Chapter 7

Malleable cast iron

Introduction
Malleable irons are cast white, that is, their as-cast structure consists of
metastable carbide in a pearlitic matrix. The castings must then be annealed
to convert the brittle carbide structure and develop a structure of roughly
spherical graphite aggregates in a matrix which can be either ferritic or
pearlitic, depending on composition and heat treatment.
There are two types of malleable iron, blackheart and whiteheart. Malleable
iron has a long history, whiteheart iron having been developed in 1722 by
the French metallurgist, R6aumur, while blackheart iron was developed in
the USA in 1820. Malleable iron was widely used for automotive and
agricultural components, pipe fittings, valves etc. but since the development
of spheroidal graphite ductile iron its use has declined, due to the high cost
of the annealing treatment which requires expensive furnace equipment.
Malleable iron is still widely used for small pipe fittings, electrical fittings
and builders hardware, particularly for thin section castings and castings
which are subsequently galvanised.

Whiteheart malleable

In the whiteheart process, the white, as-cast iron is decarburised during

annealing leaving a structure of iron carbide in a metallic matrix. When
fractured, the appearance is whitish, giving rise to the name, 'whiteheart'.
Decarburisation is only possible in thin sections; in heavier sections, some
conversion of carbide to graphite nodules occurs so that the annealed casting
has a white rim with a core having different structure and mechanical
properties. This limits the applications to which it can be put. Whiteheart
can be melted in a cupola and is a low cost material which still finds
applications in small, thin section castings.

Composition of whiteheart malleable

Typical compositions are

 Malleable cast iron 91

Before annealing After annealing

Total carbon 3.0-3.7% 0.5-2.0%
Silicon 0.4-0.8 0.4-0.7
Manganese 0.1-0.4 0.1-0.4
Sulphur 0.3 max 0.3 max
Phosphorus 0.1 max 0.1 max

A n n e a l i n g is a c o m b i n e d d e c a r b u r i s a t i o n a n d g r a p h i t i s a t i o n p r o c e s s
p e r f o r m e d in a n o x i d i s i n g a t m o s p h e r e . O r i g i n a l l y it w a s d o n e b y p a c k i n g
c a s t i n g s into i r o n ore m i x t u r e s b u t n o w it is c a r r i e d o u t in c o n t i n u o u s ,
a t m o s p h e r e c o n t r o l l e d f u r n a c e s at a b o u t 1070°C. S m a l l c a s t i n g s m a y be
fully d e c a r b u r i s e d a n d are r e f e r r e d to as w e l d a b l e m a l l e a b l e irons. Table 7.1
lists the E u r o p e a n s p e c i f i c a t i o n s for w h i t e h e a r t m a l l e a b l e iron. The U S A h a s
no equivalent standard.

Table 7.1 Specifications for whiteheart malleable cast irons

Grade Test bar Tensile Elongation 0.2% Proof HB

dia. strength strength typical
(mm) (min) (%) (min)
( N / m m 2) ( N / m m 2)

EN-GJMW-300-4 12 350 4 - 230

EN-GJMW-360-12 12 360 12 190 200
EN-GJMW-400-5 12 400 5 220 220
EN-GJMW-450-7 12 450 7 260 260
EN-GJMW-550-4 12 550 4 340 340

International ISO 5922-1981

Whiteheart
W 35-04 9 340 5 -
12 350 4 - 230 max
15 360 3 -
W38-12 9 320 15 170
12 380 12 200 200 max
15 400 8 210
W40-05 9 360 8 200
12 400 5 220 220 max
15 420 4 230
W45-07 9 400 10 230
12 450 7 260 150 max
15 480 4 280

The European Standard CEN 1562:1997 has superseded the former national standards,
for example:
France: NF A32-701(1982); Germany: DIN 1692 (1982); UK: BS6681:1986.
Notes: It is advisable to consult the original standards for details of the mandatory
values, methods of testing etc.
USA has no standard for whiteheart malleable iron.
92 Foseco Ferrous Foundryman's Handbook

Blackheart malleable iron

The iron is typically melted in a cupola and duplexed into an electric furnace
where temperature and composition are adjusted. The cupola metal has the
composition:

C Si Mn S P
2.5-2.6 1.1 0.2-0.3 0.2 0.1

The final composition in the electric furnace is:

C Si Mn S P Cr
2.4-2.6 1.3-1.45 0.4-0.55 0.2 max 0.1 max 0.05 max

Castings are poured at around 1450°C. Sometimes small additions (around

0.01%) of bismuth are added in the ladle to ensure fully white as-cast
structures. White irons contract on solidification so to ensure freedom from
shrinkage, the castings must be fed, see Chapter 19. As-cast malleable iron
is extremely brittle, allowing feeders and running systems to be broken
easily from the castings. Castings which have abrupt changes of section
develop internal stresses on cooling which may be enough to cause cracking
of the castings after shakeout. Slow cooling in the mould may be needed to
avoid this happening.
The castings are annealed to develop the required graphite clusters (Fig.
2.3). A typical cycle is about 48 hours long (Fig. 7.1) it may be carried out in
batch-type or continuous furnaces in a controlled atmosphere to avoid
oxidation of the castings. The rate of cooling in the final section of the heat

