This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles

for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

Designation: A159 − 83 (Reapproved 2020)

Standard Specification for

Automotive Gray Iron Castings1
This standard is issued under the fixed designation A159; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the U.S. Department of Defense.
This specification replaces Federal specification AA-I-653A.

1. Scope 4. Ordering Information

1.1 This specification applies to gray iron castings, cast in 4.1 Orders for materials under this specification shall in-
sand molds, used in the products of the automobile, truck, clude the following information:
tractor, and allied industries. 4.1.1 ASTM designation,
1.2 The values stated in inch-pound units are to be regarded 4.1.2 Grade designation of gray iron required (3.1),
as standard. No other units of measurement are included in this 4.1.3 If special heat treatment is required (see Section 6),
standard. 4.1.4 If special microstructure requirements are needed (see
1.3 This international standard was developed in accor- Section 7),
dance with internationally recognized principles on standard- 4.1.5 Surface where hardness test is to be performed (see
ization established in the Decision on Principles for the 9.4),
Development of International Standards, Guides and Recom- 4.1.6 Depth and surface hardness of case required (see 9.6),
mendations issued by the World Trade Organization Technical 4.1.7 Inspection lot and sampling plan required (see Section
Barriers to Trade (TBT) Committee. 10),
4.1.8 If additional requirements are needed (see 11.3), and
2. Referenced Documents 4.1.9 Whether special packaging and marking are required
2.1 The following documents of the issue in effect on the (see Section 12).
date of material procurement form a part of this specification to
the extent referenced herein: 5. Hardness
2
2.2 ASTM Standards: 5.1 The foundry shall exercise the necessary controls and
A247 Test Method for Evaluating the Microstructure of inspection techniques to ensure compliance with the specified
Graphite in Iron Castings hardness range. Brinell hardness shall be determined in accor-
E10 Test Method for Brinell Hardness of Metallic Materials dance with Test Method E10, after sufficient material has been
2.3 Military Standard:3 removed from the casting surface to ensure representative
MIL-STD-129 Marking for Shipment and Storage hardness readings. The 10-mm ball and 3000-kg load shall be
2.4 Federal Standard:3 used unless otherwise agreed upon. The area or areas on the
Fed. Std. No. 123 Marking for Shipment (Civil Agencies) casting where hardness is to be checked shall be established by
agreement between supplier and purchaser and shall be shown
3. Grades
on the drawing.
3.1 The specified grades, hardness ranges, and metallurgical
description are shown in Tables 1 and 2 and in Section 9. 6. Heat Treatment
1
This specification is under the jurisdiction of ASTM Committee A04 on Iron
6.1 Unless otherwise specified, castings of Grades G1800
Castings and is the direct responsibility of Subcommittee A04.01 on Grey and White and G2500 may be annealed in order to meet the desired
Iron Castings. hardness range.
Current edition approved May 1, 2020. Published May 2020. Originally
approved in 1935. Last previous edition approved in 2015 as A159 – 83 (2015). 6.2 Appropriate heat treatment for removal of residual
DOI: 10.1520/A0159-83R20. stresses, or to improve machinability or wear resistance, may
2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or be specified by agreement between supplier and purchaser.
contact ASTM Customer Service at [email protected]. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website. 7. Microstructure
3
Available from Standardization Documents Order Desk, DODSSP, Bldg. 4,
Section D, 700 Robbins Ave., Philadelphia, PA 19111-5098, http:// 7.1 The microstructure shall consist of flake graphite in a
www.dodssp.daps.mil. matrix of ferrite or pearlite or mixtures thereof.

