(Cast Iron)

2

1.

2.

(Ferrous metals)
(base metal)

(Nonferrous metals)

(base metal)
2

Ferrous metals
1.

2.
3.

(Fe2O3)
1538
C

Timeline
1.

2.

3.

4.

2900 B.C.

2000 B.C.
1350 1000
B.C.
200 B.C

2. Steel Making
5

1. Reduction of iron compounds to molten iron

2. Process Steelmaking
3. Casting
4. Rolling
5. Heat treatment
7


1.

(Float)
(Magnetic separation)

(Agglomeration) 1

Agglomeration of iron ore

 ()
,
,

Magnetite (Fe3O4) 70%
Hematite (Fe3O3) 70%
Siderite (FeCO3) 60%
Pyrite (FeS2)
45%
Limonite (HFeO2) 35%
10

http://www.soes.soton.ac.uk/resources/collection/minerals/minerals/

Magnetite
Magnetite (Fe3O4)
70%

Hematite

Hematite (Fe3O3)

70%

Pyrite
Pyrite (FeS2)
45%

11

http://www.musee.ensmp.fr/mineral//11087x.jpg
http://www.gc.maricopa.edu/earthsci/imagearchive/limonite.htm

Siderite
Siderite (FeCO3)
60%

Limonite
Limonite (HFeO2)
35%

12

2. Process Steelmaking
(% )


Blast furnace

flux CaO CaCO3

13

3.5%
2%,
1.5%,
1%
1%
2

14

3.
(Pig iron)

1600 C

Oxidation
Slag
90%Fe


Mn, Cr, Mo, Ni V
15

:Furnace
1. The basic open-hearth furnace

16

17
www.key-to-steel .com

2. The Basic oxygen furnace

oxygen

18

19

20

3. The electric arc furnace

Radiation




21

22

23

3.

Casting ()



2
1.
2.

Continuous Casting
Ingot Casting
24

3.1 Continuous Casting

Billet,
Bloom, Slab

3.2 Ingot Casting

(mould)
Ingot

25

4. Rolling () and Mechanical treatment (hot

rolling, cold rolling, forging, extruding ect.)
Ingot

hot rolled
5. Heat treatment ()


26

3.1
3

3.2

27

3.

Low alloy

High alloy

C C C

Plain HSLA Plain

Plain

Heat
Treatable

28


2
1. (Steels) C 2wt%
2. (Cast Irons) C
2wt%

29

C
Mn
Si
Ni
P

:
:
Yield strength
, 0.25%

, ,

30

S
Sn
Al
Cu

Cr

(Toughness) (Cracking)
Casting (S) Mn , S (Fe)
FeS Hot shortness
(Cracking)

Inclusion
(Castability)

(Edge cracks)
(Corrosion resistance)
,
31

Pb
Nb
V
Mo
Ti

(Intergranular corrosion)

32

Cast Irons

2 % Si

Steels

33

Engineering cast iron, Melting

point ~1140-1200 C

L+
1532 C

910 C

L+

-austenite

1148 C

L + Fe3C
+ Fe3C

727 C

-ferrite + Pearlite

Pearlite + Fe3C

Pearlite

+ferrite

0.025 0.8

Steel

2.08

Fe3C

4.3

6.67 %C

Tensile strength
Elongation

Cast Iron

34


(Gray cast iron)
2. (White cast iron)
3. (Ductile cast iron)
4. (Malleable cast iron)
(Alloys or Special
cast iron)
1.

5.

35

1. Gray Cast Iron

(Pig
Iron) (Blast furnace) C
2 4 wt%

(Graphite Flake)

36

200-250 MPa

37

Graphite flake

Ferrite

Gray Cast Iron ASTM

type A
38

2.White Cast Iron

1.7-3 wt%,
1%Si, 0.5%Mn P<0.1%, S<0.2%
C
solid solution

C (Fe3C)

39


Pearlite
Cementite (Fe3C) (Ledebulite)
Cementite

Fe3C
Pearlite

40

3.Malleable Cast Iron

1600 F 24 - 48

Carbon atom
graphite
Ferrite
Pearlite

41

Rosette graphite

Ferrite grain

ferrite matrix

42

4. Ductile Iron
4.24.6 wt% Eutectic

ferrite, pearlite
graphite graphite (Nodular)
Nodular graphite Mg

Modulus of elasticity

43

Ferrite grain

Nodular Graphite
44

5. Alloys or Special Cast Iron

Cr , Si , Ni, Cu 1


matrix

Ni-Resist

45

 Wear resistant Hi-Cr cast iron

(Fe-2.6C-17Cr-2Mo-2Ni wt%)
Chromium Carbide (M7C3)

46

 ASTM Standard

Cast iron Microstructure

Gray
Ferrite +Pearlite
Pearlite
Fine Pearlite
Ductile Ferrite +Pearlite

UTS, ksi YS, ksi %Elongation

18
30
40
80
55
6

Malleable Ferrite + Graphite 50/54

Pearlite
60/105
High alloy Ductile iron
55/60

32/35
40/90
28/30

10/18
1/10
6/20
47

Cast iron

Process

Graphite

Matrix

Ductility

White

Rapid cooling rates Carbide

Ferrite

No

Gray

Slow cooling rates Flake

Ferrite/Pearlite

No

Malleable White+annealing

Flake to
nodule

Ferrite/Pearlite

Good

Nodular

Mg +slow cooling

Nodular

Ferrite/Pearlite

Good

Alloy

alloying element

Carbide

Ferrite/Pearlite

Good
48


1.

2.

3.

4.

5.

Cr and Mn Cementite stabilizers

Si, Al and Ni graphite formers

graphite ferrite matrix

graphite pearlite matrix

49

1.

a)
b)
c)

2.

3.

) Mg

) Carbon 2-4wt%

) 1600F 24-48 .
50

Introduction to Solidification

Ingot
billet Ingot

51

 Equilibrium

Temperature

Freezing
point
Undercooling
Solidification time

1.
2.
3.
4.

52

Time

1. (Nucleation)
2. (Crystal Growth)

: Equlibrium

53

 Cooling curve
At Freezing point, TE :
Embryo (Critical size)
Nucleus

Nucleus
(Hf,
Latent heat of fusion, J/cm3) Freezing
Temperature

54

Undercooling Solidification

Embryo TE, Freezing Temperature

( )
TE
TN = Nucleation Temperature


TG= Growth Temperature

TN< TG< TE
55

Temperature

Undercooling

TE
TG
TN

Time
56

Solid Grain

Temperature

Solid+Liquid Liquid
Dendrite tip
TE = Freezing temperature
TG = Growth temperature
TN = Nucleation temperature

TE
TG
TN
X,
Mould

57
6.4 Undercooling

Dendrite structure

(orientation)

Orientation

58

(Crystal
directions) Dendrite

Dendrite arm

59

TE
TG
TN

TE>TG>TN

60

TE
TN
TG

TE>TN>TG
61

 Grain refiner

TN
TE
TG

TN>TE>TG
62

Grain Refining

63

(Particles or compounds or elements)

Grain Refiner

64

 grain refiner

+ 0.25%Ti
+ 0.1%Ti
+ 0.05%Ti

grain refiner

65

1. (Cooling rate)
2. (Temperature
gradient)

66

2. Temperature gradient
1.1
Equiaxed grain
1.2
columnar grain

67


Mould
Fine Equiaxed grain


Columnar grain

Mould surface

(Mould)

Large Equiaxed grain

dendrite

68

Rapid cooling

slow cooling

Moderate cooling

69