STANDARDS

STANDARDS
•B.S British Standards

•A.F.S American Foundry Society

•J.I.S Japanese Industrial Standards

JAPANESE INDUSTRIAL STANDARDS
•FC Cast Iron
•FCD Ductile Cast Iron
•SC Steel Casting
•FCM Malleable Cast iron
GRADES OF FC GRADES OF FCD

FC 15 FCD 45

FC 20 FCD 60

FC 25 FCD 70

FC 30 FCD 75

FC 35  
• In between FC and FCD, we have another grade called
compacted vermicular graphite iron(CV) with tensile
strength 40kgf/mm2

• i.e. FC CV FCD

• Currently FCD is replacing FCM and even some steel

because it is simple to make. More so, the market
value of FCD is growing higher and higher
• Tensile strength of grey cast iron 15-35 kgf/mm2
and Sulphur content ≤ 0.1%

• Tensile strength of Ductile iron 45-75 kgf/mm 2

and
Sulphur content is ≤ 0.02%

• FC is melted in coreless Induction furnace(LFIF)

• FC is also melted in a cupola ( s content is high)
• FCD is melted comfortably in coreless induction
furnace

• FCD is also melted in cupola furnace(But base metal

needs desulphurization to reduce the level of s)

• CaCo3, CaO or CaC2 is used for the desulphurization.

This is done using continuous desulphurization
method or desulphurising tank.
 COMPARING INDUCTION FURNACE AND CUPOLA MELTING

• Melting rate of Induction furnace is lower than cupola.

• E.g.5 tons/3 tons induction furnace = 1.6 ton/hr
• 5 tons capacity cupola = 5 tons/hr

• Initial cost(purchase of installation) of induction furnace is higher than

cupola.

• E.g. 5 tons induction furnace = ¥ 35m

• 5 tons cupola furnace = ¥20m
• During solidification,
• FC graphitizes as flakes (i.e. carbon precipitates as flakes)
• FCD graphitizes as nodules / spheroids
• SC Skin formation type of solidification

• AL
 

• FCD - massy solidification (i.e. when FCD is solidifying, the

precipitation of graphite causes expansion )
 FOUNDRY RAW MATERIALS
• Sand and its additives (e.g. silica sand, bentonite,
coal dust, dextrin, molasses etc. )

• Scraps ( steel, cast iron, non-ferrous)

• Pig iron - Ordinary pig iron(Instant pig iron)
• Ductile pig iron/ malleable pig iron, silvery pig iron
• Pig iron is produced from the blast furnace.
• Ferro Alloys – Most ferro alloys are made by electric
smelting furnace. However, 6-12% silicon silvery iron is
produced from blast furnace

Some other ferro alloys commonly used in the foundry:

• Ferro manganese (FeMn)

• Ferro chrome (FeCr)
• Ferro silicon (FeSi)
 OBJECTIVES OF THE FERRO ALLOY ADDITION

• Regulation of chemical composition of

ordinary cast iron (e.g. FeSi, FeMn)

• Addition of special element for alloy cast iron

• Inoculation
 TYPES OF ADDITION
• Furnace addition
• Ladle addition

INOCULATION
• Prevents chilling
• Refines the microstructure of metal
• Improves mechanical properties and
machinability