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 ~ 6.6!
Properties depend on
"# Carbon content
2# Coolin$ rate of the castin$
%# &lloyin$ ele'ents
Carbon content
"# (e$ree of solution
I =
C%
4.3-0.3(S%+P%)
T)" *ypereutectic Ledeburite + Pr. Cementite
T=" +utectic Ledeburite
T)" *ypoeutectic Ledeburite + Perlite
Cooling rate
2# Coolin$ rate
,lo- coolin$ rate Iron + Graphite
section si.e ) "/ ''
0uic1 Coolin$ rate Iron + Cementite
section si.e 2 "/ ''
Alloying elements
Graphite producin$ ele'ents
Co, P, Cu, Ni, Ti, Si, C, Al
Carbide producin$ ele'ents
W, Mn, Mo, S, Cr, V, Mg, Ce
The 'icrostructure depends on3
Carbon and Sili!on !ontent
Se!tion "i#e $!ooling rate%
Maurer diagram
Ferrite + Graphite
White cast iron
4'etastable#
Gray cast iron
4,table#
Microstructure
Hypoeutectic white cast iron
Perlite and ledeburite
Hypereutectic white cast iron
Primer cementite and ledeburite
Gray cast iron
Ferrite and graphite
Gray cast iron
Ferrite, perlite and graphite
Greiner - Klingenstein diagram
C

+

S
i
%
Wall thickness (mm)
"/
2/ %/ 5/
6/
6/ /
Ferrite + Graphite
Ledeburite+
Perlite
Perlite +
Graphite
L + P + G
&t a $i7en C8,i! the $raphite
producin$ ele'ents9 effects
increases -ith increasin$ section si.e
Mechanical properties of cast iron
T
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S
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g
t
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Perlitic
microstructure
Ferritic
microstructure
&''
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Graphite9s effect on Tensile stren$th
graphite produ!e" not!h e))e!t
graphite e*!lude" part" in the matri*
Mechanical properties of cast iron
(isad7anta$e of cast iron
: Gray cast iron has lo- stren$th
: $ray cast iron has no plastic strain = brittle
Graphite for's in $ray cast iron
Mechanical properties of cast iron
&d7anta$e of cast iron
: Good co'pressi7e stren$th
: hi$h da'pin$ capability 4tool 'achines#
: $ood 'achinability
: $ood -ear resistance 4$raphite as lubricant#
: lo-er cost
Utilization of gray cast iron
Machine stands; en$ines; etc
ncreasing the strength of cast iron
a# Increase the perlite a'ount in the 'atri<
b# Modify the shape and distribution of the $raphite
fla1es
c# &lternatin$ the $raphite9s $eo'etry fro' fla1e to
spheroidal $raphite
ncreasing the strength of cast iron
ncrease the perlite amount in the matri!
Ferrite + Graphite
ST! "#$ "# 4psi# "# 4MPa# "
Class $% "6/ "
&% 2// /.=5
&' 26/ /.>>
ncreasing the strength of cast iron
Modify the size and distribution of graphite fla(es
)e#i and Ca#i as centers of crystalli.ation 4nucleation#
Method3 ?7erheatin$ the 'olten iron and alloy
@e,i ~/.6! Ca,i /.6~"!
: finer fla1es
: hi$her stren$th
ST! "#$ "# 4psi# "# 4MPa# "
Class *% %// /.>
'% %6/ /.6
+% 5// /.2
ncreasing the strength of cast iron
&lternatin$ the $raphite9s $eo'etry fro' fla1e to
spheroidal $raphite
%uctile or &odular cast iron
M$ and ,i alloyin$
M$ alloyin$ by +eCuMg and +eNiMg
F + P +Sph + F'
S
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!g %
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F + P + Sph(
F + P + Sph(
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Microstructure
Ductile cast iron
Ferrite and spherical graphite
Ductile cast iron
Ferrite, Perlite and spherical graphite
spherical graphite
in gray cast iron
20 m
Utilization of ductile cast iron
Machine parts; $ears; pipes; cran1shaft; etc
ncreasing the strength of cast iron
(uctile or nodular cast irons
ST! #*+ "# 4MPa# ,#4Mpa# -l 4!# structure
Grade ,-."-./$ 5// 26/ "> @errite
Grade $-.++.-, 6// %/ 6 @ 8 P
Grade /--.0-.-# // 52/ % P 4&0#
Grade /1-.*-.-1 >// 5>/ 2 M 408T#
0longation $/%
1ield Stre"" $p"i%
Ten"ile "trength $p"i%
Malleable cast iron
Con7ert iron:carbibe to te'per
carbon
increases the ductility
@erritic structure -ith te'per carbon
ST! "0 "# 4MPa# ,#4Mpa# -l 4!#
Grade #1+./- 5// "%/ "/
.lac( heart malleable cast iron
time
/edaburitic-perlitic structure
ron carbide disociates to )e and C
Austenite transforms to ferrite and
graphite
)errite 0 temper carbon
T

(
2
C
)
&''
23-
1$ 2 *3 hours
4(' 5C
neutral
atmo"phere
@erritic structure -ith lo- carbon content
ST! "0 "# 4MPa# ,#4Mpa# -l 4!#
Grade "+-.-, %"/ "6 6
Grade ,--.-" 52/ 26/ 5
Grade $--.-1 66/ %5/ 2
Grade *--.-/ 66/ 5%/ "
White heart malleable cast iron
/edaburitic-perlitic structure
C 4 5 &6
ron carbide dissociates to )e and C
)erritic structure 7 lo8 carbon
C 4 5 %916
T

(
2
C
)
&''
23-
$' -1%% hours
&'''5C
time
o*idi#ing
atmo"phere
Carbon diffuses to the surface and
burns there9
Microstructure
Black heart cast iron
Temper-carbon in ferrite matri
Utilization of malleable cast iron
Machine parts; 'achine stands; etc