Bangladesh University of Engineering and Technology

Course No: MME 346

Experiment No: 06
Name of the experiment: Cast Iron Foundry Practice.

Date of performance:
Date of submission: 07-01-23

Submitted by-
Name: Farjana Yesmin
Student ID: 1811014
Level/Term: 3/2
Other group members:
1811008,1811009,1811010,1811011,1811012,1811013
Objective
Main objective of this experiment is to study the effects of process variables on the properties and
nature of cast iron.

Introduction
Cast iron is those which contains higher carbon percentage, normally 2 to 6.67 percent. Due to the
presence of high carbon content, this is very brittle in property. It is called cast iron because casting
is the only process by which it can be shaped. Depending on the cooling condition, carbon
percentage and other compositions, different phases like pearlite ledeburite, austenite , transformed
ledeburite may formed in cast iron. Also, excess carbon may produce graphite flakes.

Depending on the fracture, cast iron may classified in different types such as white cast iron, gray
cast iron, nodular cast iron, malleable cast iron, mottled cast iron and so on. These show different
physical and mechanical properties, for which uses of these are also different. Many of them show
graphite flakes of different shapes which are very important for their property. Different factors
are controlled in different ways to form graphite flakes to get desired amount and shape of graphite
flakes. Section size, superheat, inoculation are some factors of them. Inoculations are basically
chemical compounds which promote the graphitization process. With a higher thickness of section,
cooling rate becomes lower and graphite formation occurs in higher amount. For the thin section,
property is opposite to it. Cooling rate and graphitization also vary from edge area to centroid area
of sample specially for wedge-shaped. Depending on these factors, mechanical properties and
microstructure also vary from edge to central area.

Procedure

• A previously prepared wedge-shaped cast iron sample had been taken.

• Dry grinding, wet polishing and etching have been done.
• The sample was placed properly on a glass plate in the microscope.
• Microstructure was observed and picture has been captured.
• The sample was taken for measuring Brinell hardness.
• Readings of indenter diameter, applied force and sample diameter had been taken.
• Data table had been prepared using the measured data.
Calculation
For Brinell hardness:

Force, P= 1000 kgf

Diameter of indentation, D = 10mm

Depression diameter, for ‘a’ point, da = 47 division =3.48 mm

For ‘b’ point, db = 48 division = 3.56 mm

For ‘c’ point, dc = 47division = 3.48 mm

For ‘d’ point, dd = 48 division = 3.56 mm

For ‘e’ point, de = 50 division = 3.70 mm

For ‘f’ point, df = 48 division = 3.56 mm

2𝑃
Brinell hardness Number, BHN = 1
πD(D−(𝐷2 −𝑑2 )2 )

Figure 1: cross section of wedge-shaped

cast iron sample

Indentation Depression Brinell hardness

Applied force, P
Name of point diameter, D diameter, d number, BHN
( kgf)
(mm) (mm) (kgf/mm2)
a 3.48 101.85
b 3.56 97.17
c 3.48 101.85
10 1000
d 3.56 97.17
e 3.70 89.70
f 3.56 97.17
Result

Figure-1: microstructure for Figure-2 : microstructure for

‘a’ point ‘b’ point

ferrite

Graphite
flakes

Figure-3: microstructure for Figure-4: microstructure for

‘c’ point ‘d’ point
 cementite

Pearlite

Figure-5: microstructure for Figure-6: microstructure for

‘e’ point ‘f’ point

Discussion
The microstructure of sample has been observed in different points of the surface at 500x
magnification. In different sections, there exists ferrite, pearlite phases in matrix with graphite
flakes. For a, c, e, f points, matrix contains maximum portion of pearlite with a small amount of
ferrite phase. On the other hand, in b and d points, maximum portion of matrix consists of ferrite
phase and small portion of pearlite. There observed a very small portion of cementite also in some
of the pictures.

1. Effect of inoculations: Inoculations are those chemical compounds which are used to
promote graphitization rate. That means at the presence of inoculations, more graphite
flakes will form in the cast iron structure. Also, it helps to produce more eutectic cells. The
presence of multiple inoculants affect the properties of cast iron in many ways. When
ferrosilicon is used as secondary inoculants, it increases the hardness of the sample. By
being present in the structure, it reduces undercooling.
When it is producing white cast iron with no graphite flakes, it can be transformed into
gray cast iron by using proper kind and amount of inoculants.
In this experiment, no inoculants were used in casting of sample for which microstructure
and hardness have been observed. If inoculants were used, amount of graphite flake might
 be increased in the sample. Also mechanical and physical properties may differ from
present value.
Effect of cooling rate: Cooling rate has a significant effect on the structure and properties
of cast iron. With a higher cooling rate, it promotes the formation of cementite structure
rather than graphite flakes, which influences the formation of white cast iron. On the other
hand, with a lower cooling rate, it promotes the formation of graphite flakes. Thus, it may
produce gray or other types of cast iron rather than white cast iron. In thin sections, cooling
rate remains faster than thick sections. Therefore, there exists many possibilities to get
more cementite in thin sections and formation of cast iron with graphite flakes may not
occur.
Depending on these microstructures of cast iron properties also vary from one to another.
Normally, cast iron produced by fast cooling, shows higher hardness , lower strength,
higher brittleness. It also decreases castings machinability.
In this experiment, as a previously prepared sample was used, it was not possible to observe
the effect of cooling rate.
2. Reason for adding inoculations just before pouring:
Normally it is asked to add inoculants just before pouring in casting procedure. Reason
behind doing this is, inoculants show maximum efficiency within 10 to 20 minutes time
period from the time when added. After this, its effectiveness decreases gradually. That’s
why it seems important to add this as late as possible. Thus, to ensure the best output,
inoculant addition is done late. This also influence the reduction of fading effects, necessity
of lower cost, improving metallurgical consistency in composition and so on.