7

7
(Composition Control and Graphite Cast Iron)

1.
2. ()
()

1. (Introduction)
1.1

(Cast Iron)

4
o (White cast iron)
o (Malleable cast iron)
o (Grey cast iron)
o (Ductile cast iron)

1.1.1 (Grey cast iron)

(Damping capacity)

(Pig iron)
(Graphite)
(Cementite) [1] 1
()
1 [2]

3
[1]
o
o
o
2.5-4.0%

(Graphite-forming elements)

(Carbide forming elements)



1

1 Grey cast iron

Type A graphite Inoculation
Moderate
undercooling

Type B graphite (neareutectic composition) , Eutectic

cell , Type B graphite Low undercooling
Type C graphite (Hyper eutectic cast
irons) Minimum undercooling
Type D graphite Hypoeutectic Eutectic irons
Type E graphite Strongly hypoeutectic irons
Type D and E graphite
High undercooling

2 type A, type b), type C, type D, type E type N [1].

1.1.2 (Ductile cast iron)

40-70
kg/mm2 392-686 MPa 8-25% [1]
(Ductile cast iron)
(Nodular graphite or spheroidal graphite cast iron)
3
.. 1948 [3]
(Ce) (Mg)
3.5-3.8%
2.2-2.8%

2

3 Ductile cast iron

2 [1]
(Metallic phase as the matrix)
-

(Morphology and distribution of graphite)

2 [4]
JAPAN SPHEROIDAL GRAPHITE IRON CASTINGS
JIS G 5502-1995
Mechanical properties of separately cast test sample
Symbol of
grade

Tensile
strength
(N/mm2)

Yield
strength
(N/mm2)

Elongation
(%)

FCD 350-22
FCD 350-22L
FCD 400-18
FCD 400-18L
FCD 400-15
FCD 450-10

350 min.
400 min.
450 min.

220 min.
250 min.
280 min.

22 min.
18 min.
15 min.
10 min.

FCD 500-7

500 min.

320 min.

7 min.

FCD 600-3

600 min.

370 min.

3 min

FCD 700-2

700 min.

420 min.

2 min.
-

FCD 800-2

800 min.

480 min.

Charpy absorption energy

(Information reference)
Test
Mean value
Individual Hardness
Matrix
Temp. of 3 pieces
value (J)
(HB)
structure
(oC)
(J)
23 5
40 2
23 5
20 2
-

17 min.
12 min.
14 min.
12 min.
-

14 min.
9 min.
11 min.
9 min.
-

150 max.
130 to 180
140 to 210
150 to 230
170 to 270
180 to 300
200 to 330

Ferrite
Ferrite +
pearlite
Pearlite +
ferrite
Pearlite
Pearlite or
tempered
structure

1.2

(Composition Control of the Melt)

(Chemical composition)

Spectrometer

- 4 [6] 2%
( 2%)
(% C.E.)
% C.E.
% . . = % +

% + %
3

% C.E. 4.3 % C.E.

4.3

Si

C Si 5 C
Si

4 Phase diagram of Fe-C [6]

C.E.
(Flotation) (Ductile iron) C.E.
Chilling 10 40
C Si (C.E. = 4.3 )

Si C.E. chilling
( )
(nodularity) C.E. Si
Nodularity

5 [6]
(Pig iron)

Ferrosilicon
(Innoculant) (Nodularizer)

1.3

(Inoculation)

Nodule count
(Chill)


(Heterogeneous nucleus)

Degree of Supercooling
Eutectic cell
-

Superseed
3 0.4-1.0

Chill - (Ca) ,
(Sr) , (Al) , ( Ba )

3 Superseed 75
Element
Si
Sr
Ca
Al

Content
73-78 %
0.6-1.0 %
0.10% max
0.50% max

1.4

(Inoculation)

0.15

(Magnesium Treatment)
1100 C

5.0-6.0
(Nodularizer) 4

protective atmosphere (Residual magnesium)

0.020 0.030 wt%
-

0.04-0.06 wt% Mg
0.015 wt% S
0.035-0.04 wt% Mg

Sandwich process 6 [1]

10

6 Sandwich process. [1]

1.5

1 (Si)

4
(Target composition)
Element
C
Si
%C.E.

Weight percent
3.5
2.5
4.3

30
0.4%

5
Element
Si
Sr
Ca
Al

Weight percent
73-78
0.6-1.0
0.10 (max)
0.5 (max)

11

0.4
30 = 0.12 = 120
100

120
=

75
120 = 90
100

120 Si 90

% =

,
90
100 =
100 = 0.3%

30 1000

120 (0.4%)
2.5 2.8
2.5- 0.3 2.2
2 30
(Mg
treatment) 6
6
Element
Silicon
Magnesium
Calcium
Rare earth
Aluminium
Iron

Content
44 - 48 %
5.0 - 6.0 %
0.4 - 0.6 %
0.25 - 0.4 %
0.8 - 1.2 %
Balanced

% .
.

% =

12

0.04

5.5

. . 100
0.04 = 100
= 218.18
30 1000

0.06

5.5
100 . . 100
= 327.27
0.06 =
30 1000

1450 Sandwich process 5.0 % Mg ferrosilicon
40 % Recovery = 60%

0.04 % Recovery = 60% 30

100
100
. 60
218.18 60
%=
=
= 1.20 . %
30 1000
30 1000

0.06 % Recovery = 60%

30

100
100
. 60
327.27 60
%=
=
= 1.82 . %
30 1000
30 1000

%Residual 0.04-0.06
1.2-1.8 % Recovery = 60

13

3
5
0.4 30
4
1)
1450 2) 6 3)
0.04-0.06
1.3

(0.4/100) x (30x1000 g.) = 120

(75/100) x 120 g. = 90
(90 g. x100)/(30 x 1000 g.) = 0.3

1.3 (1.3/100) x (30x1000 g.) = 390
(45/100) x 390 g. = 175.5
(175.5x100) / (30x1000 g.) = 0.585

0.3% + 0.585% = 0.885

2.5

2.5% - 0.885% = 1.615

14

2. (Experimental procedure)
2.1

-
-
-
-
-
-
- (Spectrometer)

2.2

- 30-35 1500

- Spectrometer

- 5

- 1450 1500
- 1280 1380

C
Si
2.5 - 4.0
1.0 - 3.0
3.0 - 4.0
1.8 - 2.8

Mn
0.2 - 1.0
0.1 - 1.0

P
S
0.002 - 1.0 0.02 - 0.25
0.01 - 0.10 0.01 - 0.03

15

7 Sandwich process

16

3. (Experimental results)
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4. (Discussion)
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5. (Conclusions)
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19

6.
6.1

What element is the most important for promoting graphitization in gray cast
irons?
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6.2

What is the chief cause of the relatively low tensile strengths of gray cast irons
and higher tensile strength in ductile cast iron?
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6.3

Explain the sandwich process.

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7
[1]

2536

[2]

International standard (ISO 185 First edition 1988-12-15)

[3]

Morrough H., William W.J., Journal of the Iron and Steel (1948) Vol.158, 306-22.

[4]

http://www.ductile.org

[5]

http://www.thermoscientific.com/ecomm/servlet/productsdetail

[6]

J.R. Davis Davis & Associates, ASM speciality handbook Cast Irons, 1996

21