ME 2301: Metallic Material Science

CAST IRON

Md. Ramjan Ali

Asst. Prof., Dept. of ME
DUET, Gazipur
Classification scheme for the various ferrous
alloys

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 2

Cast Iron
• Cast irons are basically alloys of iron and carbon and is obtained
by re-melting pig iron with coke, limestone and steel scrap in a
furnace known as cupola.

• Cast irons contain between 2 and 6.67 percent carbon. Since high
carbon content tends to make the cast iron very brittle, most
commercially manufactured types are in the range of 2.5 to 4
percent carbon.

• It also contains small amounts of silicon, manganese, phosphorus

and sulphur in form of impurities elements.
1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 3
Allotropic Transformation of Pure Iron

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 4

Iron–Iron Carbide (Fe–Fe3C) Phase Diagram

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 5

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 6
Iron–Iron Carbide (Fe–Fe3C) Phase Diagram

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 7

Iron–Iron Carbide (Fe–Fe3C) Phase Diagram

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 8

Iron–Iron Carbide (Fe–Fe3C) Phase Diagram

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 9

Iron–Iron Carbide (Fe–Fe3C) Phase Diagram

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 10

Iron–Iron Carbide (Fe–Fe3C) Phase Diagram

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 11

Iron–Iron Carbide (Fe–Fe3C) Phase Diagram

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 12

Iron–Iron Carbide (Fe–Fe3C) Phase Diagram

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 13

Iron–Iron Carbide (Fe–Fe3C) Phase Diagram

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 14

Iron–Iron Carbide (Fe–Fe3C) Phase Diagram

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 15

Cementite or Iron Carbide
• Cementite or Iron Carbide, chemical formula Fe3C
contains 6.67 percent carbon by weight.

• It is a typical hard and brittle interstitial compound of

low tensile strength (approx. 5,000 psi) but high
compressive strength.

• It is the hardest structure that appears on the iron iron-

carbon diagram.

• Its crystal structure is orthorhombic.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 16
Ferrite
• Ferrite is the name given to the α solid solution. It is an
interstitial solid solution of a small amount of carbon dissolved
in α (b.c.c.) iron.

• The maximum solubility is 0.025 percent C at 1333 oF, and it

dissolves only 0.008 percent C at room temperature.

• It is the softest structure that appears on the diagram.

• Average properties are: tensile strength, 40,000 psi; elongation,

40 percent in 2 in.; hardness, less than Rockwell C 10 or less
than Rockwell B 90.
1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 17
Austenite
• Austenite is the name given to the γ solid solution. It is an
interstitial, solid solution of carbon dissolved in γ (f.c.c.) iron.

• Maximum solubility is 2 percent C at 2065 oF.

• Average properties are: tensile strength 150,000 psi; elongation

10 percent in 2 in.; hardness Rockwell C 40, appprox.; and
toughness, high.

• It is normally not stable at room temperature. Under certain

conditions it is possible to obtain austenite at room
temperature.
1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 18
Photomicrographs of (a) ferrite and (b)
austenite

Fig. 01: Photomicrographs of (a) ferrite and (b) austenite

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 19

Pearlite
• Pearlite is the eutectoid mixture containing 0.80 percent carbon
and is formed at 1333 oF on very slow cooling.

• It is a very fine platelike or lamellar mixture of ferrite and

cementite. The fine fingerprint mixture called pearlite.

• The white ferritic background or matrix which makes up most of

the eutectoid mixture contains thin plates of cementite.

• Average properties are: tensile strength, 120,000 psi; elongation,

20 percent in 2 inch; hardness, Rockwell C 20, Rockwell B 95 –
100, or BHN 250 – 300.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 20

Photomicrograph of pearlite

Fig. 02: Photomicrograph of a eutectoid steel showing the pearlite microstructure

consisting of alternating layers of ferrite (the light phase) and Fe3C (thin layers
most of which appear dark).
1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 21
Ledeburite
• Ledeburite is the eutectic mixture of austenite and cementite.

• It contains 4.3 percent C and is formed at 2065 oF.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 22

What determines the type of cast iron?
• 1) %Si & %C content: Increasing silicon and carbon content
retards cementite formation and stabilizes graphite.