1st stage 2nd stage

~,~ ,,~

960 '
0

~ 790

~ 720

500

I d I I I
12 4 36 48 60
Time (h)

Figure 7.1 Typicalheat treatment cycle for a short cycle blackheart malleable iron.
(From Elliott, R. (1988) Cast Iron Technology, Butterworth-Heinemann, reproduced
by permission of the publisher.)
 Malleable cast iron 93

t r e a t m e n t d e t e r m i n e s t h e m a t r i x s t r u c t u r e of the c a s t i n g s w h i c h c a n b e
ferritic or p e a r l i t i c a c c o r d i n g to t h e p h y s i c a l p r o p e r t i e s r e q u i r e d .

Specifications for malleable cast irons

Table 7.2 lists t h e E u r o p e a n a n d I n t e r n a t i o n a l s p e c i f i c a t i o n s for b l a c k h e a r t

m a l l e a b l e cast irons. T h e E u r o p e a n S t a n d a r d C E N 1562:1997 h a s s u p e r s e d e d
t h e f o r m e r n a t i o n a l s t a n d a r d s . Table 7.3 lists t h e US A S T M s p e c i f i c a t i o n s .

Table 7.2 European and international specifications for blackheart malleable cast
irons

Grade Test bar Tensile Elongation 0.2% Proof HB

dia. (mm) strength (min.) (%) stress (min.) typical
( N / m m 2) ( N / m m 2)

EN-GJMB-300-6 12 or 15 300 6 - 150 max

EN-GJMB-350-10 12 or 15 350 10 200 150 max
EN-GJMB-450-6 12 or 15 450 6 270 150-200
EN-GJMB-500-5 12 or 15 500 5 300 165-215
EN-GJMB-550-4 12 or 15 550 4 340 180-230
EN-GJMB-600-3 12 or 15 600 3 390 195-245
EN-GJMB-650-2 12 or 15 650 2 430 210-260
EN-GJMB-700-2 12 or 15 700 2 530 240-290
EN-GJMB-800-1 12 or 15 800 1 600 270-320

International Standard ISO 5922-1981

Blackheart
B30-06 12 or 15 300 6
B32-12 12 or 15 320 12 190 150 max
B35-10 12 or 15 350 10 200

Pearlitic
P45-06 12 or 15 450 6 270 150-200
P50-05 12 or 15 500 5 300 160-220
P55-04 12 or 15 550 4 340 180-230
P60-03 12 or 15 600 3 390 200-250
P65-02 12 or 15 650 2 430 210-260
P70-02 12 or 15 700 2 530 240-290
P80-01 12 or 15 800 1 600 270-310

The European Standard CEN 1562:1997 has superseded the former national standards,
for example:
France: NF A32-702(1982); Germany: DIN 1692 (1982); UK: BS6681:1986.
Notes: It is advisable to consult the original standards for details of the m a n d a t o r y
values, methods of testing etc.
94 Foseco Ferrous Foundryman's Handbook

Table 7.3 US specifications for blackheart malleable irons

Specification Grade Test bar Tensile Elong. Yield stress Hardness

diameter strength (%) ( N / m m 2) (HB)
(mm) ( N / m m 2)

ASTM A 47-90 220M10 15.9 340 10 220 156 max

Ferritic 32510 50000 psi 32000 psi
ASTM A220-88 280M10 15.9 400 10 280 149-197
Pearlitic 40010 60000 psi 40000 psi
310M8 15.9 450 8 310 156-197
45008 65000 psi 45000
310M6 15.9 450 6 310 156-207
45006 65000 psi 45000
340M5 15.9 480 5 340 179-229
50005 70000 psi 50000 psi
410M4 15.9 550 4 410 197-241
60004 80000 psi 60000 psi
480M3 15.9 590 3 480 217-269
70003 85000 70000 psi
550M2 15.9 650 2 550 241-285
80002 95000 psi 80000 psi
620M1 15.9 720 1 620 269-321
90001 105000 psi 90000 psi
ASTM A602-94 M3210 (10) (32000 psi) 156 max 1
Automotive M4504 (4) (45000 psi) 163-2172
malleable M5003 (3) (50000 psi) 187-2412
castings M5503 (3) (55000 psi) 187-2413
M7002 (2) (70000 psi) 229-2693
M8501 (1) (85000 psi) 269-3023

ASTM A47-90 (reapproved 1995) covers ferritic malleable irons, a metric version
was reapproved in 1996.
ASTM A220-88 (reapproved 1993 including a metric version) covers pearlitic malleable
irons.
ASTM A602-94 covers automotive malleable castings.
Note: ASTM A602-94 specifies only hardness and heat treatment. Annealed I Air-
quenched 2 and tempered 3 Liquid quenched and tempered.