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"Penggunaan Austempered Ductile Iron atau ADI sebagai material alternatif semakin meningkat di dunia, baik dari sektor industri otomotive maupun bidang lainnya salah satunya di bidang pertahanan dan keamanan. Material ADI tidak tergolong dalam material ringan, light weight, tetapi dengan fleksibilitas design yang dimilikinya ADI dapat bersaing dengan logam lain yang lebih ringan diantaranya Aluminium dan paduannya. Penelitian ini merupakan bagian dari suatu rangkaian penelitian material untuk untuk menghasilkan thin wall austempered ductile iron (TWADI).Pada penelitian ini pertama-tama akan dilakukan proses pengecoran FCD450 dengan ketebalan 5, 4mm. Proses pengecoran yang digunakan yaitu pengecoran vertikal (soundness casting) dengan model P1T1 yang akan di bandingkan dengan model P5T1 dimana pada model P5T1 ini dilakukan proses permesinan (surface grinding) untuk menghilangkan lapisan kulit skin effect pada permukaan plat TWDI yang dihasilkan, sehingga sifat mekanis tidak terganggu serta meminimalisasi terjadinya kegagalan baik akibat konsentrasi tegangan dan distorsi yang ada dari benda cor.Hasil penelitian memperlihatkan bahwa kekuatan tarik meningkat seiring di hilangkannya lapisan kulit (skin effect) oleh proses permesinan dalam hal ini Surface Grinding Machine. Pada plat dengan ketebalan 4mm dengan UTS 328.1(N/mm2) menjadi 460(N/mm2) dan pada plat 5mm dengan UTS389.6(N/mm2) menjadi 420 (N/mm2).

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The use of Austempered Ductile Iron or ADI as an alternative material in the automotive industry and other industries such as national defence and military are increased recently. Although the ADI material does not fall into the category of light weight material, its design flexibility makes it competitive with other lighter metals like aluminum and its alloys.

The purpose of this research is to study the effect of surface grinding on thin wall ductile iron (TWDI) which is prepared as TWADI base material, that was produced by casting FCD450 five (5) and four (4) mm in thickness using soundness casting. There were two types of models used in this soundness casting: P1T1 and P5T1. The difference between these two models lay on the machining process after casting in which P5T1 applied surface grinding to remove the skin effect on the TWDI surface. This step is beneficial to minimalize the possibility of failure resulted from either stress concentration or distorsion.

The results showed that tensile strength increased when the skin effect was removed by machining process, in this case was by surface grinding machine. The tensile strength of plate 4 mm and 5 mm in diameter increased from UTS 328.1 N/mm2 to 460 N/mm2 and from UTS389.6 N/mm2 to 420 N/mm2, respectively."

"In producing Thin Wall Ductile Iron (TWDI) plate, special notice should be taken on the skin effect formation. Skin effect is a rim of flake interdendritic graphite formed in the surface. In a normal ductile iron casting, skin effect can be removed with machining process. Unfortunately this procedure cannot be applied in TWDI due to the thickness. This paper discusses the effect of casting design to the skin effect formation. Vertical casting design is used in this work. Variations are made in the thicknesses of the plate. The T1 model is equipped with 5 plates with thicknesses of 1, 2, 3, 4, and 5 millimeters; while the T1-Mod is equipped also with 5 plates, but with the same thickness, which is 1 mm. Skin thicknesses, nodule count, and nodularity are measured by NIS Element software. The result showed that skin effect formation is determined by magnesium content and cooling rate. Skin effect thicknesses are determined by cooling rate and the interaction area of molten metal with the mould. The presence of the skin effect in similar thickness and position of plate improved nodule count. In the same thickness, without the presence of the skin effect, the nodule count tends to increase as the positions of the plates increase. In the design ranging from 1 to 5 mm plate thickness, the highest nodule count is 1284 nodule/mm2 gained by 1 mm plate thickness in 1st position and the lowest one is 512 nodule/mm2 gained by 5 mm plate thickness in 5th position. As for the design of all 1 mm thickness where skin effect is not formed the highest nodule count is 1689 nodule/mm2 gained by 1 mm plate thickness in the 5th position and the lowest is 1113 nodule/mm2 gained by 1 mm plate thickness in the 1st position (near the in gate). The highest nodule count is 90 and the smallest is 85."

"Penelitian ini membahas tentang pengecoran besi tuang nodular (BTN) dinding tipis sebagai alternatif bagi material aluminium pada aplikasinya di bidang otomotif dalam rangka penghematan energi. Permasalahan yang dihadapi adalah penurunan sifat mekanis akibat terbentuknya lapisan kulit pada BTN dinding tipis. Lapisan kulit terbentuk akibat terjadinya degradasi bentuk grafit nodul dalam logam cair di dinding cetakan pada saat pengecoran. Digunakan tiga jenis variabel dalam penelitian ini yang bertujuan untuk mengurangi ketebalan lapisan kulit : pelapis cetakan grafit yang bersifat aktif; MgO yang bersifat reaktif; dan metode pelapisan cetakan ganda MgO/grafit. Ketebalan rata-rata lapisan kulit paling tipis yang didapatkan dalam penelitian adalah sebesar 30,41µm dengan metode pelapisan cetakan ganda, lebih rendah 57% dari ketebalan lapisan kulit variabel pelapis cetakan MgO (71,46 µm) dan 60% dari ketebalan lapisan kulit variabel pelapis cetakan grafit (74,44 µm). Berkurangnya ketebalan lapisan kulit berpengaruh terhadap peningkatan sifat mekanis BTN sehingga didapatkan kekuatan tarik rata-rata sebesar 376 MPa dan elongasi rata-rata sebesar 2,76% pada variabel metode pelapisan cetakan ganda. Kekuatan tarik yang didapatkan dari variabel pelapisan cetakan ganda 69% lebih tinggi dari kekuatan tarik variabel pelapis cetakan MgO (223 MPa) dan 26% lebih tinggi dari variabel pelapis cetakan grafit (297 MPa). Elongasi variabel metode pelapisan cetakan ganda adalah yang paling tinggi sebesar 2,76%, atau 93% lebih tinggi dari elongasi variabel pelapis cetakan MgO (1,43%) dan grafit (1,43%).

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This research explains about thin wall ductile iron (TWDI) casting as an alternative for aluminum usage in automotive parts. The occurring problem in TWDI casting is the formation of casting skin which reduces mechanical properties of TWDI. Casting skin is formed by degradation of nodular graphite shape at the mould interface while casting process is in progress. Three variables were uside in this experiment : graphite as active mould coating, MgO as reactive mould coating, and MgO/graphite double layer coating method. Average casting skin thickness was found at lowest value in double layer coating method variable (30,41µm), 57% lower than casting skin thickness in MgO coating variable (71,46 µm) and 60% lower than graphite coating variable (74,44µm). The reduction of casting skin thickness increased the mechanical properties of TWDI so that highest UTS value of 346 MPa and elongation of 2,76% could be achieved by using double layer coating method, which UTS is 69% higher than using MgO coating variable (223 MPa) and 26% higher than using graphite coating variable (297 MPa). Elongation value achieved by using double layer coating method was the highest (2,7%), which was 93% higher than using MgO (1,43%) coating variable and graphite coating variable (1,43%)."