Materials Engineering: Cast Irons

Cast irons have a microstructure and mechanical properties that depend on their carbon content, cooling rate, and alloying elements. There are several types of cast iron including gray, white, nodular, and malleable. Gray cast iron has a microstructure of ferrite and graphite flakes which gives it good compressive strength but low tensile strength and brittleness. Ductile or nodular cast iron has a spheroidal graphite morphology that increases its strength and ductility. Malleable cast iron is heat treated to convert iron carbides to temper carbon, producing a ductile ferritic structure suitable for machine parts.

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Materials Engineering: Cast Irons

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Tokkummaa Cimsaa

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Materials engineering

Cast Irons
Outline
Properties of cast irons
Microstructure
Mechanical properties
Types
Gray cast iron
White cast iron
Nodular cast irons
Malleable cast irons
Properties
Cast Iron
C = 2 ~ 6.6!
Properties depend on
"# Carbon content
2# Coolin$ rate of the castin$
%# &lloyin$ ele'ents
Carbon content
"# (e$ree of solution
I =
C%
4.3-0.3(S%+P%)
T)" *ypereutectic Ledeburite + Pr. Cementite
T=" +utectic Ledeburite
T)" *ypoeutectic Ledeburite + Perlite
Cooling rate
2# Coolin$ rate
,lo- coolin$ rate Iron + Graphite
section si.e ) "/ ''
0uic1 Coolin$ rate Iron + Cementite
section si.e 2 "/ ''
Alloying elements
Graphite producin$ ele'ents
Co, P, Cu, Ni, Ti, Si, C, Al
Carbide producin$ ele'ents
W, Mn, Mo, S, Cr, V, Mg, Ce
The 'icrostructure depends on3
Carbon and Sili!on !ontent
Se!tion "i#e $!ooling rate%
Maurer diagram
Ferrite + Graphite
White cast iron
4'etastable#
Gray cast iron
4,table#
Microstructure
Hypoeutectic white cast iron
Perlite and ledeburite
Hypereutectic white cast iron
Primer cementite and ledeburite
Gray cast iron
Ferrite and graphite
Gray cast iron
Ferrite, perlite and graphite
Greiner - Klingenstein diagram
C

+

S
i
%
Wall thickness (mm)
"/
2/ %/ 5/
6/
6/ /
Ferrite + Graphite
Ledeburite+
Perlite
Perlite +
Graphite
L + P + G
&t a $i7en C8,i! the $raphite
producin$ ele'ents9 effects
increases -ith increasin$ section si.e
Mechanical properties of cast iron
T
e
n
s
i
l
e

S
t
r
e
n
g
t
h
Perlitic
microstructure
Ferritic
microstructure
&''
(''
Graphite9s effect on Tensile stren$th
graphite produ!e" not!h e))e!t
graphite e*!lude" part" in the matri*
Mechanical properties of cast iron
(isad7anta$e of cast iron
: Gray cast iron has lo- stren$th
: $ray cast iron has no plastic strain = brittle
Graphite for's in $ray cast iron
Mechanical properties of cast iron
&d7anta$e of cast iron
: Good co'pressi7e stren$th
: hi$h da'pin$ capability 4tool 'achines#
: $ood 'achinability
: $ood -ear resistance 4$raphite as lubricant#
: lo-er cost
Utilization of gray cast iron
Machine stands; en$ines; etc
ncreasing the strength of cast iron
a# Increase the perlite a'ount in the 'atri<
b# Modify the shape and distribution of the $raphite
fla1es
c# &lternatin$ the $raphite9s $eo'etry fro' fla1e to
spheroidal $raphite
ncreasing the strength of cast iron
ncrease the perlite amount in the matri!
Ferrite + Graphite
ST! "#$ "# 4psi# "# 4MPa# "
Class $% "6/ "
&% 2// /.=5
&' 26/ /.>>
ncreasing the strength of cast iron
Modify the size and distribution of graphite fla(es
)e#i and Ca#i as centers of crystalli.ation 4nucleation#
Method3 ?7erheatin$ the 'olten iron and alloy
@e,i ~/.6! Ca,i /.6~"!
: finer fla1es
: hi$her stren$th
ST! "#$ "# 4psi# "# 4MPa# "
Class *% %// /.>
'% %6/ /.6
+% 5// /.2
ncreasing the strength of cast iron
&lternatin$ the $raphite9s $eo'etry fro' fla1e to
spheroidal $raphite
%uctile or &odular cast iron
M$ and ,i alloyin$
M$ alloyin$ by +eCuMg and +eNiMg
F + P +Sph + F'
S
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%
!g %
&''
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F + P + Sph(
F + P + Sph(
F
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Microstructure
Ductile cast iron
Ferrite and spherical graphite
Ductile cast iron
Ferrite, Perlite and spherical graphite
spherical graphite
in gray cast iron
20 m
Utilization of ductile cast iron
Machine parts; $ears; pipes; cran1shaft; etc
ncreasing the strength of cast iron
(uctile or nodular cast irons
ST! #*+ "# 4MPa# ,#4Mpa# -l 4!# structure
Grade ,-."-./$ 5// 26/ "> @errite
Grade $-.++.-, 6// %/ 6 @ 8 P
Grade /--.0-.-# // 52/ % P 4&0#
Grade /1-.*-.-1 >// 5>/ 2 M 408T#
0longation $/%
1ield Stre"" $p"i%
Ten"ile "trength $p"i%
Malleable cast iron
Con7ert iron:carbibe to te'per
carbon
increases the ductility
@erritic structure -ith te'per carbon
ST! "0 "# 4MPa# ,#4Mpa# -l 4!#
Grade #1+./- 5// "%/ "/
.lac( heart malleable cast iron
time
/edaburitic-perlitic structure
ron carbide disociates to )e and C
Austenite transforms to ferrite and
graphite
)errite 0 temper carbon
T

(
2
C
)
&''
23-
1$ 2 *3 hours
4(' 5C
neutral
atmo"phere
@erritic structure -ith lo- carbon content
ST! "0 "# 4MPa# ,#4Mpa# -l 4!#
Grade "+-.-, %"/ "6 6
Grade ,--.-" 52/ 26/ 5
Grade $--.-1 66/ %5/ 2
Grade *--.-/ 66/ 5%/ "
White heart malleable cast iron
/edaburitic-perlitic structure
C 4 5 &6
ron carbide dissociates to )e and C
)erritic structure 7 lo8 carbon
C 4 5 %916
T

(
2
C
)
&''
23-
$' -1%% hours
&'''5C
time
o*idi#ing
atmo"phere
Carbon diffuses to the surface and
burns there9
Microstructure
Black heart cast iron
Temper-carbon in ferrite matri
Utilization of malleable cast iron
Machine parts; 'achine stands; etc