Cast Irons

Dr. Muhammad Riaz Bhatti

Abraham Darbys Ironbridge

Ductile iron used in drain grids

16/05/11

WEC

Table of contents

Overview of cast iron Microstructure of cast iron Production of cast iron Types of cast iron

Production, properties & uses

Effect of alloying elements

16/05/11

WEC

Overview of cast iron

Iron with 2.0 to 4.5% carbon and 0.5 to 3% silicon Lower melting point and more fluid than steel (better castability) Low cost material usually produced by sand casting A wide range of properties, depending on composition & cooling rate

Strength Hardness Ductility Thermal conductivity Damping capacity

WEC
3

16/05/11

Composition of Cast Iron

A typical cast iron contains

2.0 to 4.5% carbon,

1.0 to 3.0% silicon,

less than 1.0% manganese, and

less than 0.2% sulfur.

16/05/11

WEC

Iron carbon diagram

d

Liquid g+ L
Austenite
1130C g + Fe3C L + Fe3C

910C

Carbon Steel
a+g

Cast Iron

723C

a
0%
16/05/11

a + Fe3C
0.8% ~2%
WEC

~3%
5

Cast Iron
On solidification of Cast Iron the

eutectic reaction has two distinct possibilities:

liquid liquid

austenite + Fe3C austenite + graphite

16/05/11

WEC

Microstructure of Cast Iron

The final microstructure of cast iron has

two possible extremes:

all of the Carbon-rich phase being

intermetallic Fe3C and

all of the Carbon-rich phase being

graphite.

16/05/11

WEC

Microstructure of Cast Iron

Both (Fe3C & graphite) microstructures can be obtained by controlling the chemistry and other process variables.

Graphite formation is promoted by: high carbon & silicon contents,

heavy or thick section sizes,

slow cooling inoculation practices, and the

presence of sulfur, phosphorus, aluminum, magnesium, antimony, tin, copper, nickel, and cobalt. 16/05/11 8 WEC

Microstructure of Cast Iron

Cementite (Fe3C) formation is favoured by: low carbon & silicon levels, thin sections, fast cooling, and alloy additions of titanium, vanadium, and zirconium, chromium, manganese,

molybdenum.

16/05/11

WEC

Production of cast iron

Raw material

Pig iron, scrap steel, limestone and carbon (coke)

16/05/11

Cupola Electric induction furnace Electric arc furnace Usually sand cast, but can be gravity die cast in reusable graphite moulds finishing by machining WEC
10

Cupola Furnace

16/05/11

WEC

11

Dependence of Types of cast iron

Various types of cast iron can be produced, depending on the

Chemical composition, Cooling rate, and the type and amount of Inoculants used.

16/05/11

WEC

12

Effect of composition

Carbon Equivalent (CE) = C + Si / 3 A CE over 4.3 (hypereutectic) promotes gray cast iron A CE less than 4.3 (hypoeutectic) promotes white iron

16/05/11

WEC

13

Effect of cooling rate

Slow cooling favours the formation of graphite & low hardness Rapid cooling promotes carbides with high hardness

Thick sections cool slowly, while thin sections cool quickly

Sand moulds cool slowly, but metal chills can be used to increase cooling rate & promote white iron
WEC
14

16/05/11

Types of cast iron

Gray cast iron - carbon as graphite White cast iron - carbides, often alloyed Ductile cast iron

nodular, spheroidal graphite

Malleable cast iron

Graphite nodules are irregular clusters / tempered graphite

Compacted graphite cast iron

CG or Vermicular Iron

16/05/11

WEC

16

Microstructures of cast iron

Gray iron a Fe and graphite flakes

Nodular iron a Fe and graphite spheres

White iron cementite and pearlite

low melting point, castable, cheap; however, can be brittle.

16/05/11

Malleable iron a Fe and tempered graphite flakes

Compacted Graphite Iron

WEC
17

Gray Cast Iron

16/05/11

WEC

18

Raw Materials used for Gray Cast Irons

Iron Sources Iron Scrap

Internal Returns Machined Chip Briquettes

External Purchased Scrap

16/05/11

Steel Scrap Pig Iron Coke Graphite and Silicon Carbide

WEC Ferro-silicon and Ferro-manganese
19

Gray cast iron

16/05/11

Gray cast iron forms when Cooling is slow, as in heavy sections High silicon or carbon, Mn = 0.4 to 1.0 % Flake graphite in a matrix of pearlite, ferrite or martensite Properties depend strongly on casting shape & thickness Low ductility - elongation 0.6% High conductivity, high damping Wide range of applications WEC

20

Matrix structure

Pearlite or ferrite

Transformation is to ferrite when

Cooling rate is slow High silicon content High carbon equivalence Presence of fine undercooled graphite

16/05/11

WEC

21

Properties of Gray cast irons

Excellent compressive strength (compressive strength is typically 3-4 times tensile strength),

Excellent machinability (graphite acts to break up the chips and lubricate contact surfaces),

Excellent wear resistance (graphite flakes self-lubricate),

and

Outstanding sound and vibration-damping capacity (graphite flakes absorb transmitted energy).

