Cast Iron H

Structure and Properties of White Cast Iron

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Cast Iron

Compacted
Ductile Malleable
Grey Cast White Cast Graphite
Cast Cast
Cast

Structure Properties

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Cast Iron H
Structure and Properties of White Cast Iron

Cast Iron
• Cast iron is part of a large family of multi-component Fe-C-Si alloys, which
solidify according to the eutectic of the Fe-C system.

• Cast iron is an alloy of iron with more than 2% carbon as the main alloying
element.

• In addition to carbon, cast iron also contain 0.5- 3% silicon, 0.1- 1.2%
manganese and traces of impurities such as sulfur and phosphorus.

• Cast iron is made by reducing iron ore in a blast furnace. Liquid iron is cast into
crude ingots called pig iron.

• Pig iron is subsequently melted with scrap and alloying elements in a cupola
furnace. The refined product is known as cast iron.
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Cast Iron H
Structure and Properties of White Cast Iron

Classification of Cast Iron

• Cast iron is classified based on the form of carbon present and according to
their solidification morphology.

• The types of cast iron are as follows:

• Grey cast iron
• White cast iron
• Ductile, nodular or spheroidal cast iron
• Malleable cast iron
• Compacted graphite cast iron

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Cast Iron H
Structure and Properties of White Cast Iron

Classification of Cast Iron – Grey Cast Iron

• The presence of carbon in the form of
graphite flakes makes the fractured
surface of this alloy look greyish.

• Therefore, this form of cast iron is

called grey cast iron.

• It is a result of stable solidification and

is produced by slow cooling.
Figure 1: Microstructure of gray cast iron

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Cast Iron H
Structure and Properties of White Cast Iron

Classification of Cast Iron – White Cast Iron

• White irons is formed from alloys low
in silicon content, with carbon
equivalent sufficiently below the
eutectic point or with sufficient rapid
cooling rate.

• The structure of white iron consists of

dendrites of pearlite surrounded by
iron carbide.

Figure 2: Microstructure of white cast iron

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Cast Iron H
Structure and Properties of White Cast Iron

Classification of Cast Iron – Ductile Cast Iron

• This type of cast iron consists of
graphite in small, rounded, well
distributed particles. This results in
higher ductility.

• This iron is stronger and more

ductile than grey cast iron.

Figure 3: Microstructure of ductile cast iron

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Cast Iron H
Structure and Properties of White Cast Iron

Classification of Cast Iron – Malleable Cast Iron

• In this type of cast iron,
graphite is present in the form
of clusters in the matrix of
pearlite and ferrite.

• Malleable cast iron is produced

by controlled heat treatment of
white cast iron at 900o C.

Figure 4: Microstructure of malleable cast iron

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Cast Iron H
Structure and Properties of White Cast Iron

Classification of Cast Iron – Compacted Graphite Cast Iron

• This type of cast iron consists of
graphite in the form of short, thick
and interconnected flakes with
rounded ends.

• The properties of this cast iron are

consistent throughout the casting.

• Compacted graphite cast iron’s

dumping and thermal properties Figure 5: Microstructure of compacted
are similar to the gray cast iron. graphite cast iron

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Cast Iron H
Structure and Properties of White Cast Iron

Classification of Cast Iron

• The following table shows the percentage of alloying elements present in cast
iron:

Type of Cast Iron Carbon % Silicon % Manganese % Sulfur % Phosphorus

%

Grey cast iron 2.5 – 4.0 1.0 – 3.0 0.2 – 1.0 0.02 – 0.025 0.02 – 1.0

White cast iron 1.8 – 3.6 0.5 – 1.9 0.25 – 0.8 0.06 – 0.2 0.06 – 0.2

Ductile cast iron 3.0 – 4.0 1.8 – 2.8 0.1 – 1.0 0.01 – 0.03 0.01 – 0.1

Malleable cast iron 2.0 – 2.9 0.9 – 1.9 0.15 – 1.2 0.02 – 0.2 0.02 – 0.2

Compacted graphite cast 2.5 – 4.0 1.0 – 3.0 0.2 – 1.0 0.01 – 0.03 0.01 – 0.1
iron

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Cast Iron H
Structure and Properties of White Cast Iron

Structure and Properties of White Cast Iron

• White cast iron is the only member in the cast iron family in which carbon is
present only as a carbide

• The name come from the surface which has a white crystalline appearance
when it is fractured.

• The absence of graphite in white cast iron makes the appearance look lighter.

• White cast iron consist of different carbides, depending on the alloy content.

• Therefore, white cast iron is extremely hard and resistant to abrasion, but is
very brittle.

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Cast Iron H
Structure and Properties of White Cast Iron

Structure of White Cast Iron

• An improved form of white cast iron is called chilled cast iron.

• The carbon content in this type of iron is in the form of cementite and pearlite.

• White cast iron can be produced by either of two methods:

1. Molten gray cast iron is cooled at a very high rate after it is poured in the
mould. The high cooling rate converts all the carbon into carbide leaving
no free carbon.

2. By adjusting the composition of gray cast iron so that carbon and silicon
content is kept low. When the silicon percentage is low, the chances of
forming graphite are reduced. Thus, the resulting structure has carbon in
the form of cementite or pearlite.

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Cast Iron H
Structure and Properties of White Cast Iron

Structure of White Cast Iron

• When the silicon content in white cast iron is below 1%, it hard, brittle, and
wear resistant.

• When chromium is added above 3%, it prevents the formation of graphite and
the result has better high temperature resistance and corrosion resistance.

• The chemical composition of white cast iron is given below:

• C = 3.2 to 3.6%
• Si = 0.4 to 1.1%
• Mg = 0.1 to 0.4%
• P = less than 0.3%
• S = less than 0.2%
• Fe = remaining percentage

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Cast Iron H
Structure and Properties of White Cast Iron

Properties of White Cast Iron

• The freshly broken surface of white cast iron shows a bright white fracture.

• Very hard and brittle, due to the presence of iron carbide (Fe3C). Accordingly,
white cast iron is also difficult to machine.

• Excellent abrasive wear resistance.

• Solidification range is 2650 – 2065o F.

• Can shrink to 1/8 inch per foot.

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