Cast iron

Cast ironis a group ofiron-carbonalloyswith a

carbon content greater than 2%.
Its usefulness derives from its low melt temperature.
The alloy constituents affect its colour when fractured:
white cast iron hascarbideimpurities which allow
cracks to pass straight through;grey cast ironhas
graphite flakes which deflect a passing crack and
initiate countless new cracks as the material breaks
Carbon (C) ranging from 1.84wt%, andsilicon(Si) 1
3wt% are the main alloying elements of cast iron.
Iron alloys with less carbon content are known as
steel.

type

Grey C.I
White C.I
Malleable C.I
Ductile C.I

Grey cast iron

Grey cast iron is characterised by its graphitic microstructure,
which causes fractures of the material to have a grey appearance.
It is the most commonly used cast iron and the most widely used
cast material based on weight.
Most cast irons have a chemical composition of 2.54.0%
carbon, 13% silicon, and the remainder iron.
Grey cast iron has less tensile strength and shock resistance than
steel, but its compressive strength is comparable to low- and
medium-carbon steel.
These mechanical properties are controlled by the size and shape
of the graphite flakes present in the microstructure and can be
characterised according to the guidelines given by the ASTM.
Grey C.I is strong under compression, but not under tension.

Chemical composition of Grey cast

iron
Name

Grey cast iron (ASTMA48)

Nominal composition (%
by wt)

C3.4, Si1.8,Mn0.5

Form and condition

Cast

Yield strength [ksi(0.2%

offset)]
Tensile strength [ksi]

50

Elongation [% (in
2inches)]

0.5

Hardness [Brinell scale]

260

Uses

Enginecylinder
blocks,flywheels, gearbox
cases, machine-tool bases

Graphite structure in Grey

cast iron
Diagrammatic representations of the
standard flake graphite sizes in grey cast
iron at x100 magnification

Graphite distribution in grey

cast iron

Graphite distribution in grey

cast iron

Inoculants

a series of high quality inoculants to treat cast iron and

ensure the production of the ideal graphite form,
distribution and freedom from chill (cementite).
The following are examples

Inoculant

Active
Element

Advantages and Uses

Superseed
75/50

Si Sr

Low Al content. Low eutectic cell

count through lower addition rates.
High chill reduction.

Ultraseed

Si Ca Ce (Al S High
nodule
count.
Improved
O)
nodularity. Helps to prevent microshrinkage. Reactivates "dead" irons.

Superseed
Extra

Si Sr Zr

In addition to the advantages of

Superseed
75
inoculant,
Superseed Extra produces grey
irons with a refined graphite
structure and enhanced mechanical
properties.

Ductile cast iron

nodularorductile cast ironhas its graphite in the form of very
tiny nodules with the graphite in the form of concentric layers
forming the nodules.
As a result, the properties of ductile cast iron are that of a
spongy steel without the stress concentration effects that flakes
of graphite would produce.
Tiny amounts of 0.02 to 0.1%magnesium, and only 0.02 to
0.04%ceriumadded to these alloys slow the growth of graphite
precipitates by bonding to the edges of the graphite planes.
Along with careful control of other elements and timing, this
allows the carbon to separate as spheroidal particles as the
material solidifies.
The properties are similar to malleable iron, but parts can be
cast with larger sections.

Chemical composition of Ductile

cast iron
Name

Ductile or nodular iron

Nominal composition (%
by wt)

C3.4, P0.1, Mn0.4,Ni1.0,

Mg0.06

Form and condition

Cast

Yield strength [ksi(0.2%

offset)]

53

Tensile strength [ksi]

70

Elongation [% (in
2inches)]

18

Hardness [Brinell scale]

170

Uses

Gears,camshafts, crankshafts

Graphite size in ductile

iron

Some abnormal graphite forms in

ductile iron