Inhomogeneity in mechanical properties of ductile iron pipes: A comprehensive analysis

Ductile iron pipes are widely used in pipe manufacturing for water and sewage transmission and distribution. In pipeline standards such as EN545, the pipe material is assumed isotropic and its mechanical properties are determined by tensile testing of round bars extracted along the longitudinal direction. This study experimentally examined the mechanical properties of centrifugal casting ductile iron pipes, focusing on the effects of sampling orientation, location, preparation, and test methodology. A ring hoop tension test (RHTT) was designed to evaluate circumferential properties. Force analysis of RHTT was performed and theoretical equation was derived to quantify the friction coefficient that existed between the coupon specimen and the loading fixture. A numerical study was conducted to further validate the effectiveness of the proposed theory. The test results indicated that the pipe mechanical property was inhomogeneous across the wall thickness, being inferior in the internal section and superior in the middle and external sections. This inferior layer would develop crack first and lead to subsequent outward propagation. This phenomenon led to a substantial degradation in the overall mechanical performance of the entire specimens, in comparison to the material in the middle portion. The material exhibited better performance in the circumferential direction compared to the longitudinal direction in terms of its mechanical properties, such as tensile strength and ductility. Flattened specimens showed enhanced strength and reduced ductility compared to the base pipe material. Fractographic and metallographic analyses revealed the existence of casting defects of porosity and agglomerated graphite in the internal section, which were the primary cause of material inhomogeneity. The round bars suggested per EN545 tended to overestimate the actual mechanical behaviour of ductile iron pipes, and may not be a true representation of the finished product of pipes. Flattened specimens as per ASTM E8/E8M were not recommended for ductile iron pipe material assessment, as the flattening process altered the stress–strain characteristics significantly.