• 2) Cooling rate: Slow cooling favors graphitization.

• 3) Temperature: At high temperatures (>1000ºC) Fe3C tends to

decompose to form graphite.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 23

Microstructure of
Cast Iron

Fig. 03: From the iron–carbon

phase diagram, composition
ranges for commercial cast
irons. Also shown are
schematic microstructures that
result from a variety of heat
treatments.
Gf, flake graphite;
Gr, graphite rosettes;
Gn, graphite nodules;
P, pearlite;
α, ferrite.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 24

Gray Cast Iron
• The carbon and silicon contents of gray cast irons vary

between 2.5 and 4.0 wt.% and 1.0 and 3.0 wt.%, respectively.

• For most of these cast irons, the graphite exists in the form of

flakes (similar to corn flakes), which are normally surrounded

by an α-ferrite or pearlite matrix.

• Because of these graphite flakes, a fractured surface takes on a

gray appearance, hence its name.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 25

Fig. 04: Optical photomicrographs of gray iron: the dark graphite flakes are
embedded in an α-ferrite matrix.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 26

Properties of gray cast iron

• Mechanically, gray iron is comparatively weak and brittle in

tension as a consequence of its microstructure.

• The tips of the graphite flakes are sharp and pointed, and may
serve as points of stress concentration when an external tensile
stress is applied.

• Strength and ductility are much higher under compressive

loads.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 27

Properties of gray cast iron

• According to American Society of Testing Materials (ASTM) the

gray-iron castings are classed in seven classes (Nos. 20, 25, 30, 35,
40, 50, 60) which give the minimum tensile strength of test bars in
thousands of pounds per square inch.

• For example, class 20 gray iron would have a minimum tensile

strength of 20,000 psi; class 30, 30,000 psi; and so on.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 28

Properties of gray cast iron

(Ref. Table 11.3 Avner)

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 29

Applications

• Gray irons are very effective in damping vibrational energy. Base

structures for machines and heavy equipment that are exposed to
vibrations are frequently constructed of this material.

• In addition, gray irons exhibit a high resistance to wear.

• Furthermore, in the molten state they have a high fluidity at

casting temperature, which permits casting pieces having
intricate shapes; also, casting shrinkage is low.

• Finally, and perhaps most important, gray cast irons are among
the least expensive of all metallic materials.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 30

Applications

Fig. 05: Comparison of the relative vibrational

damping capacities of (a) steel and (b) gray
cast iron.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 31

Applications

• Gray iron castings are used for counterweights for elevators and
industrial furnace doors.

• It is widely used also for guards and frames around hazardous

machinery.

• Many types of gear housings, enclosures for electrical equipment,

pump housings, and steam turbine housings are cast in gray iron
because of its low cost.

• Other similar gray-iron castings are used for motor frames, fire
hydrants, and sewer covers.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 32

Ductile (Nodular or Spheroidal Graphite)
Iron
• Adding a small amount of magnesium and/or cerium to the gray iron
before casting produces a distinctly different microstructure and set of
mechanical properties.
• Graphite still forms, but as nodules or sphere-like particles instead of
flakes.
• The resulting alloy is called nodular or ductile or spheroidal graphite
iron.
• The matrix phase surrounding these particles is either pearlite or
ferrite, depending on heat treatment; it is normally pearlite for an as-
cast piece.
• However, a heat treatment for several hours at about 700C (1300F)
will yield a ferrite matrix.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 33

Fig. 06: Optical photomicrographs of Nodular (ductile) iron: the dark graphite
nodules are surrounded by an α-ferrite matrix.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 34

Properties

• Castings are stronger and much more ductile than gray iron.

• In fact, ductile iron has mechanical characteristics approaching those

of steel.

