Case Study: IDI800 Excavator Attachment Optimized with Härenviks
Our expertise in materials, casting, structural engineering, and machining leads to excellent results
Optimization of an excavator attachment by upgrading the material from EN-GJS-500-7 to IDI800
This case study describes the optimization of an excavator attachment achieved by upgrading the material from EN-GJS-500-7 to IDI800 isothermal spheroidal graphite cast iron.
The project was developed in close collaboration with Härenviks, our engineering and design partner. The main benefits achieved include superior mechanical performance, greater reliability, and higher safety margins in a demanding and safety-critical application.
The primary objective was to improve the component’s mechanical performance and prevent failure in service under severe operating conditions.
Industrial applications of the excavator attachment
The excavator attachment is the key interface between the earthmoving machine and its tools, combining tilt and rotation functions. The component operates under high dynamic loads, repeated stress cycles, and impacts, in an environment where full compliance with stringent safety requirements is essential to ensure operator protection and machine control.
In this safety-critical application, the choice of material is a strategic decision driven by design requirements and operational risks.
In addition to the construction sector, these fasteners are widely used in mining and quarrying, forestry and agriculture, recycling, railway and infrastructure maintenance, and industrial and urban maintenance, where versatility and performance are critical.
Technical challenge and engineering approach
The original material, EN-GJS-500-7, provided a solid foundation. Increasing performance requirements in terms of strength, reliability, repeatability, and wear resistance called for further optimization. Härenviks played a central role in the development, driving the optimization through a structured engineering process:
- Structural analysis to identify critical stress areas
- Selection of material and heat treatment based on mechanical requirements
- Development and optimization of the alloy to enhance its interaction with the austempering process
- Design alignment with the requirements for machining and localized laser hardening
- Ongoing coordination between the foundry and Zanardi Fonderie
Results obtained with IDI800
The austempering process provides a superior balance between strength and ductility. The transition from EN-GJS-500-7 to IDI800 meets mechanical requirements and structural analysis criteria. It is not intended to improve production efficiency.
High load capacity
+60% tensile strength, +50% yield strength: the component can withstand higher loads without increasing cross-sectional area or overall dimensions compared to the original design in EN-GJS-500-7.
Resistance to fatigue
390 MPa fatigue strength: IDI800 withstands the repeated cycles and dynamic loads typical of excavation, extending the component’s service life under harsh operating conditions.
Consistent performance over time
IDI800 ensures repeatability in mass-produced components: consistent mechanical properties across production batches and predictable long-term performance in service.
Wear resistance
Hardness up to 270 HB: The component is resistant to abrasion, debris, and particulates in excavation, quarrying, recycling, and forestry applications, where there is constant contact with loose materials.
Improved reliability
+90% K-resilience at -40°C (from 25 J to 47.5 J): the component withstands impacts and low temperatures, offering robust safety margins for safety-critical applications.
The solution: IDI800
Zanardi Fonderie performs heat treatment on EN-GJS-400-15 cast components produced by a third-party foundry. The treatment significantly enhances the material’s performance while preserving the benefits of the casting process.
Performance Comparison
The Value of Collaboration
The combination of Härenviks’ engineering expertise and Zanardi Fonderie’s metallurgical know-how has enabled the development of an optimized and cost-effective solution to meet demanding application requirements.
Examples of excavator attachments
Case History
Real cases explaining the development of client projects
