Chapter Three

CHAPTER THREE
CAST IRON
 Outlines:-
 Introduction
 Method of production
 Types of Cast Iron:- Gray Cast Iron, White Cast Iron,

Malleable Cast Iron, Nodular Cast Iron and Alloy Cast
Iron
 Micro structure,
 Properties, Composition, Advantages and Applications;
 Heat Treatment of Cast Iron.

27-Apr-22 Zemach S. (MSc.) 2
Introduction
 Cast iron is made from pig iron, which is the product of
melting iron ore in a blast furnace.
 Cast iron can be made directly from the molten pig iron or
by re-melting pig iron, often along with large quantities of
iron, steel, limestone, carbon (coke) and taking various steps
to remove undesirable contaminants.
 Cast iron is one of the oldest ferrous metals in commercial
use and primarily composed of iron (Fe), carbon (C) and
silicon (Si), but may also contain traces/chains of sulfur (S),
manganese
27-Apr-22
(Mn) and phosphorus
Zemach S. (MSc.)
(P). 3
Con…
 It has a relatively high carbon content of 2% -5% & typically
brittle and nonmalleable (i.e. it cannot be bent, stretched or
hammered into shape) and relatively weak in tension.
 Cast iron members tend to fracture with little prior deformation.
 Cast iron, however, has excellent compressive strength and is

commonly used for structures that require this property.
 The composition of cast iron, the method of manufacture and

heat treatments employed are critical in determining its final
characteristics.

Manufacture of Cast-Iron:
• The cast-iron is manufactured by re-melting pig-iron with
coke and limestone.
• This re-melting is done in a furnace known as the cupola

furnace.
• It is more or less same as the blast furnace, but it is smaller

in size.
• Its shape is cylindrical with diameter of about 1 m and

height of about 5 m.

Con…
shows a typical cupola furnace.

Con…
 To achieve the best casting for a particular application
consistent with the component‟s requirements; It‟s-
necessary-to have an understanding of the various types of
cast iron.
• The general description of cast iron is meaningless, except
when distinguishing the part from a steel casting.
• Therefore, a more specific description should be made; Cast
irons can be divided into five or more groups, based on
composition and metallurgical structure.
Con…
 It contain iron with more than 2% carbon and versatile
metal that‟s used in a wide range of consumer and
commercial applications.
 It‟s been around since the 5th century B.C., during which it
was used to make weapons and agriculture products. Since
then, it become an increasingly common type of metal.
 While all cast iron has a carbon content of above 2% and

there are several different types of cast iron, each of which
is unique.
Types of Cast Iron
1. Gray cast iron
2. Ductile cast iron
3. White cast iron
4. Malleable cast iron
5. Compacted graphite iron
6. Alloy cast iron

Con…
 The composition of cast iron (CI) varies significantly
depending upon the grade of pig iron used in its
manufacturing.
 The mode & concentration of carbon in the CI is controlled

to produce various grades of CI, which differ significantly
in their mechanical properties and weld-ability.
 Because of their relatively high silicon content; cast irons

naturally resist oxidation & corrosion by rising a tightly
adhering oxide & subscale to minimize further attack.
Con…
 Iron castings are used in applications where this resistance
provides relatively long service lives.
 Resistance to heat, oxidation and corrosion are appreciably

enhanced with alloyed irons.
 However, since cast irons contain more than 2% C, 1-3%

silicon and up to 1% manganese, their weld-ability is poor.
 As cast irons are relatively inexpensive, easily cast into

complex shapes and readily machined, they are an important
group of materials.
Con…
 Unfortunately most grades are not weld-able and special
precautions are normally required even with the weld-able
grades.
 One reason for the wide use of iron castings is the high ratio
of performance to cost that they offer.
 This high value results from many factors, one of which is
the control of microstructure and properties that can be
achieved in the cast condition, enabling a high percentage of
ferritic and pearlitic iron castings to be produced without the
extra
27-Apr-22
cost of heat treatment.
Zemach S. (MSc.) 12
1. Gray Cast Iron
 The most common type is gray cast iron; its features is a
graphite microstructure consisting of many small fractures.
 It‟s called “gray cast iron” because the presence of these

small fractures creates the appearance of a gray color.
 When gray cast iron is produced, the fractures open up to

reveal the gray-colored graphite below the surface.
 Gray cast iron isn‟t as strong as steel, nor is it able to absorb

the same shock as steel.

