MM212_Experiment: 4

Microstructure of Cast Iron

Abhishek Kumar
19D110002

Aim: Microstructural observation of different types of cast iron, measuring their volume
fraction.

Procedure:

The grain size of phases

● We are using line intercepts techniques using Imagej.

● Lines are drawn in the photo microstructure using the Imagej software and
the number of grain boundaries is calculated.The length of the line is set
with help of scale bar given in the image section.
● If line cutting the boundary , take it as 1 , If line touching the boundary ,
take it as 0.5 , If line passing the triple point , take it as 3/2.
● Repeat it for multiple random lines and collect the data.
● The total number of grain boundaries(or say, total no. of intercepts) are
denoted by N and the sum of the length of the lines is denoted by L
● Mean linear intercept is then calculated by L_0=L/N and grain size by
D=3/2* L_0.

Volume fraction measurement (Grid method)

● We consider mean volume fraction = mean area fraction = mean point

fraction.
● Open the given image in ImageJ.
● Insert grid in the image using ‘Analyze’ -> ‘Tools’ ->‘Grid’.
● Select Area per point as required and select Randomoffset.
● Now count the number of points lying on phase 2 using the following
conventions: - Point lying completely in the phase(p1) – 1 - Point touching
the phase(p2) - ½
● Volume fraction = (1*p1 + ½*p2)/(Total number of points).
● Do this calculation 5 times using different random offsets.
● Collect this data from all other members of the group.
● Calculate the mean, standard deviation, standard error for this data
Analysis and Results:

For Image C5 :

1. Volume Fraction :

For C5_200X_1.jpg:

Total No. of Points lying on Points lying N = 0.5*H + F

points(T) boundary (H) completely
inside Pearlite
(F)
88 15 6 18

Volume Fraction = N/T = 0.2045 = 20.45%

Using Team’s Data:

Mean Volume Fractions of 6 Teammates:

C5_200X_M1 0.1988

C5_200X_M2 0.2187

C5_200X_M3 0.2245

C5_200X_M4 0.2045

C5_200X_M5 0.2134

C5_200X_M6 0.1868

Mean = 0.20778 = 20.78%

Standard Deviation = 1.387%

For Image C4_100X_2.Jpg:

Total No. of Points lying on Points lying N = 0.5*H + F
points(T) boundary (H) completely
inside Pearlite
(F)
88 17 7 20.5

Volume Fraction = N/T = 0.2329 = 23.29%

Using Team’s Data:

Mean Volume Fractions of 6 Teammates:

C4_100X_M1 0.2434

C4_100X_M2 0.2210

C4_100X_M3 0.2329

C4_100X_M4 0.2288

C4_100X_M5 0.2456

C4_100X_M6 0.2148

Mean = 0.23108 = 23.11%

Standard Deviation = 1.215%

3. Identify and Label the Phases Present

White Part : Ferrite White Part : Cementite

Black Part : Graphite Black Part : Graphite
Conclusion:

● Mean Volume Percentage for C-4 calculated is 23.108% .

● Mean Volume Percentage for C-5_200x calculated is 20.78%.

Theory Questions

1. Compare mechanical properties with reference to its microstructures for

different cast irons.

● White Cast iron: Due to the lack of graphite, white cast iron has a light
appearance. It has a high compressive strength and maintains its
hardness and strength at elevated temperatures. Depending on the alloy,
different carbides are present.

● Gray Cast Iron: A good property of gray cast iron is that free graphite in its
structure acts as a lubricant. For this reason, it is highly suitable for parts
where sliding action is desired.

● Malleable Cast iron: The malleable cast iron is ductile and may be bent
without breaking or fracturing the section. Its tensile strength is higher than
gray cast iron and has excellent machining qualities.

● Ductile iron: The spheroidal shape of ductile iron's graphite is responsible

for its extraordinary mechanical properties: tensile strength, impact
resistance, high elastic limit, and good elongation. Controlling the chemical
analysis and heat treatment of the metal matrix improves these properties
even more.

● Alloy cast iron: To improve the mechanical and physical qualities of cast
iron, certain alloying elements are added. Chromium carbide is formed
when chromium is added. This improves the strength, wear, and abrasion
resistance of the material. To dissolve huge cementite granules and hence
strengthen the matrix, copper is used.
2. Explain Hypereutectic, Eutectic, and Hypoeutectic white Cast iron with the help
of Fe-C equilibrium phase diagram.

● White cast iron is classified as eutectic cast iron (4.3 percent carbon),
hypoeutectic cast iron (<4.3 percent carbon), or hypereutectic cast iron
(>4.3 percent carbon).The melt solidifies as follows if the cast iron has a
eutectic content of 4.3 percent carbon.At a thermal arrest, this is typical.
● A delicate combination of austenite has formed as a result of the severe
supercooling.Cementite is generated as a result of this process. This finely
dispersed austenite eutectic microstructure Cementite is also known as
ledeburite-I when it has solidified.When it comes to Only austenite primary
crystals precipitate from the melt of hypoeutectic cast iron.when you hit the
liquidus line.This increases the carbon content in the residual melt.
● Once the carbon content has finally risen to 4.3 % at 1147 °C, the residual
melt crystallizes at a constant temperature to form the eutectic
(ledeburite-I). Immediately after solidification, the microstructure consists of
the eutectic and the previously primarily precipitated austenite crystalsIn
hypereutectic cast iron, only primary cementite with a strip-like structure
crystallizes out initially during solidification.
● Due to the associated carbon precipitation from the residual melt, the
carbon content there is reduced. Once the eutectic composition of 4.3 %
carbon at 1147 °C is finally reached in the residual melt, it solidifies to the
eutectic ledeburit.
3. Write short notes on:

● Machinability of Cast Iron: For mass-production components, cast iron is

a frequent choice. It appeals to machines because it produces very small
chips under practically every cutting situation. Machinability is relatively
high and is mostly determined by the quality of the manufacturing process
and the hardness of the material. It varies from about 200 percent in soft
alloys such as GG10 to 60 percent in strong alloys such as GGG80.

● Weldability of Cast Iron: This is determined by the microstructure and

mechanical properties of the material. Gray cast iron, for example, is
intrinsically fragile and frequently fails to bear the strains imposed by a
cooling weld. Because coarse graphite flakes produce a lack of ductility,
graphite clusters in malleable irons and nodular graphite in SG irons
provide much higher ductility, which improves weldability.

● Damping Capacity of Cast Iron: The amount, shape, and size of graphite
in a lamellar graphite cast iron structure have a significant impact on its
damping ability. The stronger the damping capacity, the greater the amount
and the rougher the precipitation. Strength, on the other hand, diminishes
with increasing graphite concentration and lamella size. The elastic
modulus is inversely related to the damping capacity.

● Applications of Cast Iron: Cast iron can be used for many types of
materials and making different tools. Gray cast iron: Engine cylinder
blocks, flywheels, gearbox cases White cast iron: Bearing surfaces. Ductile
cast iron: Gears, camshafts, crankshafts, piston ring. Cast iron is used to
make a variety of sanitary fittings, including sewer pipes, manholes, water
pipes, and cisterns. Cast iron can be used to create column bases and
metal columns. Lamp posts, metal staircases, gates, and other items are
cast using this mold.