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 A159 − 83 (2020)
TABLE 1 Grades of Gray Iron distribution, 4 to 7 flake size in accordance with Test Method
Grade Casting Hardness Range Description A247. The amount of primary carbides and location at which
G1800 HB 187 max ferritic-pearlitic the structure is checked shall be a matter of agreement between
4.4 BID min or as agreedA the supplier and the purchaser.
G2500 HB 170–229 pearlitic-ferritic
4.6–4.0 BID or as agreedA 9.6 Selective Hardening—The cam areas of camshaft cast-
G3000 HB 187–241 pearlitic
4.4–3.9 BID or as agreed A ing are usually selectively hardened by flame or induction
G3500 HB 207–255 pearlitic hardening by the supplier. The depth and surface hardness of
4.2–3.8 BID or as agreedA the hardened case shall be as agreed upon between supplier and
G4000 HB 217–269 pearlitic
4.1–3.7 BID or as agreedA
purchaser.
A
Brinell impression diameter (BID) is the diameter in millimetres of the impression 10. Quality Assurance Provisions
of a 10-mm ball at 3000-kg load.
10.1 Responsibility for Inspection—Unless otherwise speci-
fied in the contract or purchase order, the producer is respon-
sible for the performance of all inspection and tests require-
7.2 As graphite size and shape somewhat affect hardness-
ments specified in this specification. Except as otherwise
strength ratio and other properties, the type size and distribu-
specified in the contract or purchase order, the producer may
tion of the graphite flakes at a designated location on the
use his own or any other suitable facilities for the performance
casting may be specified by agreement between supplier and
of the inspection and test requirements specified herein, unless
purchaser in accordance with Test Method A247.
disapproved by the purchaser. The purchaser shall have the
7.3 Unless otherwise specified, the matrix microstructure of right to perform any of the inspection and tests set for in this
castings covered by this specification shall be substantially free specification where such inspections are deemed necessary to
of primary cementite. Castings in Grades G1800 and G2500 ensure that material conform to prescribed requirements.
may have a matrix of ferrite or pearlite, or both. Grades G3000,
10.2 Lot—For the purpose of inspection, lot and sampling
G3500, and G4000 shall be substantially pearlite in matrix
plans shall be agreed upon between the purchaser and the
structure.
producer.
8. Heavy-Duty Brake Drums and Clutch Plates 11. General
8.1 These castings are considered as special cases and are 11.1 Castings furnished to this specification shall be repre-
covered in Table 2. sentative of good foundry practice and shall conform to
dimensions and tolerances specified on the casting drawing.
9. Alloy Gray Iron Automotive Camshafts
11.2 Minor imperfections usually not associated with the
9.1 These castings are considered as special cases.
structural function may occur in castings. These are often
9.2 Grade Designation—G4000d. repairable but repairs shall be made only where allowed by the
9.3 Chemistry—Alloy gray iron camshafts shall contain purchaser and only by approved methods.
alloys within the following range or as agreed upon between 11.3 Additional casting requirements may be agreed upon
supplier and purchaser. by purchaser and supplier. These should appear as product
Chromium 0.85–1.25 % specifications on the casting or part drawing.
Molybdenum 0.40–0.60 %
Nickel as agreed 12. Preparation for Delivery
9.4 Casting Hardness—HB 241–321 determined on a bear- 12.1 Unless otherwise specified in the contract or purchase
ing surface as agreed by supplier and purchaser. order, castings shall be cleaned, preserved, and packaged in
9.5 Microstructure—Extending 45° on both sides of the accordance with supplier’s standard commercial practice.
centerline of the cam nose and to a minimum depth of 1⁄8 in. 12.2 Government Procurement—When specified for gov-
(3.2 mm), the surface shall consist of primary carbides (of ernment procurement, castings shall be marked for shipment in
acicular or cellular form or a mixture thereof) and graphite in accordance with MIL-STD-129 for military procurement and
a fine pearlitic matrix. The graphite shall be Type VII A and E Fed. Std. No. 123 for civil agency procurement.

