Microstructure-based CZE model for crack initiation and growth in CGI: effects of graphite-particle morphology and spacing

Compacted graphite iron (CGI) is an engineering material with the potential to fill the application gap between flake- and spheroidal-graphite irons thanks to its unique microstructure and competitive price. Despite its wide use and considerable past research, its complex microstructure often leads researchers to focus on models based on representative volume elements with multiple particles, frequently overlooking the impact of individual particle shapes and interactions between the neighbouring particles on crack initiation and propagation. This study focuses on the effects of graphite morphology and spacing between inclusions on the mechanical and fracture behaviours of CGI at the microscale. In this work, 2D cohesive-zone-element-based models with different graphite morphologies and spacings were developed to investigate the mechanical behaviour as well as crack initiation and propagation. ImageJ and scanning electron microscopy were used to characterise and analyse the microstructure of CGI. In simulations, both graphite particles and metallic matrix were assumed isotropic and ductile. Cohesive zone elements (CZEs) were employed in the whole domain studied. It was found that graphite morphology had a negligible effect on interface debonding but nodular inclusions can notably enhance the stiffness of the material and effectively impede the propagation of cracks within the matrix. Besides, a small distance between graphite particles accelerates the crack growth. These results can be used to design and manufacture better metal-matrix composites.