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Cast Iron Types and Properties Overview

This document summarizes the properties and types of cast iron materials. It discusses how the microstructure and mechanical properties of cast iron depend on factors like carbon content, cooling rate, and alloying elements. The main types covered are gray cast iron, which has a microstructure of ferrite and graphite; ductile or nodular cast iron, which has a microstructure of ferrite and spherical graphite; and malleable cast iron, which undergoes a heat treatment to improve ductility. Methods to increase the strength of cast iron include modifying the graphite shape and distribution, and altering the microstructure.

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300 views25 pages

Cast Iron Types and Properties Overview

This document summarizes the properties and types of cast iron materials. It discusses how the microstructure and mechanical properties of cast iron depend on factors like carbon content, cooling rate, and alloying elements. The main types covered are gray cast iron, which has a microstructure of ferrite and graphite; ductile or nodular cast iron, which has a microstructure of ferrite and spherical graphite; and malleable cast iron, which undergoes a heat treatment to improve ductility. Methods to increase the strength of cast iron include modifying the graphite shape and distribution, and altering the microstructure.

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suhail
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  • Introduction to Cast Irons: Sets the framework for the presentation by introducing the subject of cast irons within materials engineering.
  • Outline of Cast Irons: Lists key topics covered in the document including properties and types of cast irons.
  • Properties of Cast Irons: Describes key properties of cast iron including carbon content, cooling rate, and alloying elements.
  • Types of Cast Irons: Illustrates different types of cast irons with diagrams and microstructure images.
  • Mechanical Properties of Cast Irons: Analyzes the mechanical properties like tensile strength and disadvantages associated with cast irons.
  • Utilization of Gray Cast Iron: Lists common applications and uses for gray cast iron in industry.
  • Increasing Strength of Cast Iron: Outlines methods to enhance the strength of cast iron, including altering the microstructure.
  • Microstructure in Cast Iron: Shows detailed images of ductile cast iron microstructure.
  • Utilization of Ductile Cast Iron: Describes the industrial applications of ductile cast iron including machinery and automotive parts.
  • Malleable Cast Iron: Explores aspects of producing and using malleable cast iron in various applications.
  • Microstructure of Malleable Cast Iron: Visuals and descriptions of the microstructure specific to black heart, temper-carbon in a ferrite matrix.
  • Utilization of Malleable Cast Iron: Illustrates the specific applications of malleable cast iron based on its unique properties.

Materials engineering

Cast Irons

Outline
Properties of cast irons
Microstructure
Mechanical properties

Types

Gray cast iron


White cast iron
Nodular cast irons
Malleable cast irons

Properties
Cast Iron
C = 2 ~ 6.67%
Properties depend on
1) Carbon content

2) Cooling rate of the casting


3) Alloying elements

Carbon content
1) Degree of solution

%
4.30.3(%+%)

T>1

Hypereutectic

Ledeburite + Pr. Cementite

T=1

Eutectic

Ledeburite

T>1

Hypoeutectic

Ledeburite + Perlite

Cooling rate
2) Cooling rate

Slow cooling rate

Iron + Graphite

section size > 10 mm

Quick Cooling rate

Iron + Cementite

section size < 10 mm

Alloying elements
Graphite producing elements
Co, P, Cu, Ni, Ti, Si, C, Al

Carbide producing elements


W, Mn, Mo, S, Cr, V, Mg, Ce

The microstructure depends on:


- Carbon and Silicon content
- Section size (cooling rate)

Maurer diagram
Gray cast iron
(Stable)
Ferrite + Graphite

White cast iron


(metastable)

Microstructure

Hypoeutectic white cast iron


Perlite and ledeburite

Gray cast iron


Ferrite and graphite

Hypereutectic white cast iron


Primer cementite and ledeburite

Gray cast iron


Ferrite, perlite and graphite

Greiner - Klingenstein diagram

C + Si %

At a given C+Si% the graphite


producing elements effects
increases with increasing section size
Ferrite + Graphite

