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<p>The hydraulic system is mainly used in manufacturing, aerospace, agriculture, and construction industries due to its ability to produce high force and high precise control. To achieve accuracy in controlling the pressurized hydraulic fluid in the system, directional control valve (DCV) is used. The performance and life of DCV in a hydraulic system is a significant factor to be considered. To enhance the performance and the endurance of DCV, selection of right material could be a solution. Most of the industries choose Flake Graphite Iron (Grey cast iron or Lamellar Graphite Iron) to manufacture DCVs. In recent times, CGI (Compacted Graphite Iron) is being used to produce valves due to its unique properties, such as higher strength-to-weight ratio, stiffness, better thermal expansion coefficient, good wear and corrosion resistance when compared to FGI. In this research, as-cast FG-30, CG-300 and austempered FG-30, CG-300 DCVs are used to make DCVs and the performance study is conducted by using an auto rig test. The austempering process was carried out by austenitizing the DCVs at 900°C for 2 hours, followed by quenching it in a salt bath for 370°C austempering temperature for 1 hour and 30 minutes. The internal leakage, pressure drop, clearance (between the valve body and the spool) and endurance tests were measured and analyzed before and after 1 million cycles. It is found that the valve made of austempered CG-300 exhibits better performance metrics after 1 million cycles, succeeding in maintaining the required tolerance levels.</p>

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Austempering of Directional Control Valves made using Flake Graphite Iron and Compacted Graphite Iron—A Performance Study

  • 期刊论文

  • 发表日期：

    2025年4月20日

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  • G. Thilak,
  • P. Chandramohan,
  • V. S. Saravanan,
  • B. Nandakumar

摘要

The hydraulic system is mainly used in manufacturing, aerospace, agriculture, and construction industries due to its ability to produce high force and high precise control. To achieve accuracy in controlling the pressurized hydraulic fluid in the system, directional control valve (DCV) is used. The performance and life of DCV in a hydraulic system is a significant factor to be considered. To enhance the performance and the endurance of DCV, selection of right material could be a solution. Most of the industries choose Flake Graphite Iron (Grey cast iron or Lamellar Graphite Iron) to manufacture DCVs. In recent times, CGI (Compacted Graphite Iron) is being used to produce valves due to its unique properties, such as higher strength-to-weight ratio, stiffness, better thermal expansion coefficient, good wear and corrosion resistance when compared to FGI. In this research, as-cast FG-30, CG-300 and austempered FG-30, CG-300 DCVs are used to make DCVs and the performance study is conducted by using an auto rig test. The austempering process was carried out by austenitizing the DCVs at 900°C for 2 hours, followed by quenching it in a salt bath for 370°C austempering temperature for 1 hour and 30 minutes. The internal leakage, pressure drop, clearance (between the valve body and the spool) and endurance tests were measured and analyzed before and after 1 million cycles. It is found that the valve made of austempered CG-300 exhibits better performance metrics after 1 million cycles, succeeding in maintaining the required tolerance levels.