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 A159 − 83 (2020)
TABLE 2 Brake Drums and Clutch Plates for Special Service
Microstructure
Grade Carbon min, %A Casting Hardness
Graphite Matrix
G2500a 3.40 HB 170–229 Type VII, size 2–4B lamellar pearlite
4.6–4.0 BID or as agreed A distribution ferrite if present not to exceed 15%
G3500b 3.40C HB 207–255 Type VII, size 3–5B lamellar pearlite
4.2–3.8 BID or as agreed A distribution ferrite or carbide if present not to exceed 5%
G3500c 3.50C HB 207–255 Type VII, size 3–5B lamellar pearlite
4.2–3.8 BID or as agreed A distribution ferrite or carbide, if present not to exceed 5%
A
The chemical analysis for total carbon shall be made on chilled pencil-type specimens or from thin wafers approximately 1⁄32 in. (0.8 mm) thick cut from test coupons.
Drillings are not reliable because of the probable loss of graphite.
B
See Test Method A247.
C
Grades G3500b and G3500c normally require alloying to obtain the specified hardness at the high carbon levels specified.

APPENDIX

(Nonmandatory Information)

X1. GRAY IRON

X1.1 Definition TABLE X1.2 Usual Composition of Brake Drums and Clutch
Plates for Special Service
X1.1.1 gray iron—a cast iron in which the graphite is
Chemical Grade Grade Grade
present as flakes instead of temper carbon nodules as in Composition, % G2500a G3500b G3500c
malleable iron or small spherulites as in ductile iron. Carbon, total (mandatory) 3.40 min 3.40 min 3.50 min
Silicon (as required) 1.60–2.10 1.30–1.80 1.30–1.80
X1.2 Chemical Composition Manganese (as required) 0.60–0.90 0.60–0.90 0.60–0.90
Sulfur, max 0.12 0.12 0.12
X1.2.1 The ranges in composition generally employed in Phosphorus, max 0.15 0.15 0.15
producing the various grades of most automotive gray iron Alloys as required as required as required
castings are shown in Table X1.1. The composition ranges for
such special applications as heavy-duty brake drums and clutch
plates and camshafts are shown in Table X1.2 and Table X1.3, TABLE X1.3 Usual Chemical Composition of Alloy Gray Iron
Automotive Camshafts
respectively. The contents of certain elements for these appli-
Grade G4000d, %
cations are critical in terms of service requirements and the
Total carbon 3.10–3.60
ranges are specified in the standard. Silicon 1.95–2.40
X1.2.2 The specific composition range for a given grade Manganese 0.60–0.90
Phosphorus 0.10 max
may vary according to the prevailing or governing section of Sulfur 0.15 max
the castings being produced. Chromium 0.85–1.25
Molybdenum 0.40–0.60
X1.2.3 Alloying elements such as chromium, copper, Nickel 0.20–0.45 optional
nickel, tin, molybdenum, or other elements may be employed Copper residual
to meet the specified hardness or microstructural requirements
or to provide the properties needed for particular service
conditions.
design, and foundry techniques as they affect solidification and
X1.3 Microstructure subsequent cooling rate and heat treatments, if any.
X1.3.1 The microstructure of the various grades of gray iron X1.3.2 The distribution and size of graphite flakes like the
are generally a mixture of flake graphite in a matrix of ferrite, matrix structure of gray iron depends greatly on the solidifi-
pearlite, or tempered pearlite. The relative amounts of each of cation rate and cooling rate of the casting. If a section solidifies
these constituents depends on the analysis of the iron, casting very rapidly, an appreciable amount of carbide causing a

TABLE X1.1 Typical Base Compositions, %

Approximate Carbon
Grade Carbon Silicon Manganese Sulfur, max Phosphorus, max
Equivalent
G1800 3.40–3.70 2.30–2.80 0.50–0.80 0.15 0.25 4.25–4.5
G2500 3.20–3.50 2.00–2.40 0.60–0.90 0.15 0.20 4.0–4.25
G3000 3.10–3.40 1.90–2.30 0.60–0.90 0.15 0.15 3.9–4.15
G3500 3.00–3.30 1.80–2.20 0.60–0.90 0.15 0.12 3.7–3.9
G4000 3.00–3.30 1.80–2.10 0.70–1.00 0.15 0.10 3.7–3.9
(usually alloyed)

