Introduction
C.I. are basically the alloys of iron and carbon which
covers a wide range of properties.
It contains 2 to 6% carbon and 1 to 3% silicon, that
passes through the eutectic reaction during
solidification.
Small % of other constituents Silicon, manganese,
Sulphur and Phosphorus, termed as Plain cast irons
and if Nickel, Chromium, Copper and Manganese
added, the cast irons termed as Alloy cast irons.
Benefits of C.I. over Steels
• They are easier to melt because of their lower melting
temperature as compared to steels.
• They have excellent castability due to high fluidity of
melt and lower shrinkage during solidification.
• Their corrosion resistance is fairly good.
• In general, they are brittle and their mechanical
properties.
• Good compressive strength and damping capacity is
good.
Production of Cast Iron
Pig iron in solid form
i.e. scrap, etc
Cupola
Refinement process
Cast iron
Classification of Cast Iron
• Classification on the basis of Furnace
– Cupola C.I.
– Electric Furnace C. I.
• Classification on the basis of composition and Purity
– Low carbon, low silicon cast iron
– High carbon, low sulphur cast iron
– Nickel alloy cast iron, etc
Classification of Cast Iron on the basis on
microstructure and appearance of fracture
White CI
Grey CI
CAST IRONS
S.G. cast iron
Malleable CI
Chilled and Alloy cast iron
Alloying elements in Cast Irons
• The extent of graphitization or chill depth depends on the
amount of graphitizing elements, particularly Si present along
with its equivalent carbon.
SR.NO ELEMENTS % OF COMPOSITION
1 Carbon 2.3 – 3.75
2 Silicon 0.5 - 3
3 Phosphorus 0.1 - 0.3
4 Sulphur 0.06 - 0.12
5 Manganese 0.5 - 1.0
L (γ+Fe3C)
Austenite+ Fe3C+ledeburite
Led.
Pearlite+ Fe3C+TL
TL
TL (P+Fe3C)
Factors Influencing Microstructure and
properties of Cast Iron
• Amount of total Carbon
• Amount of silicon
• Amount of phosphorus
• Amount of Sulphur
• Amount of manganese
• Cooling rate
Amount of total Carbon
• Carbon is a Graphitizer
• Increasing carbon 2-6.67%, increases tendency of
Graphitization
• Increasing carbon 2-6.67%, High hardness also
induces brittleness, also acts as Graphitiser
Amount of Silicon
• Stronger Graphitizer
• Decomposes cementite to iron and graphite
• Amount of silicon varies from 0.5 to 3.0 %.
• With lower amount of silicon ,the cast iron solidifies as white
cast iron and with higher amount, it solidifies as gray cast iron.
Composition: Graphite formation is promoted by the
presence of silicon and to less degree phosphorus, nickel
and copper. If silicon content is lower than 1 wt%
graphitization may not takes place.
Amount of phosphorus
• Strong Graphitizer like silicon.
• Most of the phosphorus combines with iron and
forms iron phosphide(Fe3P).
• This iron phosphide separates out as eutectic mixture
with cementite and austenite.
• This ternary eutectic of iron phosphide, cementite and
austenite is called steadite.
• Usual amount of P – 0.1 to 0.3%
Amount of Sulphur
• Sulphur combines with iron and form iron sulfide (FeS)
hard and brittle compound due to its low melting point
appears at interdendritic regions in a solidified casting
and increase the brittleness of casting.
FeS promotes the formation of iron carbide without
participating in its formation.
MnS present has no influence on carbide or graphite
formation.
Usual amount of Su – 0.06 to 0.12%
Amount of manganese
Manganese:
• Reduces the brittleness due to formation of iron
sulphide (MnS)
• It takes care of sulphur by forming manganese
sulphide.
• Usual amount of Mg – 0.5 to 1.0%
Cooling rate
• Cooling rate: Slower cooling rates, during
solidification, favors graphitization. While higher
rate of cooling during solidification tends to favor the
formation of cementite.
• Rapid cooling supresses the graphitization, it results
in white structure (WCI)
Slow cooling favors the graphitization
(Fe3C->3Fe+C)
results in gray structure.
Relation Between Carbon and Silicon
Content in C. I.
Graphitization
carbon in cast irons is present in either following
two forms:
1- free carbon or graphite
2- combined carbon or cementite,
Cementite can transform to ferrite and graphite
Fe3C 3 Fe () + C (graphite)
White Cast Iron
• It has a structure of Pearlite in a cementite matrix making it
hard, brittle and difficult.
