Graphite Morphology

The mechanical and physical properties of gray iron are governed in part by the shape, size, amount, and distribution of
the graphite flakes. A method for evaluating graphite flake distribution and size is given in ASTM A 247, and the
metallography of cast irons is discussed in Ref 7, 8, 9.

There are five graphite flake distributions: A to E (Fig. 4). Type A graphite flakes are randomly distributed and oriented
throughout the iron matrix. This type of graphite is found in irons that solidify with a minimum amount of undercooling,
and type A is the structure desired if mechanical properties are to be optimized.

Type B graphite is formed in irons of near-eutectic

composition that solidify with a greater amount of
undercooling than that associated with type A graphite.
Rosettes containing fine graphite, which are characteristic
of type B, precipitate at the start of eutectic solidification.
The heat of fusion associated with their formation increases
the temperature of the surrounding liquid, thus decreasing
the undercooling and resulting in the formation of type A
graphite.

Types D and E graphite form when the amount of

Fig. 4 Graphite distributions specified in ASTM A 247
undercooling is high but is not sufficient to cause carbide
formation. Both types are found in interdendritic regions.
Type D graphite is randomly distributed, while the type E
flakes have a preferred orientation. The manner in which
the plane of polish intersects the graphite flakes may be
responsible for this difference in orientation. Elements such
as titanium and aluminum have been found to promote
undercooled graphite structures. The iron matrix associated
with undercooled graphite is usually ferrite because
formation of the fine, highly branched flakes reduces
carbon diffusion distances and results in a low-carbon
matrix. Because ferrite has a lower tensile strength than
pearlite, there is a reduction in the anticipated strength of
the iron. Examples of type A, B, and D graphite found in
commercial irons are shown in Fig. 5.

Fig. 5 Examples of type A (a), type B (b), and type D (c) graphite from foundry-produced gray irons. As-
polished. 100×

Type C graphite occurs in hypereutectic irons, particularly those with a high carbon content. Type C graphite precipitates
during the primary freezing of the iron. Kish graphite, as it is often called, appears as straight, coarse plates. It greatly
reduces the mechanical properties of the iron and produces a rough surface finish when machined. Type C graphite is,
however, desirable in applications requiring a high degree of heat transfer.

Graphite flake sizes as categorized in ASTM A247 are shown in Fig. 6. Large flakes are associated with irons having high
carbon equivalents and slow cooling rates. Strongly hypoeutectic irons and irons subjected to rapid solidification
generally exhibit small, short flakes. The large flakes are desirable in applications requiring high thermal conductivity and
damping capacity. Small flakes, because they disrupt the matrix to a lesser extent, are desired when maximum tensile
properties and a fine, smooth surface finish are needed.

Fig. 6 Graphite flake sizes as specified in ASTM A 247

Matrix Structure

An etchant such as 2% nital is required to reveal the matrix phases in which the graphite flakes reside. Commonly found
phases in cast iron are ferrite, cementite, and pearlite.