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 Cast iron is the name given to those ferrous

metals containing more than 1.8% carbon.
 The structure of cast iron is marked by presence
of graphite flakes in ferrite or pearlite matrix.
 Cast iron like steels are basically alloys of iron
and carbon.
 Most commercially manufactured types are in
the range of 2 to 4.3 percent carbon.
 Cast iron is made from pig iron,
which is the product of smelting iron
ore in a blast furnace.
 Cast iron can be made directly from
the molten pig iron or by re-melting
pig iron in a cupola furnace.
 Cast iron is the cheaper
metallurgical material available to
the engineers whose composition has
undergone some changes during
melting process.
 It has Good Casting properties.
 It is available in large quantities, hence
produced in mass scale.
 Tools required for casting process are
relatively cheap and inexpensive.
 It can be given any complex shape and
size without using costly machining
operations.
 It has three to five times more
compression strength compared to
steel.
 It has good machinability and excellent
damping properties.
 It has excellent resistance to wear,
abrasion, tear, deformation.
 Grey Cast Iron
 White Cast Iron
 Malleable Cast Iron
 Ductile Cast Iron
 Chilled Cast Iron
 Alloy Cast Iron
 These are iron-carbon alloys having
more than 2.11% carbon.
 All the carbon are present in the
combined cementite form, which
makes the fracture of these alloys to
have dull and white colour, and that
is the reason of their name as white
irons.
 These are very hard and brittle and
cannot be easily machinable, only
grinding can be done.
 Its Compositions: 1.8% - 3.6% Carbon,
0.5% - 1.9% Silicon, 1% - 2%
Manganese and rest Iron.
 It can be used as liners of
cement mixers, ball mills,
drawing dies and extrusion
nozzles.

1. It has good compressive

strength.
2. It is difficult to machine.
3. It has resistance to wear.
 It is produced from white cast iron on
prolonged heating at 900 degree Celsius
followed by slow cooling.
 Two techniques are used to make it
malleable:
1. White Heart Method
2. Black Heart Method
 Graphite is in globular form.
 Graphite nodules are in irregular form.
 Its Compositions: 2.16-2.9% Carbon, 0.9-
1.9% Silicon, 0.15-1.25% Manganese, 0.02-
0.2% Sulphur, 0.02-0.15% Phosphorus.
 It can be used in making parts of
agriculture machinery and
implements, pipe fittings, in
railways for railroad track, etc.

1. They have high ductility.

2. They are tougher than gray cast
iron.
3. They have excellent machining
capabilities.
 It is commonly known as graphite
cast iron.
 It contains flakes form of graphite
whose tips are sharp.
 Here cementite breaks into austenite
and graphite and this process is
known as graphitization.
 During graphitization the colour
changes to grey, therefore it is called
grey cast iron.
 Its Composition: 1.5-4.3% Carbon,
and 0.3-5% Silicon plus manganese,
sulphur and phosphorus.
 It can be used in making wind turbine
housing, electrical boxes, hydraulic
components, stove parts, etc.

1. It has good machinability.

2. It has good resistance to galling and
wear.
3. It is brittle.
 It contains graphite in the form of
spheroidal nodule.
 Its nodule structure irregularity is
less than malleable cast iron.
 A molten metal is desulphurised to
get ductile cast iron, and small
amount of alloys are added such as
magnesium and cobalt in molten
metal.
 It is strong, tough and less porous
compared to grey cast iron.
 Its Compositions: 3.2 to 3.6%
Carbon, 2.2 to 2.8% Silicon, 0.1 to
0.2% Manganese, 0.03 to 0.04%
Magnesium, 0.005 to 0.04%
Phosphorus, rest is iron.
 It can be used in making pipe,
automotive components, gear boxes,
etc.

1. It has high ductility.

2. It has high strength.
 Rapid cooling process is called
chilling and the iron we get by rapid
cooling is called chilled cast iron.
 In this method moulding chills are
attached and due to this molten
metal in surface gets cooled faster
than the molten metal in the core.
 There occurs rapid cooling due to
which layers of white cast iron is
seen in the surface metal.
 It is difficult for machining process
but can be processed by grinding.
 It can be used in making hammers,
dies, road rollers, etc.

1. It is difficult to machine.
2. It has resistance to wear.
 External elements are added to cast
iron to overcome the deficiencies and
to increase them and make superior.
 Mechanical properties gets upgraded.
 Through alloying cast ability and
machine ability gets increased.
 Common Alloys: Nickel, Copper,
Chromium, Molybdenum, Vanadium,
etc.
 It is prone to rusting.
 It has poor tensile strength.
 Failure of its parts is sudden and
total, it does not exhibit yield
point.
 It has high weight to strength ratio.
 Compared to steel it has poor
machinability.
 It has high brittleness.
 It has poor impact resistance.