Con…
 In another said gray cast iron offers similar compressive
strength as steel. As a result, it‟s become a popular choice of
metal for applications involving compressive strength.
 Its is one of the most widely used castings and typically
contains between 2,5%-4%C and between 1% -3% silicon.
 Gray CI is the oldest and most common form of CI.
 As a result, many people assume it is the only form of CI &
the terms “cast iron” & “gray iron” are used interchangeably.
 Unfortunately, the brittleness of gray iron also assigned to all
CIs.
Con…
 When a gray iron casting fractures, the crack path follows
these graphite flakes and the fracture surface appears gray
because of the presence of exposed graphite.
 The flakes of graphite have good damping characteristics

and good machinability because the graphite acts as a chip
breaker and lubricates the cutting tools.

2. White Cast Iron
 While not as common as gray cast iron, white cast iron is
another type worth mentioning.
 It receives its namesake from its off-white color, which is

the result of iron compounds known as cementite.
 Like gray cast iron, white cast iron features many small
fractures.
 The difference is that white cast iron features cementite

below its surface, whereas gray cast iron features graphite
below its surface.
Con…
 The graphite creates the appearance of a gray color, while
the cementite creates the appearance of a white color.
 White cast iron is hard and offers excellent resistance

against abrasions.
 White CIs are hard; brittle and cannot be machined easily.
 White CI is the only member of the CI family in which

carbon is present only as carbides.
 Because of the absence of graphite, it has a light

appearance.
Con…
 The presence of different carbides makes white CIs
extremely hard and abrasion resistant, but also very brittle.
 The microstructure of white CI contains massive cementite

(white) and pearlite.
 White cast iron derives its name from the white, crystalline
crack surface observed when a casting fractures.
 Most white cast irons contain less than 4.3% carbon, with
low silicon contents to inhibit the precipitation of carbon as
graphite.
Con…
 It is used in applications where abrasion resistance is
important and ductility not required, such as liners for
cement mixers, ball mills, certain types of drawing dies and
extrusion nozzles.
 White cast iron is generally considered unweldable.
 The absence of any ductility that can accommodate

welding-induced stresses in the base metal and heat affected
zone adjacent to the weld results in cracking during cooling
after welding.
3. Ductile Cast Iron
• Also known as nodular cast iron, ductile cast iron is a type
of soft, ductile iron alloy with a high carbon content.
• It‟s typically made with trace amounts of other compounds,

including magnesium and cerium.
• When added, these trace compounds inhibit the speed at

which graphite grows, thereby keeping the metal soft and
ductile.
• Ductile cast iron was invented in the early to mid-1940s.

4. Malleable Cast Iron
 Malleable cast iron that easily “workable.” and It‟s typically
created using heat treatment processes on white cast iron.
 The white cast iron is heated treated for up to two days,

after which it‟s cooled.
 When finished, malleable cast iron can be bent and

manipulated to achieve unique shapes and sizes.

Con…
 Malleable irons are a class of cast irons with mechanical
strength properties that are intermediate to those of gray and
ductile cast irons.
 The microstructure provides properties that make malleable

irons ideal for applications where toughness and
machinability are required and for components that are
required to have some ductility or be malleable so that they
can be bent or flexed into position without cracking.

Con…
 They are often used as the material of choice for small
castings or castings with thin cross sections which, in other
irons, would tend to have chill (carbides at the surface due
to the rapid cooling rates in thin sections).
 Another significant aspect is that the malleable properties

can exist up to the surface of the casting (as opposed to in
ductile irons where the cast surface can contain flake or
distorted graphite), creating a stronger casting.

