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Gray iron refers to a broad class of ferrous casting alloys which are
defined as an iron having a chemical composition such that after
solidification, a large portion of its carbon is distributed throughout the
casting as free or graphite carbon in “flake form”
In other words, iron which is normally characterized by a micro
structure of flake graphite in a ferrous matrix. Gray irons are in
essence iron carbon silicon alloys containing small quantities of other
elements.
Gray iron always leaves a sooty surface when fractured.
For purpose of clarity and simplicity the chemical analysis of gray iron
can be broken down into 3 categories.
Major elements - the 3 major elements are iron, silicon, and carbon.
Both carbon and silicon influence the nature of the castings, so their
impact on the solidification is attributed for by introducing a factor
CARBON EQUIVALENCE, CE.
CE = % C + [% Si / 3]
If we take the effect of phosphorus in account,
CE = % C + [% Si + % P / 3]
Irons with a CE of 4.3 are considered to be of eutectic composition.
Most gray irons are hypoeutectic. Nearly all of the properties of gray
iron are closely related to CE value.
Minor elements - these are phosphorus and the two inter related
elements like manganese and sulphur.
Phosphorus increases the fluidity of iron, by forming a low melting
phosphide called steadite. At high levels it can promote shrinkage
porosity while very low levels can increase metal penetration into the
mold. Its concentration is 0.02 – 0.10 %.
Sulphur plays a significant role in nucleation of graphite in gray iron.
Sulphur levels should be in the range of 0.05 – 0.12 %.
Sulphur content should be balanced with the manganese to promote
the formation of manganese sulphides. This is achieved by
% Mn >= 1.7% S + 0.3%
Trace elements – trace elements like antimony, arsenic, bismuth,
boron, chromium, nickel can be present or can be added in the gray
iron to induce some properties.
All the elements normally present in gray iron exert some influence on
the microstructure of the iron. The effects of different elements on the
properties are discussed below:
Carbon: Carbon in gray iron is present from about 2.5 to 4.5 per cent
by weight. Carbon occurs in two different forms. Elemental carbon in
form of graphite flakes and combined carbon as Fe3C.
The degree of graphitization may be assessed by the following
relationship
% total carbon = % graphitic carbon + % combined carbon
If graphitization is complete the percentage of total carbon and
percentage of graphitic carbon is equal. If no graphitization has
occurred, the percentage of graphitic carbon is zero.
If about 0.5 to 0.8 % combined carbon exists in a gray iron, it generally
indicates that the microstructure is largely pearlitic since pearlite in
gray iron having about 0.2 % silicon forms from the austenite eutectoid
containing about 0.60 per cent carbon.
For sufficient graphitization to develop during solidification of a true
gray iron, certain minimum total carbon content necessary, which is
around 2.20 %, but this value depends on Silicon percentage in the
iron.
Silicon : silicon is present in gray iron about 1.0 to 3.50 per cent by
weight. Increasing silicon percentage shift the eutectic point of the iron
carbon diagram to the left.
The eutectic shift is described by the following relationship-
Most gray irons are hypo eutectic in nature. The sequence of events
associated with the solidification of hypo eutectic irons can be studied
with simplified version of the iron- carbon- silicon ternary phase
diagram taken at 2% Si.
Figure 1: Simplified iron-carbon-silicon phase diagram at 2% Si
Large flakes are associated with irons having high CE and slow cooling
rates. The large flakes are suitable for applications requiring high
thermal capacity and thermal conductivity.
Strongly hypoeutectic irons and irons subjected to rapid solidification
generally exhibits small, short flakes. Small flakes because they disrupt
the matrix to lesser extent, are desired when maximum tensile
properties and a fine smooth surface finish is to be obtained.
INOCULATION AND ITS INFLUENCE ON THE STRUCTURE AND
PROPERTIES OF GRAY CAST IRON:
Mold inoculation involves placement of the alloy in the mold, such a sin pouring basins,
at the base of the sprue or in suitable chambers in the runner system. Inoculants fir this
method can be crushed material, powder bonded into a pellet, or pre-cast slugs or blocks.
As in stream inoculation, alloy dissolution rate is an important factor. The pre-cast and
bonded alloys are designed to dissolve at a controlled rate throughout the entire pouring
cycle.
There are several advantages of late inoculation over ladle inoculation. Fading is
virtually eliminated, and because the castings are inoculated to the same extent, there is
greater consistency in structure form casting to casting. It has also been observed that the
late inoculation is more successful in preventing carbide formation in thin sections, thus
eliminating heat treatment.
REFERENCES
1. ASTM Handbook. “Ferrous Casting Alloys”, pg 629-645,
D.B.Craig, M.J. Hornung and T.K.McCluhan,
2. “Principles of Metal Casting” Tata Mc Gram Hill Publications, 30th
reprint 2005, pg 575-611, , Philip .C. Rosenthal, Richard
.W.Heine, Carl. R. Loper
3. www.wikipedia.com/search=gray+cast+iron+metallurgy.htm,
retrieved on 5-10-2010 at 3:30 pm
4. www.mifco.com/inoculation.htm retrieved on 5-10-2010 at 3:50
pm