CAST IRONS

Cast irons are basically iron carbon alloys containing

more than 2.01%C. Since high carbon content makes
them brittle the carbon content is generally restricted to
2.5 -4%.
Properties in general:
(i) Poor ductility
(ii) Most of them are not malleable at any temperature.
(iii) Casting properties are very good.
Low melting point,
good flow properties;
can be cast into any complicated shape.
(iv) Cheap
(v) Properties can be enhanced by alloying, foundry
control and heat treatment.

Classification:
According to metallographic structure they are classified
as
(i) White cast iron: All carbon is in the combined form
(ii) Malleable cast iron: Most or all carbon is in
uncombined form, temper carbon.
(iii) Grey cast iron: Most or all carbon is in the form of
graphite flakes.
(iv) Spheroidal graphite (SG) Iron :Carbon is present
as nodules of graphite.

6
5
4

wt % C

Silicon in Cast irons:

Silicon is a very
important element in
cast irons. It improves
fluidity. Eutectic point
shifts to lower carbon
concentration (0.3% C
for every 1 % Si). It also
decreases eutectic
temperature. It is a
strong graphitizer.
Efficiency of
graphitization depends
on carbon.

3
2

III
Ferritic
grey CI

II
Pearlitic
grey CI

White
CI

0
0

10

wt % Si

Region I: Low C, Low Si : Fe3C is stable and no

graphitization.
Region II: High C and Si, partial graphitization.
Region III: Large Si and C ; graphitization of all
Fe3C.

White Cast Iron:

Typical Composition:
C: 2.5-3.5% , Si: 0.4-1.5%, Mn:
0.4-0.6%, P: 0.1-0.4%, S:
0.15, Fe: balance
Tensile strength: 140-490 MPa,
Compressive: 1400-1750 MPa,
Hardness: 375-600 BHN.

The proeuctectoid cementite makes the material hard, wear resistant but
brittle. Hence it has limited applications. Used for Liner of (i) cement
mixers,
(ii) ball mills
(iii) extrusion nozzles.
It is also a raw material for malleable cast iron.
(Si should be less than 1.4%)

Malleable Cast iron:

Typical Composition:
C: 2.0-2.65% , Si: 0.9-1.4%, Mn: 0.25-0.55%, P: <0.18%, S:
0.05, Fe: balance.
Fe3C is a metastable phase. There is a tendency to decompose
according to,
Fe3C = 3Fe + C
Production: White Cast iron is heated slowly to 900-950oC
Fe3C + pearlite = Fe3C +
During this heating, pearlite transforms to and graphite nucleates
at the - Fe3C Interface.
As T increases more Fe3C is dissolved.
Holding at 900-950oC (20-70 hrs), graphitization continues.
As graphitization occurs gets depleted of C and draws C from Fe 3C
which results in more dissolution of Fe3C.
At the end of this stage we will have Fe3C in matrix. This is called
first stage of graphitization (FSG).
After FSG, the casting is cooled rapidly to 730 -740oC. From this
stage the castings are cooled at a very very slow rate (5-10oC/hr)
called second stage graphitization (SSG). During this slow cooling
transforms to ferrite and graphite. We end up in following
microstructure.

Pearlitic malleable cast iron can

be obtained either by adding
manganese which promotes
pearlite or after SSG the castings
are quenched.

Ferritic malleable cast iron

Property

Ferritic

Pearlitic

T. S. (MPa)

390

450-700

Y. S. (MPa)

250

280-500

% elongation

15 %

16 %

Hardness
(BHN)

115

160-210

Applications;
Ferritic: Automotive industry, Agriculture, Pipe fittings
Pearlitic: Rolls, pumps, Nozzles, Crank shafts, clamps, wrenches.

Grey Cast Iron:

Typical Composition:
C: 2.5-3.5% , Si: 1.4-2.8%, Mn: 0.5-0.8%, P: 0.10.9%, S: 0.12, Fe: balance.
Because of high Si, Fe3C becomes unstable and the
system follows Fe-graphite phase diagram.
Eutectic reaction: L= + graphite.

Solidification sequence,
L = L + = + eutectic = graphite + pearlite.
Some Fe3C of pearlite also may decompose giving graphite
flakes surrounded by ferrite in a pearlitic matrix. If Si and
C content is too high then matrix will be entirely ferritic

S promotes Fe3C and also reduces fluidity. Mn is not as efficient as

sulphur to promote Fe3C. It forms MnS and reduces hot shortness. P if
excess can form steadite which is not desirable.
Carbon, S, P influence tensile strength. Effect is given as carbon
equivalent value,
CEV=total %C + (%P + % S)/3
Size and distribution of flakes is important as they interrupt continuity in
pearlite and reduce strength and ductility. Small flakes are preferred.
Applications:
Pressure vessels, housings, machine foundations ..etc.

Spheroidal graphite (SG)/ Nodular/Ductile Iron:

Graphite is present as tiny nodules.
Achieved by melt treatment and not by heat treatment.
Composition is same as grey cast iron.
Spheroidisation is achieved by ladle additions of Mg or Ce.
S content should be low (0.015%). Otherwise these
elements combine with S and become ineffective.
Generally Mg is added as a master alloy (1-2 wt% of Ni20Mg alloy) to get a Mg content of 0.03-0.06%.

Nodular cast Iron showing Bulls eye structure

Property
T. S. (MPa)

400-700

Y. S. (MPa)

270-390

% elongation

10-20

Applications:
Crank shafts, cam
shafts, suspension
components,
Railway couplings,
Agricultural
equipment ..etc.