Professional Documents
Culture Documents
Note:
Changes in
eutectic and
eutectoid
compositions
and
temperatures
The Need for Silicon
• The eutectic of graphite occurs at 1154 oC,
• This eutectic reaction is given by
3.66%C
1.5%C
0.05%C undercooling
(Fe-2%Si)-C Phase Diagram
Cast irons contain 1.15 – 2.85% Si – and are thus conveniently described in terms of a pseudo-binary (Fe+2%Si)-C phase diagram.
• The -field is severely constricted – compared to the Fe-C diagram.
• The maximum solubility of C in -Fe is 1.5%C – instead of 2.11% C.
• The eutectic is 3.66%C – instead of 4.26%C
• Thus, the eutectic is given by
%Si
Carbon Equivalent (C.E.) %C 4.3
3
%Si %P
C.E. %C 4.3
3
Effect of Other Elements on the Fe-C Eutectic
• Beside Si and C – the -Fe-Graphite eutectic is also promoted by the following elements:
• Ni – Mg – Al – Ti – Zr – Cu
• which are expensive so not generally added.
• Carbide forming elements – such as Cr & Mo – stabilize the carbide phase and thus promote the (-Fe + Fe3C) eutectic.
• Mn is also a strong carbide (Fe3C) forming solute – but its effect on the eutectic depends on the presence – or absence – of
Sulphur.
• Sulphur is present in cast irons – from the coke used to smelt the pig iron.
• It does not actually form a carbide – but strongly promotes carbide formation, e.g., 0.01%S can offset the graphitizing effect of
0.15% Si.
Effect of Other Elements on the Fe-C Eutectic
• S has a similar affinity for Mn – forming MnS, which itself is neutral - but the first additions of S remove some of
the carbide-stabilizing Mn – and thus can cause the amount of graphite to increase.
• Similarly – the first additions of Mn can remove the S from solution – and again increase the amount of graphite.
• Phosphorus can act in two ways:
• 1) Physically – it forms a phosphide eutectic with a lower melting point than FeC (graphite) – which increases the
time available for Si to promote graphite.
• 2) Chemically – it promotes carbide formation – so large amounts increase carbide formation.
The various alloying elements must thus be carefully balanced to obtain a desired grey or white cast iron.
The Need for Silicon
For Si contents > 2%
• The eutectic is composed of (–Fe + C (graphite)) when
the alloy is cooled slowly.
• These Fe-C alloys are the grey cast irons.
• The eutectic is composed of (–Fe + Fe3C) when the
alloy is chill cast.
• These alloys are the white cast irons.
Casts Irons
• When a sample of cast iron is fractured – the exposed surface may be grey – white- or a mottled
grey/white mixture.
• A sooty grey fracture indicates that the microstructure is composed of graphite flakes in a ferrite matrix.
• This graphite is relatively weak – as the fracture goes from flake to flake – so the grey fracture is mostly
exposed graphite.
• Gray cast iron contains small, interconnected graphite flakes in an alpha iron matrix.
• It has low strength and low ductility.
• Gray cast iron is the most commonly used cast iron for engine blocks.
Casts Irons
• A white fracture means that the microstructure consists of cementite and ferrite – with the
fracture going along – or through – the brittle white areas of cementite.
• White cast iron contains massive amounts of cementite.
• When it fractures it’s surface appears white, hence the name.
• White cast irons are very hard and resistant to wear.
• A mottled colour means that graphite flakes are present in some areas, while cementite is
present in others.
Casts Irons
Schematic drawings of five types of cast irons a) gray iron, b) white iron,
c) malleable iron, d) ductile iron and e) compacted graphite iron.
We will discuss
these in detail.
Casts Irons
Sketch in a) and photograph in b) of the flake structure of graphite in gray cast iron.
Time Temperature Transformation (TTT)
Diagram of Cast Iron
Later we will
discuss TTT
diagrams in
detail.
In fact we’ll
use TTT
diagrams to
make steel
alloys.
Forms of Graphite Flakes
Many forms of cast iron exist depending on its solidification.
• The iron-carbon eutectic can solidify by one or other of the
two reactions:
liquid austenite + graphite What does superheated
liquid austenite + cementite mean?
If a cast iron is superheated to destroy the graphite nuclei –
undercooling will result – and the lower temperature (-
Fe+Fe3C) will form.
However – if there is sufficient Si and/or C present – the
cementite will break down to austenite plus graphite – the
sequence is thus:
liquid austenite + cementite – then cementite
austenite + graphite
This secondary graphite is quite distinct from the eutectic
graphite and forms between the austenite dendrites.
Dendritic Growth Mechanism
Images of dendrites
What is inoculation?
A B
C D
Eutectic Graphite
A. Uniform flakes – random orientation
B. Rosette graphite – by inoculation
C. Non-uniform flakes – random orientation
Secondary Graphite
D. Interdendritic – random orientation
E E. Interdendritic – preferred orientation
Sizes of Graphite Flakes
• Rapid solidification results in finer graphite flakes.
• But too rapid solidification will result in cementite
unless there is a very high Si and C concentration.
Graphite flakes are classified in sizes – like ASTM grain
sizes – according to the maximum length observed at a
magnification of 100x. What does ASTM stand for?
No. 1 Longest flakes > 4 in (100 mm)
No. 2 Longest flakes 2 - 4 in (50 – 100 mm)
No. 3 Longest flakes 1 - 2 in (25 – 50 mm)
No. 4 Longest flakes 0.5 – 1 in (12.5 – 25 mm)
No. 5 Longest flakes (0.25 – 0.5 in (6.25 – 12.5)
No. 6 Longest flakes (0.125 – 0.25 in (3.125 – 6.25)
Etc.
Sizes of Graphite Flakes
What does BHN
And UTS stand for?
Note: C-Eq.
(carbon equivalent)
Graphitization in the “Solid State”
Both grey and white cast irons contain austenite.
• In hypereutectic irons – the austenite is only in the eutectic.
• In hypoeutectic irons – the austenite is the pro-eutectic
constituent – as well as being a constituent of the
eutectic – so the structure consist of austenite dendrites
surrounded by interdendritic eutectic.
• This helps us to understand the structures we see.
• During slow cooling from the eutectic to the eutectoid
temperature – the proeutectic austenite will precipitate
carbon.
• The graphite – or carbide – in the eutectic exerts a strong
nucleation effect – so that the precipitation of excess
carbon from the proeutectic austenite results in the
growth of the eutectic graphite – or cementite.
Graphitization in the Solid State
During slow cooling from the eutectic to the eutectoid
temperature – the proeutectic austenite will precipitate
carbon.
The Eutectoid Transformation in White Cast Irons
Nucleation sites
pearlite
Interdendritic
carbide
The Eutectoid Transformation in Grey Cast Irons