The elimination of the flake skin is one of the key elements of unlocking the full design potential of CGI. Capitalizing on the results of a previously AFS sponsored effort 04-05#02, "Study of the Effect of the Casting Skin on the Tensile Properties of Light Weight Ductile Iron Castings", the Department of Materials Science and Engineering at The Ohio State University (OSU) proposes to conduct research with the goal of understanding the mechanism of formation of casting skin in CGI, evaluating its effect on selected mechanical properties, and developing the methodology for its complete elimination. The results of this research will be of immediate applicability to the industry without major capital investment.

The research strategy is designed to develop the knowledge required to improve and ultimately eliminate skin quality of CGI castings and to generate data on its impact on the static mechanical and fatigue properties of CGI, as well as on the efficiency of shot blasting in improving these properties. Additionally, the study may help in the definition of the minimum thickness of the layer that must be removed by machining to avoid negative skin quality effects. The research will capitalize on the experience in the characterization of casting skin accumulated in the Virtual Solidification and Casting Laboratory (VisionCast) at OSU.

The success of this investigation will rely on the completion of extensive experimental work that will provide critical data required in the understanding of casting skin formation and elimination. The developed correlations between process variables, casting skin quality and mechanical properties will provide the impetus to further expand the applications of CGI.

Status Update: The test mold has been designed and casting tests will begin. Those wishing further information on the project should contact Prof. Doru Stefanescu, The Ohio State University, at This e-mail address is being protected from spam bots, you need JavaScript enabled to view it .