L Austenite + Fe3C Pearlite + Lideburite +
Cementite
• In this cast iron, all the carbon is present in the combined
form i.e. cementite and there is no free carbon.
• It has a white colored appearance when surface is fractured.
Composition
C- 2.3- 3%
Si – 0.85-1.2%
Mn- 0.5-1%
P – 0.05-0.2%
S- 0.06-0.1%
Stable
Metastable
Properties
• White cast irons are a hard and brittle
• Resistance to Abrasive wear
• Strong in compression (140 0to 1750 MPa)
• High Hardness (350 – 500 VHN)
• UTS = 600 – 800 MPa
• Elongation = 2 – 3%
Applications
Due to brittleness, only hypoeutectic white cast irons
are mfg. and their useful applications are
• Wearing Plates
• Road roller surfaces
• Pump liners
• Mill liners
• Grinding balls
• Dies
• Extrusion Nozzles
• Raw material for malleable cast iron
Malleable Iron
• These cast irons are produced from white cast iron castings by
a malleablizing heat treatment
• Heat white CI between Eutectiod and Eutectic Temp. And
hold it for long time.
• During malleablizing heat treatment , the cementite present in
white cast iron decomposed and graphite rosettes , are
produced.
White Cast Iron Malleable Cast Iron
Malleabilize
To Increase Ductility
48 hrs
Fe3C (WCI)
2 stage heat treatment
Graphite Temper Nodules (Malleable Iron)
Composition
• C- 2.3- 3%,
• Si – 0.85-1.2%,
• Mn- 0.5-1%,
• P – 0.05-0.2%,
• S- 0.06-0.1%
Malleable Iron
2-3 Moderate Cooling Rate (Pearlitic) 1. Carbon in the form
2-3’ Intermediate Cooling Rate (Pearlitic - Ferritic ) of graphite
2-3” Slow Cooling Rate (Ferritic)
2. Graphite in rosettes
form
3. Produced by heat
treatment of white
cast iron
4. Graphite rosettes
are irregular
clusters
5. Similar properties to
ductile iron
Malleable Iron
Pearlitic Matrix Ferrite (White)
Graphite (black)
Pearlite (grey)
Partially Malleabilized Iron Ferritic Matrix
Incomplete Ferritizing Anneal
Ferrite (White)
Graphite (black)
10 m
Fully Malleabilized Iron
Complete Ferritizing Anneal
Properties
• These cast iron shows ductility, toughness and are
bendable in contrast to gray cast iron
• T. S. = 250 – 700 MPa
• Elongation = 6 to 18%
• Hardness = 80 to 275 BHN
• Good Machinability
• It is to be hammered and rolled into different shapes.
• It possesses high strength and corrosion resistance.
• It possesses high yield strength
• It has good wear resistance and vibration damping
capacity.
Applications
• Ferritic Malleable:-Pipe fittings, valves, farm equipment, chairs, bearing
blocks, automotive parts
• Pearlitic Malleable:- Switch gears, axles, cam and crank shafts, gears
Conveyor Equipments, parts of guns, tanks
Wrenches, hammers, clamps
Vehicle components
– Power trains, frames, suspensions and wheels
– Steering components, transmission and differential parts, connecting rods
Railway components
Grey Cast Iron
Flaky graphite in a matrix of Pearlite, ferrite or martensite
Wide range of applications
Low ductility - elongation 0.6%
Production of grey cast iron
• Composition similar to grey cast iron except for higher purity.
• Magnesium as wire, ingots or pellets is added to ladle before
adding hot iron.
• Mg vapour rises through melt, removing sulphur.
Composition
• C- 3.2- 3.7%,
Graphite Flakes
• Si – 2.0-3.5%,
• Mn- 0.5-1%,
• P – 0.1-0.2%,
• S- 0.06-0.1%
Grey Cast Iron: Microstructure
Graphite Flakes
33
Form of Graphite
Shape/ size / Distribution of Free
carbon has great influence on
Properties of Cast Iron
34
Properties : Grey cast iron
Machinability is excellent
low Ductility & impact resistance
high Damping capacity
high Thermal conductivity
Excellent wear properties
Applications
1) Cylinder blocks and heads for I.C. engines.
2) Piston rings.