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 A159 − 83 (2020)
mottled fracture or chilled corners can be present. If a section TABLE X1.5 Typical Mechanical Properties
cools slowly, as in a massive heavy section casting, an Mechanical Grade Grade Grade
appreciable amount of ferrite may be present. In like manner, Properties G2500a G3500b G3500c

light sections will contain small graphite flakes while graphite Tensile strength, min:
psi 25 000 35 000 35 000
will form in much larger flakes if the same iron is poured into kgf/mm2 17.5 24.5 24.5
a heavy casting. Transverse strength, min:
lb 2000 2400 2400
X1.3.3 For these reasons the strength and hardness of gray kg 910 1090 1090
iron are greatly influenced by the rate of cooling during and Deflection, min:
in. 0.17 0.24 0.24
after solidification, the design and nature of the mold and the mm 4.3 6.1 6.1
casting, and by other factors such as inoculation practice in Hardness, HB 170–229 207–255 207–255
addition to the composition of the iron. Brinell indention diameter, mm 4.6–4.0 4.2–3.8 4.2–3.8

X1.3.4 Alloying with nickel, chromium, molybdenum, tin,

copper, or other alloys usually promotes a more stable pearlitic TABLE X1.6 Typical Applications of Gray Iron for Automotive
structure and is often done to obtain increased hardness, Castings
strength, and wear resistance, especially in heavy sections Grade General Data
subjected to severe service. G1800 Miscellaneous soft iron castings (as cast or annealed) in which
strength is not of primary consideration. Exhaust manifolds may be
X1.3.5 Alloying is sometimes used to obtain structures made of this grade of iron, alloyed or unalloyed. These may be
containing a controlled percentage of carbides as in camshaft annealed castings for exhaust manifolds in order to avoid growth
or valve lifter castings. and cracking due to heat.

X1.3.6 Primary carbides or pearlite, or both, can be decom- G2500 Small cylinder blocks, cylinder heads, air-cooled cylinders, pistons,
posed by appropriate heat treatment. Gray irons of suitable clutch plates, oil pump bodies, transmission cases, gear boxes,
clutch housings, and light-duty brake drums.
composition and structure can be hardened by liquid quenching
or by flame or induction selective hardening. G3000 Automobile and diesel cylinder blocks, cylinder heads, flywheels,
differential carries castings, pistons, medium-duty brake drums, and
clutch plates.
X1.4 Mechanical Properties
G3500 Diesel engine blocks, truck and tractor cylinder blocks and heads,
X1.4.1 The mechanical properties listed in Table X1.4 can heavy flywheels, tractor transmission cases, and heavy gear boxes.
be used for design purposes. However, the suitability of a
particular grade for an intended application is best determined G4000 Diesel engine castings, liners, cylinders, and pistons.
by laboratory or service tests. Typical mechanical properties
for such specialized applications as heavy-duty brake drums X1.5.2 Gray iron castings of the lower-strength Grades
and clutch plates are shown in Table X1.5. G1800 and G2500 are characterized by excellent
machinability, high damping capacity, low modulus of
X1.5 Application of Gray Iron in Automotive Castings
elasticity, and comparative ease of manufacture. When higher
(see Table X1.6)
strength is obtained by a reduction in the carbon or carbon
X1.5.1 The graphite flakes in gray iron give this metal many equivalent, castings are more difficult to machine, have lower
desirable properties. These include excellent machinability, damping capacity, higher modulus of elasticity, and may be
high thermal conductivity, vibration-dampening properties, and more difficult to manufacture.
resistance to wear or scuffing. Due to its low freezing tempera-
ture for a ferrous alloy, high fluidity, and low shrinkage X1.6 Special Applications of Gray Iron
properties it is more readily cast in complex shapes than other X1.6.1 Heavy-Duty Brake Drums and Clutch Plates—
ferrous metals. Automotive brake drums and clutch plates for heavy-duty

