DOI: 10.18503/1995-2732-2026-24-2-156-164
Abstract
Problem Statement (Relevance). Modern engine manufacturing is increasingly dominated by lightweight alloys. In this context, due to advances in metallurgy and modern processing technologies, cast iron has regained considerable attention despite its traditional perception as a “heavy” material with low specific strength. Modern high-strength cast irons, including compacted graphite iron (CGI), demonstrate a unique combination of mechanical and service properties, making them highly promising materials for critical engine components. Preserving the valuable properties of cast iron, such as low shrinkage, high damping capacity, thermal conductivity, and others, while simultaneously achieving high specific strength characteristics comparable to those of lightweight alloys remains an important challenge. Objectives. The aim of this work is to demonstrate the potential of austempered compacted graphite iron (ACGI) for the development of next-generation engines meeting the requirements of efficiency, reliability, and environmental sustainability, as well as to assess the prospects for its application in engine manufacturing based on investigations of their influence of modern heat-treatment technologies on the structure and properties of ACGI and their effect on the performance characteristics of engine components operating under elevated temperatures and cyclic loading conditions. Methods Applied. The paper analyzes research results obtained using modern methods of cast iron melt treatment aimed at forming compacted graphite morphology in castings. Technological aspects of CGI production are considered, including charge composition, melt treatment regimes, and thermal conditions of solidification and cooling. Thermophysical and mechanical characteristics, as well as microstructural evolution during austempering, including the effects of alloying, are investigated. The thermophysical properties and hardenability of CGI are studied to determine optimal heat-treatment conditions. Originality. The study focuses on austempered compacted graphite iron, a promising but still insufficiently investigated material in the domestic scientific literature. For the first time, its structural features are comprehensively analyzed in relation to its service properties in engine applications. Particular attention is paid to the thermal stability of structures formed during austempering, which is a key factor for high-temperature applications. Result. The successful development of industrial technologies for producing CGI with a stable compacted graphite structure, together with investigations of its unique combination of high strength, thermal fatigue resistance, dimensional stability, and damping capacity, confirms the material’s potential. The determination of optimal austempering and alloying conditions makes it possible to obtain ACGI with specific strength characteristics comparable to those of cast aluminum alloys and superior thermal resistance. Practical Relevance. The application of ACGI in the automotive and aerospace industries expands engine design possibilities, increases power output and service life, reduces weight, and improves environmental performance. Successful implementation in the Russian automotive industry (KAMAZ, GAZ, and YaMZ) and the first developments for aircraft engines by Phoenix LLC confirm the practical value of this material. Further investigations, including assessments of thermal stability, will enrich scientific knowledge and broaden the application areas of ACGI, contributing to the development of domestic mechanical engineering.
Keywords
Compacted graphite iron, property hierarchy, austempering, structural transformations, thermal stability.
For citation
Panov A.G., Gurtovoy D.A., Shaekhova I.F. Prospects for the Development of Austempered Compacted Graphite Iron for Engine Manufacturing. Vestnik Magnitogorskogo Gosudarstvennogo Tekhnicheskogo Universiteta im. G.I. Nosova [Vestnik of Nosov Magnitogorsk State Technical University]. 2026, vol. 24, no. 2, pp. 156-164. https://doi.org/10.18503/1995-2732-2026-24-2-156-164
1. Nofal A.A., Jekova L. Novel processing techniques and applications of austempered ductile iron. J. Univ. Chem. Technol. Metall. 2009;44(3):213-228.
2. Dawson S. Compacted graphite iron – a material solution for modern diesel engine cylinder blocks and heads. Proceedings of the 68th World Foundry Congress. 2008, pp. 93-99.
3. Dawson S., Panov A.G., Gurtovoy D.A., Anikin S.A. Technology of stable production of vermicular graphite in castings of mass production. Liteynoe proizvodstvo [Foundry production]. 2018;(4):7-12. (In Russ.)
4. Panov A.G., Shaekhova I.F., Gimazetdinova Ch.A., Makarova M.A., Gladysh E.D. Development of technology for producing austempered vermicular graphite cast irons for aircraft engine components. Liteynoe proizvodstvo [Foundry production]. 2023;(12):2-6. (In Russ.)
5. Panov A.G., Shaekhova I.F., Gurtovoy D.A. Effect of isothermal holding on the structure and microhardness of upper bainitic vermicular graphite cast iron. Liteynoe proizvodstvo [Foundry production]. 2021;(10):2-8. (In Russ.)
6. Galimov R.M. Experience in developing designs, technologies and production of critical castings made of vermicular graphite iron. Nauka i tekhnologii modifitsirovaniya chuguna: tezisy dokladov IV Mezhdunarodnoy nauchno-tekhnicheskoy konferentsii [Science and technologies of cast iron modification. Proceedings of the IV International Scientific and Technical Conference]. Naberezhnye Chelny, 2022, pp. 22. (In Russ.)
7. Izosimov V.A., Surkin V.I., Izosimov A.V. High-strength vermicular graphite cast iron as a promising material for manufacturing D-180 engine pistons. Liteynyy konsilium online: resurs o liteynom proizvodstve [Foundry Council online: a resource about foundry production]. Available at: https://litkons.com/info/cast-iron/vysokoprochnyy-chugun-s-vermikulyarnym-grafitom/ (Accessed on February 8, 2026).
8. Zakirov E.S. Povyshenie stabilnosti struktury i svoystv otvetstvennykh detaley mashinostroeniya iz chuguna s sharovidnym i vermikulyarnym grafitom: dis. ... kand. tekhn. nauk [Improving the stability of structure and properties of critical engineering components made of spheroidal and vermicular graphite cast iron. Ph.D. dissertation]. Kazan, 2023, 126 p.
9. Dawson S. features of vermicular graphite cast iron and properties determining its prospects in mechanical engineering. Detali mashinostroeniya iz chuguna s vermikulyarnym grafitom. Svoystva. Tekhnologiya. Kontrol: tezisy dokladov mezhdunarodnoy nauchno-tekhnicheskoy konferentsii [Mechanical engineering components made of vermicular graphite cast iron. Properties. Technology. Control. Proceedings of the International Scientific and Technical Conference]. Naberezhnye Chelny, 2017, pp. 12-13. (In Russ.)
10. Prokhorov V.Yu., Shamarin Yu.A., Krasnov N.D. Investigation of the wear process of diesel engine cylinder liners. Nadezhnost i kachestvo: trudy Mezhdunarodnogo simpoziuma [Reliability and quality. Proceedings of the International Symposium]. Penza, 2017, vol. 2, pp. 238-240. (In Russ.)
11. Krutilin A.N., Kurbatov M.I., Kurbatova M.I. Operating conditions and basic requirements for cylinder liner materials. Lityo i metallurgiya [Casting and metallurgy]. 2005;(2-1(34)):107-109. (In Russ.)