Con…
 Malleable cast iron is produced by heat treating white cast iron.
Iron carbide decomposes into iron and carbon under certain
conditions.
 This decomposition reaction is favored by high temperatures,

slow cooling rates and high carbon and silicon contents.
 At room temperature, the microstructure therefore consists of

temper carbon nodules in a ferrite matrix, generally known as
ferritic malleable cast iron resulting in improved ductility.
 The graphite nodules also serve to lubricate cutting tools, which

accounts for the very high machinability of malleable cast iron.
5. Compacted (Vermicular) Graphite Cast Iron
 Compacted graphite irons (CG irons) are a type of cast irons
having properties between those of flake and nodular
graphite cast irons.
 They are of interest because of their useful combination of
strength, thermal conductivity and other properties.
 Their production requires controls similar to those applied
in the manufacture of ductile iron castings.
 It is recommended to add a high efficiency substance for
production of CG irons.
Con…
 Higher level of inoculant additions results in a fine
distribution of compacted graphite throughout castings and
less sensitivity to carbide formation.
 Although the graphite particles are elongated and randomly

oriented as in gray iron, they are shorter and thicker and
have rounded edges.
 Furthermore, while the compacted graphite particle shape

may appear worm-like when viewed on a cross section, the
„worms‟ are actually interconnected.
Con…
 This complex graphite morphology, together with the
irregular bumpy surfaces, results in strong adhesion
between the graphite and the iron matrix, and inhibits both
crack initiation and propagation and is the source of the
improved mechanical properties relative to gray cast iron.

6. Chilled Cast Iron
 When a localized area of a cast iron is cooled very rapidly from the
melt, carbides are formed. This type of cast iron is called chilled iron.
 Adjusting the carbon composition of the white CI can produce a

chilled iron casting, so that the normal cooling rate at the surface is
just fast enough to produce carbides while the slower cooling rate
below the surface will produce gray or ductile iron.
 The depth of chill decreases and the hardness of the chilled zone
increases with increasing carbon content. Chromium is used in small
amounts (1 to 4%) to control chill depth, increase hardness, and
improve abrasion resistance.
7. Alloyed Cast Iron
 These irons are classified as two types: corrosion-resistant
and elevated-temperature service.
 Corrosion-resistant alloyed cast iron is used to produce parts

for engineering applications that operate in an environment
such as sea water, sour well oils, commercial organic and
inorganic acids and alkalis.
 Elevated-temperature service alloyed iron resists fracture

under service loads, oxidation by the ambient atmosphere,
growth and instability in structure up to 1,100°F (600°C).
Con…
 The ability to cast complex shapes and machine alloyed
irons makes them an attractive material for the production
of components in chemical processing plants, petroleum
refining, food handling and marine service.
 The high chromium containing CI is used in circumstances

where high wear resistance is desirable, such as during the
crushing of rocks and minerals.
 The iron contains a combination of very strong carbide-

forming alloying elements, such as Cr, Mo and Ni.
Properties And Specifications Of Cast Irons
 Most common features and typical applications for the
various types of CIs are given below with their
corresponding industry specifications.

Properties of Cast-Iron:
Following are the properties of cast-iron:-
a. If placed in salt water, it becomes soft.
b. It can be hardened by heating and sudden cooling, but it cannot
be tempered.
c. It cannot be magnetized.
d. It does not rust easily.
e. It is fusible.
f. It is hard, but it is brittle also.
g. It is not ductile and hence it cannot be adopted to absorb shocks
and impacts.
h. Its melting temperature is about 1250°C.
Con…
a. It shrinks on cooling. This fact is to be considered while making
patterns or moulds for foundry work.
b. Its structure is granular & crystalline with whitish/greyish tinge.
c. Its specific gravity is 7.5.
d. It lacks plasticity and hence it is unsuitable for the forging work.
e. It is weak in tension and strong in compression. The tensile and
compressive strengths of cast-iron of average quality are respectively
150 N/mm2 and 600 N/mm2.
f. The two pieces of cast-iron cannot be connected by the process of
riveting or welding. They are to be connected by nuts and bolts which
are fixed to the flanges. The holes for bolts, etc. are either drilled out
or27-Apr-22
cast in the casting. Zemach S. (MSc.) 35
 The use of cast-ironUses
is notofrecommended
Cast-Iron: in horizontal direction
either for heavy or variable loads or at places where there are
chances for the slightest shock to exist.
 The cast-iron cracks and snaps suddenly when subjected to the