TABLE X1.4 Mechanical Properties for Design Purposes

Tensile Strength, min, Transverse Strength, min, Deflection, min,
Grade Hardness RangeA
psi (kgf/mm2) lb (kg)B in. (mm)B
G1800 HB 143–187 18 000 (14) 1720 (780) 0.14 (3.6)
5.0–4.4 BID
G2500 HB 170–229 25 000 (17.5) 2000 (910) 0.17 (4.3)
4.6–4.0 BID
G3000 HB 187–241 30 000 (21) 2200 (1000) 0.20 (5.1)
4.4–3.9 BID
G3500 HB 207–255 35 000 (24.5) 2450 (1090) 0.24 (6.1)
4.2–3.8 BID
G4000 HB 217–269 40 000 (28) 2600 (1180) 0.27 (6.9)
4.1–3.7 BID
A
Brinell impression diameter (BID) is the diameter in millimetres of the impression of a 10-mm ball at 3000-kg load.
B
See Method A438 for information concerning the B transverse test bar and the transverse test.

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 A159 − 83 (2020)
service are considered as special cases. Typical chemical not normally use tensile or transverse tests for quality control
analyses and mechanical properties are listed in Table X1.2 and purposes. Camshaft iron with chemistry as given in Table X1.3
Table X1.5. Heavy-duty irons for such service require high would be expected to have the following minimum mechanical
carbon contents for resistance to thermal shock and to mini- properties.
mize heat checking. To maintain strength levels specified for Tensile strength, min:
Grades G3500b and G3500c normally requires alloying due to psi 40 000
their high carbon contents. kgf/mm2 28
Transverse strength, min:
X1.6.2 Microstructure—See Table 2 for microstructure re- lb 2600
kg 1180
quirements. Deflection, min:
X1.6.3 Suggested Usage—Following are suggested grades in. 0.27
mm 6.9
for brake drums and clutch plates according to types of service: Hardness, HB 241–321
Grade Suggested Usage BID 3.9–3.4
G2500a Brake drums and clutch plates for moderate service
requirements, where high carbon iron is desired to minimize heat X1.7.4 Microstructure—See 9.5 for microstructure require-
checking (see Section 8). ments for Grade G4000d alloy cast iron camshafts.
G3500b Brake drums and clutch plates for heavy-duty service where
both resistance to heat checking and higher strength are definite X1.8 Additional Information
requirements (see Section 8).
X1.8.1 Additional information concerning gray iron
G3500c Extra-heavy-duty service brake drums (see Section 8). castings, their properties and uses can be obtained from the
X1.7 Automotive Camshafts following sources:
(1) Metals Handbook, 8th Edition, Vols 1, 2, and 5,
X1.7.1 Alloy gray iron automotive camshafts are also con- published by the American Society for Metals, Metals Park,
sidered as special cases. The chemical composition of such Ohio.
castings is usually within the range given in Table X1.3 but
(2) Cast Metals Handbook, published by the American
may be modified by mutual agreement.
Foundrymen’s Society, Des Plaines, Illinois.
X1.7.2 In casting hardenable iron from camshafts, the aim is (3) Gray & Ductile Iron Castings Handbook, published by
to obtain a suitable microstructure in critical locations of the Gray and Ductile Iron Founders Society (1971), Cleveland,
casting and balance the composition to obtain response to Ohio.
induction or flame-hardening treatment. These depend not only (4) Physical and Engineering Properties of Cast Iron,
on the chemistry of the iron but even more on the cross section Angus, British Cast Iron Research Association (1960),
of the casting and details of melting practice. In making a given Alvechurch, Birmingham, England.
casting, it is recognized that the foundry will find it necessary (5) Engineering Data on Gray Cast Irons, G. N. J. Gilbert,
to adjust the chemistry to narrower limits within the range of British Cast Iron Research Association (1968), Alvechurch,
analysis in Table X1.3. Birmingham, England.
X1.7.3 As the performance of an automotive camshaft is (6) Gray, Ductile, and Malleable Iron Castings Current
determined by the microstructure and hardness, producers do Capabilities, ASTM STP 455, (1969).

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