with Cr Abrasion Resistant (AR) irons. Results for AR irons
and Mo.) were obtained from Reference 6.

The Ausferrite/Carbide mix of CADI offers improved Table 2 shows typical unnotched Charpy impact values
wear resistance versus ADI. Figure 21 shows pin for various materials including CADI. The impact
abrasion results for CADI, ADI and other competitive strength of CADI is similar to Carburized 8620 steel and
materials. The Abrasion Resistant Iron results are pearlitic malleable iron. Note the improvement over AR
represented by one point, but in reality encompass a irons.
family of materials which exhibit pin volume losses of up
to 0.008 cm3. [6] Figure 21 shows that CADI can Table 2: Typical un-notched Charpy impact values
compete competitively with some of the AR irons within (ft-lbs). Tested at 72F (22C).
this range.
Charpy
Material Impact Value
(ft-lbs)
A532 Abrasion Resistant Iron 2
30 - 45% Carbide 500 CADI 10
Carburized 8620 Steel 13
Pearlitic Malleable Iron 13
7003 Ductile Iron 38
Grade 5 ADI 40
5506 Ductile Iron 45
Grade 3 ADI 70
Grade 1 ADI 90
4512 Ductile Iron 95

Figure 20: CADI with a 500°F ADI matrix. This CADI

was produced from the same base material as the
CADI in Figure 19.
POTENTIAL APPLICATIONS FOR CADI SUMMARY

Agricultural components have been produced in CADI Austempered Ductile Iron (ADI) has an exceptionally
with as-cast carbides since the early 1990s. Limited high strength-to-weight ratio with good wear resistance
production quantities of CADI parts with cast-in, crushed and fracture toughness. ADI is suitable for many
carbides have been produced as well. Research into agricultural applications in drivetrains, suspensions,
chill-carbide CADI camshafts is ongoing. However, the hitches and wear components.
visibility of CADI has been greatly increased of late with
the public launch of CADI in programs at John Deere. Carbidic Austempered Ductile Iron (CADI) is a family of
ductile cast irons produced with carbides, (both
thermally and mechanically introduced), that are
subsequently Austempered to exhibit adequate
toughness and excellent wear resistance. CADI is
suitable for heavy wear applications, such as ground
engaging components.

ACKNOWLEDGMENTS

The authors of this paper greatly acknowledges the hard

work and dedication of the employees of Applied
Process, AP Southridge and AP Westshore for their
Figure 22: John Deere’s new, high performance, continued efforts in Austempering. The authors would
rotary combine uses CADI in its critical thrashing also like to thank Terry Lusk for assistance with our
research efforts, as well as John Keough for his
elements. (Courtesy of SAE Off Highway Magazine)
continued enthusiasm that drives us all.

In Addition, the contributions of the following companies

are noted:
ADI Treatments Ltd. Pty.
Carroll Ag
Case New Holland
Dana Corporation
Gothic Millhouse
Hay and Forage
John Deere Corporation

REFERENCES

1. “Applications of Austempered Cast Irons”, AFS

Transactions 02-084, May 2002, K.L. Hayrynen, K.R.
Figure 23: CADI Plow Point (Courtesy of Carroll Ag) Brandenberg, J.R.Keough
2. Gear Technology Magazine, “Austempered
Gears and Shafts: Tough Solutions”, April 2001, K.
Brandenberg, K. Hayrynen, J. Keough
3. “Austempered Materials and Their Applications
to Drive Line and Suspension Components”, SAE 2000-
01-2563, J. R. Keough
4. “Carbidic Austempered Ductile Iron (CADI)”,
November 2000, J. R. Keough, K.L. Hayrynen
Figure 24. CADI Rasp Bar 5. “Ductile Iron Data for Design Engineers”,
Chapter 4, Austempered Ductile Iron, Rio Tinto Ltd.,
CADI presents some intriguing product possibilities. revised 1998
Agricultural applications may include rippers, teeth, plow 6. Abrasion – Resistant Cast Iron Handbook, G.
points (Figure 23), wear plates, rasp bars, (Figure 24) Laird, R. Gundlach and K. Rohrig, AFS, 2000.
and harvester, picker and baler components.