shocks, overloading or fire without giving any warning of
approaching failure under such stresses.
 The cast-iron to be used on the works should be tough, close-

grained grey metal, free from air holes, sand holes, flaws and with
an even surface.
 It should be sufficiently soft to admit of being easily cut either by a

chisel
27-Apr-22 or a drill. Zemach S. (MSc.) 36
Following are the Important Uses of Cast-iron:
a. For making cisterns, water pipes, gas pipes and sewers, manhole
covers and sanitary fittings.
b. For making parts of machinery which are not subject to heavy

shocks.
c. For manufacturing compression members like columns in

buildings, bases of columns, etc.
d. For preparing agricultural implements.
e. For preparing rail chairs, carriage wheels, etc. (ii) For making
ornamental castings such as brackets, gates, lamp posts, spiral
staircases, etc.
Heat Treatment of CI
• The most common heat treatment applied to gray cast irons
is stress relief because of non-uniform cooling of castings
and annealing to improve machinability.
• Subcritical heating is used for both. Stress relief is done at

temperatures between 550-650°C (1020-1200°F) without
significantly lowering strength and hardness

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CHAPTER THREE

 Types of Cast Iron:- Gray Cast Iron, White Cast Iron,

 Properties, Composition, Advantages and Applications;

 Heat Treatment of Cast Iron.

 Cast iron members tend to fracture with little prior deformation.

 Cast iron, however, has excellent compressive strength and is

 The composition of cast iron, the method of manufacture and

27-Apr-22 Zemach S. (MSc.) 4

• This re-melting is done in a furnace known as the cupola

• It is more or less same as the blast furnace, but it is smaller

• Its shape is cylindrical with diameter of about 1 m and

27-Apr-22 Zemach S. (MSc.) 5

shows a typical cupola furnace.

 While all cast iron has a carbon content of above 2% and

2. Ductile cast iron

3. White cast iron

4. Malleable cast iron

5. Compacted graphite iron

6. Alloy cast iron

27-Apr-22 Zemach S. (MSc.) 9

 The mode & concentration of carbon in the CI is controlled

 Because of their relatively high silicon content; cast irons

 Resistance to heat, oxidation and corrosion are appreciably

 However, since cast irons contain more than 2% C, 1-3%

 As cast irons are relatively inexpensive, easily cast into

 It‟s called “gray cast iron” because the presence of these

 When gray cast iron is produced, the fractures open up to

 Gray cast iron isn‟t as strong as steel, nor is it able to absorb

27-Apr-22 Zemach S. (MSc.) 13

 The flakes of graphite have good damping characteristics

27-Apr-22 Zemach S. (MSc.) 15

 It receives its namesake from its off-white color, which is

 The difference is that white cast iron features cementite

 White cast iron is hard and offers excellent resistance

 White CIs are hard; brittle and cannot be machined easily.

 White CI is the only member of the CI family in which

 Because of the absence of graphite, it has a light

 The microstructure of white CI contains massive cementite

 White cast iron is generally considered unweldable.

 The absence of any ductility that can accommodate

• It‟s typically made with trace amounts of other compounds,

• When added, these trace compounds inhibit the speed at

• Ductile cast iron was invented in the early to mid-1940s.

27-Apr-22 Zemach S. (MSc.) 20

 The white cast iron is heated treated for up to two days,

 When finished, malleable cast iron can be bent and

27-Apr-22 Zemach S. (MSc.) 21

 The microstructure provides properties that make malleable

27-Apr-22 Zemach S. (MSc.) 22

 Another significant aspect is that the malleable properties

27-Apr-22 Zemach S. (MSc.) 23

 This decomposition reaction is favored by high temperatures,

 At room temperature, the microstructure therefore consists of

 The graphite nodules also serve to lubricate cutting tools, which

 Although the graphite particles are elongated and randomly

 Furthermore, while the compacted graphite particle shape

27-Apr-22 Zemach S. (MSc.) 27

 Adjusting the carbon composition of the white CI can produce a

 Corrosion-resistant alloyed cast iron is used to produce parts

 Elevated-temperature service alloyed iron resists fracture

 The high chromium containing CI is used in circumstances

 The iron contains a combination of very strong carbide-