Perlite +
Graphite
Ledeburite+
Perlite

10

20

30

40

50

60

70

Wall thickness (mm)


L+P+G

Tensile
Strength

Mechanical properties of cast iron

400

100

Ferritic
microstructure

Graphites effect on Tensile strength


- graphite produces notch effect
- graphite excludes parts in the matrix

Perlitic
microstructure

Mechanical properties of cast iron


Disadvantage of cast iron
- gray cast iron has low strength
- gray cast iron has no plastic strain = brittle

Graphite forms in gray cast iron

Mechanical properties of cast iron


Advantage of cast iron
- Good compressive strength
- high damping capability (tool machines)

- good machinability
- good wear resistance (graphite as lubricant)
- lower cost

Utilization of gray cast iron


Machine stands, engines, etc

Increasing the strength of cast iron


a) Increase the perlite amount in the matrix
b) Modify the shape and distribution of the graphite
flakes
c) Alternating the graphites geometry from flake to
spheroidal graphite

Increasing the strength of cast iron


Increase the perlite amount in the matrix

Ferrite + Graphite

ASTM A438

TS (psi)

TS (MPa)

Class

20

150

30

200

0.94

35

250

0.88

Increasing the strength of cast iron


Modify the size and distribution of graphite flakes
FeSi and CaSi as centers of crystallization (nucleation)

Method:

Overheating the molten iron and alloy


FeSi ~0.5%

CaSi 0.5~1%

- finer flakes

- higher strength

ASTM A438

TS (psi)

TS (MPa)

Class

40

300

0.8

50

350

0.76

60

400

0.72

Increasing the strength of cast iron


Alternating the graphites geometry from flake to
spheroidal graphite
Ductile or Nodular cast iron
Mg and Si alloying

100

Ferrite + spheroidal gr.


+ Graphite flakes

400

Ferrite + Graphite flakes

Si %

Mg alloying by Fe-Cu-Mg and Fe-Ni-Mg


F + Sph +
Graphite flakes

C=3.5%

F + P +Sph +
Graphite flakes
F + P + Sph.

F + Sph. + Carbides

Mg %

Microstructure

Ductile cast iron


Ferrite and spherical graphite
20 m

spherical graphite
in gray cast iron

Ductile cast iron


Ferrite, Perlite and spherical graphite

Utilization of ductile cast iron


Machine parts, gears, pipes, crankshaft, etc

Increasing the strength of cast iron


Ductile or nodular cast irons
ASTM A395

TS (MPa)

YS(Mpa)

El (%)

structure

Grade 60-40-18

400

250

18

Ferrite

370
420
480

6
3
2

F+P
P (AQ)
M (Q+T)

Elongation (%)
Yield Stress (psi)
Tensile strength (psi)
Grade 80-55-06
Grade 100-70-03
Grade 120-90-02

600
700
800

Malleable cast iron

Convert iron-carbibe to temper


carbon
increases the ductility

Black heart malleable cast iron


Ferritic structure with temper carbon

T (C)

ASTM A47
Grade 325-10

TS (MPa)
400

940 C

neutral
atmosphere

723

YS(Mpa)
130

El (%)
10

Ledaburitic-perlitic structure
Iron carbide disociates to Fe and C
Austenite transforms to ferrite and
graphite

Ferrite + temper carbon


100

12 48 hours

time

White heart malleable cast iron


Ferritic structure with low carbon content

T (C)

ASTM A47
Grade 450-06
Grade 600-04
Grade 800-02
Grade 900-01

TS (MPa)
310
420
550
650

1000C

oxidizing
atmosphere

723

100

YS(Mpa)
175
250
340
430

El (%)
6
4
2
1

Ledaburitic-perlitic structure
C = ~ 3%
Iron carbide dissociates to Fe and C

Carbon diffuses to the surface and


burns there.

25 -100 hours

Ferritic structure , low carbon


C = ~ 0.1%
time

Microstructure

Black heart cast iron


Temper-carbon in ferrite matrix

Utilization of malleable cast iron


Machine parts, machine stands, etc

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