3) Machine tool structure ( bed, frame)
4) Gas or water pipes for underground purpose.
5) Manhole covers.
6) Tunnel segments.
7) Frames for electric motors.
8) Ingot moulds
9) Sanitary wares.
10) Household applications.
Nodular Cast Iron (Ductile Iron) or
SPHEROIDAL GRAPHITE
• It is obtained by adding Magnesium (Noduliser) just
before pouring followed by inoculation (Mg/ Ce)
• This encourages the graphite to form spheres or
nodules.
• It consists of graphite spheroids in a matrix of ferrite,
Pearlite or both.
• It is similar to grey cast iron having low melting
point, good fluidity, castability, machinability and
wear resistance.
Composition
• Composition is same as GCI, only small amount of
Mg added as a nodulizing element
• C- 3.2- 3.7%,
• Si – 2.0-3.5%,
• Mn- 0.5-1%,
• P – 0.1-0.2%,
• S- 0.06-0.1%
Microstructure of
Nodular Cast Iron (SGCI)
Pearlite
Ferrite
Graphite nodules
Spheroidal Graphite / Nodular/ Ductile Cast Iron
Ferrite (White)
Graphite (black)
Bull’s Eye
structure
5 m
Pearlite (grey)
40
Ductile Iron/Nodular Iron
Ferrite Graphite nodules
10 m
With Ferritic Matrix With (Ferrite + Pearlite) Matrix
With Pearlitic matrix
Properties
1) It has low melting point.
2) It has good fluidity.
3) It has excellent castability.
4) It has excellent machinability.
5) It has good wear resistance.
6) It possesses excellent damping capacity.
7) Unlike long flakes as in gray cast iron, graphite
appears as rounded particles or nodules or spheroids
in nodular cast iron.
Applications
1) Paper industries machinery.
2) Internal combustion engines.
3) Power transmission equipments.
4) Farm implements and tractors
5) Earth moving machinery
6) Valves and fittings.
7) Steel mill rolls and mill equipments
8) Pipes
9) Pumps and compressors.
CHILLED CAST IRON
• Introduction:
This type CI shows white structure at surface & gray
structure at center. Due to this, the good properties
of WCI & GCI can be coupled together in it.
Composition
• C- 3.3-3.5%,
• Si- 2.0-2.5%,
• Mn- 0.55-0.60%
• P – 0.1-0.2%,
• S- 0.06-0.1%
Properties
• High hardness & wear resistance on surface,
• They have good machinability,
• Damping capacity
• Low notch sensitivity.
Application
They are used for -
• Railway
• Freight car wheels,
• Crushing rolls,
• Grinding balls,
• Road rollers,
• Hammers,
• Dies & such other applications.
ALLOY CAST IRONS
Cr, Mn, Si, Ni, Al
Enhance the range of microstructures
Beneficial effect on many properties
high temperature oxidation resistance
corrosion resistance in acidic environments
wear/abrasion resistance
1-Martensitic irons 2-Austenitic irons
Martensitic irons, which are very useful for Austenitic irons usually contain between
resisting abrasion, usually contain 4-6% 10 and 30% nickel and up to 5%
nickel and about 1% chromium. Such an chromium. These are corrosion-resistant,
alloy is Ni-hard, is martensitic in the cast heat-resistant, non-magnetic alloys.
state, whereas alloys containing rather less Some of them are treated to produce
nickel and chromium would need to be oil- structures containing spheroidal instead
quenched in order to obtain a martensitic of flake graphite
structure
Specific Applications
• Machine Tools
• Automobiles
• Pumps
• Valves
Outcomes
• Student Should able to identify various cast irons and
select them for particular application
• Student Should able to understand importance of cast
iron in mechanical Engineering.
Question Bank
Q.1 State the various factors affecting the properties of Cast Iron
Q.2 Describe the factors which control graphitization in cast iron.
Q.3. What is equivalent carbon in cast iron?
Q.4 Which factors affect the properties of gray cast iron?
Q.5 Define the following cast iron
a. White cast iron
b. Malleable cast iron
c. Gray cast iron
d. Nodular cast iron
Q. 6 Write short notes on alloy cast iron.
Q. 7 Discuss the application of cast iron.
Q. 8 What are the advantages of cast iron over steels?
Q. 9 Compare the microstructures of white cast iron, gray cast iron and nodular cast iron.
Q.10 Classify Cast iron in details.