• For example, ferritic ductile irons have tensile strengths ranging

between 380 and 480 MPa (55,000 and 70,000 psi), and ductility (as
percent elongation) from 10% to 20%.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 35

Applications
• Some typical applications of nodular iron are agricultural-tractor and
implement parts;

• Automotive and diesel-crankshafts, pistons, and cylinder heads;

• Electrical fittings, switch boxes, motor frames, and circuit breaker

parts;

• Mining-hoist drums, drive pulleys, flywheels, and elevator buckets;

• Steel mill-work rolls, furnace doors, table rolls, and bearings;

• Tool and die-wrenches, levers, handles, clamp frames, chuck bodies,

and miscellaneous dies for shaping steel, aluminum, brass, bronze, and
titanium.
1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 36
White cast iron

• For low silicon cast iron (Si<1%) and rapid cooling rates, most of
the carbon exists as cementite instead of graphite.

• A fracture surface of this alloy has a white appearance, and thus

it is termed as white cast iron.

• White cast iron contains a relatively large amount of cementite as

a continuous inter dendritic network, it makes the cast iron hard
and wear-resistant but extremely brittle and difficult to machine.

• Completely white cast irons are limited in engineering

applications because of this brittleness and lack of machinability.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 37

Properties

• The range of mechanical properties for unalloyed white irons are

as follows:

• BHN 375 to 600,

• Tensile strength 20,000 to 70,000 psi

• Compressive strength 200,000 to 250,000 psi and

• Modulus of elasticity 24 to 28 million psi

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 38

Applications

• They are used where resistance to wear is most important and the
service does not require ductility, such as liners for cement
mixers, ball mills, certain types of drawing dies, and extrusion
nozzles.

• A large tonnage of white cast iron is used as a raw material for

the manufacture of malleable cast iron.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 39

Fig. 07: Optical photomicrographs of White iron: the light cementite regions are
surrounded by pearlite, which has the ferrite–cementite layered structure.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 40

Malleable Iron

• Generally, white cast iron is used as an intermediary in the production

of malleable cast iron.

• Heating white iron at temperatures between 800C and 900C (1470F

and 1650F) for a prolonged time period and in a neutral atmosphere
(to prevent oxidation) causes a decomposition of the cementite,
forming graphite, which exists in the form of clusters or rosettes
surrounded by a ferrite or pearlite matrix, depending on cooling rate.

• The microstructure is similar to that for nodular iron, which accounts

for relatively high strength and appreciable ductility or malleability.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 41

Applications

• Representative applications include connecting rods, transmission

gears, and differential cases for the automotive industry, and also
flanges, pipe fittings, and valve parts for railroad, marine, and
other heavy-duty services.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 42

Fig. 08: Optical photomicrographs of Malleable iron: dark graphite rosettes (temper
carbon) in an α–ferrite matrix.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 43

Compacted graphite cast iron

• A relatively recent addition to the family of cast irons is compacted

graphite iron (abbreviated CGI). As with gray, ductile, and malleable irons,
carbon exists as graphite, which formation is promoted by the presence of
silicon. Silicon content ranges between 1.7 and 3.0 wt.%, whereas carbon
concentration is normally between 3.1 and 4.0 wt.%.

• Microstructurally, the graphite in CGI alloys has a worm-like (or

vermicular) shape.

• In a sense, this microstructure is intermediate between that of gray iron

and ductile (nodular) iron, and, in fact, some of the graphite (less than
20%) may be as nodules.
1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 44
Properties

• Compared to the other cast iron types, desirable characteristics of

CGIs include the following:

• Higher thermal conductivity

• Better resistance to thermal shock (i.e., fracture resulting from rapid

temperature changes)

• Lower oxidation at elevated temperatures

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 45

Fig. 09: Optical photomicrographs of Compacted graphite iron: dark graphite
worm-like particles are embedded within an α-ferrite matrix.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 46

Applications
• Compacted graphite irons are now being used in a number of
important applications—these include:
• diesel engine blocks, exhaust manifolds, gearbox housings, brake
discs for high-speed trains, and flywheels.

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 47

Comparison among Grey, White and
Spheroidal Cast Iron

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 48

Alloy Cast Iron

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 49

Alloy Cast Iron

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 50

Alloy Cast Iron

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 51

Alloy Cast Iron

1/30/23 Md. Ramjan Ali, Asst. Prof., ME, DUET 52