16/05/11

WEC

22

Properties of Gray cast irons

Good corrosion resistance and the enhanced fluidity due to high silicon contents

Thermal conductivity high The formation of the lower-density graphite reduces the amount of shrinkage, making possible the production of more complex iron castings

The pointed edges of the flakes act as preexisting notches

or crack initiation sites, giving the material a characteristic

brittle nature resulting low impact resistance

Ductility is low (0.6%)

WEC
23

16/05/11

Properties of Gray cast irons

The size, shape, and distribution of the graphite flakes have a considerable effect on the overall properties of gray cast

iron.

For maximum strength, small, uniformly distributed flakes are preferred.

16/05/11

WEC

24

Graphite Flake Distributions per ISO 945

16/05/11

WEC

25

Applications of Gray cast irons

Engines

Cylinder blocks, liners,

Transmission housing Brake drums, clutch plates Pressure pipe fittings, Machinery beds Furnace parts, ingot and glass moulds

Machine tool basis & large equipment parts subjected to compressive load & vibration
WEC
26

16/05/11

Ductile or SG iron

16/05/11

WEC

27

Ductile or SG iron

Also known as spheroidal graphite (SG), and nodular graphite iron Inoculation with Ce or Mg or both causes graphite to form as spherulites, rather than flakes Far better ductility than gray cast iron

16/05/11

WEC

28

Production of SG iron

Composition similar to gray cast iron except for higher purity

(High CE with sufficiently low in Sulfur either by original chemistry or by desulfurization)

Melt is added to inoculant (Mg) in ladle. Magnesium as wire, ingots or pellets is added to ladle before adding hot iron Mg vapour rises through melt, removing sulphur.

Prior to solidification, graphite forms as smooth-surface spheres. This addition is known as a nodulizing, and the product becomes ductile or nodular cast iron
WEC
29

16/05/11

Microstructure of SG iron

16/05/11

WEC

Graphite spheres surrounded by ferrite Usually some pearlite May be some cementite Can be hardened to martensite by heat treatment 30

Microstructure of SG iron with different matrix

FIGURE - Ductile cast iron with (a) ferrite matrix and (b) pearlite matrix; 500X.

16/05/11

WEC

31

Properties of SG iron

good ductility, high strength

Strength higher than gray cast iron Ductility up to 6% as cast or 20% annealed

Low cost

Simple manufacturing process makes complex shapes

Machineability better than steel

Good toughness, wear resistance, low-melting-point castability, up to a 10% weight reduction compared to steel makes ductile iron an attractive engineering material
WEC
32

16/05/11

Applications of SG iron

Automotive industry 55% of ductile iron in USA

Crankshafts, front wheel spindle supports, steering knuckles, disc brake callipers

Pipe and pipe fittings (joined by welding)

16/05/11

WEC

33

White cast iron

16/05/11

WEC

34

White cast iron

White fracture surface No graphite, because carbon forms Fe3C or more complex carbides. Features promoting the formation of cementite over graphite are:

low Carbon equivalent (1.8 to 3.6% carbon), 0.5 to 1.9% Silicon, 0.25 to 0.8% Manganese, &

rapid cooling very hard, brittle & abrasion resistant. For these uses it is common to pursue hard, wear resistant martensitic structure as a metal matrix 16/05/11 WEC Often alloyed

35

Uses of White cast iron

Products such as

gates,
fences, parts of stove are manufactured by using white cast iron. In addition it is also used to manufacture malleable cast iron

16/05/11

WEC

36

Malleable iron

16/05/11

WEC

37

Malleable iron

Produced by heat treatment (in the range of 900C) of white cast iron- cementite dissociate into its component element

Carbon converts into graphite nodules of irregular clusters (also

referred to as Clump or popcorn graphite)

Similar properties to ductile iron starting white iron structure restricts the size and thickness of malleable iron products such that most weigh less than 5 kg

depending on the type of heat treatment, various types of malleable iron can be produced
16/05/11

WEC

38

Heat treating cycle for malleablizing white iron

16/05/11

WEC

39

Microstructure of Malleable iron

Uniformly dispersed graphite Ferrite, pearlite or tempered martensite matrix

WEC
40

16/05/11

Properties of Malleable iron

Similar to ductile iron Good shock resistance Good ductility Good machineability corrosion resistance

16/05/11

WEC

41

Applications of Malleable iron

Similar applications to ductile iron Malleable iron is better for thinner castings

Ductile iron better for thicker castings >40mm

Vehicle components

Power trains, frames, suspensions and wheels

Steering components, transmission and differential parts, connecting rods

Railway components

Pipe fittings
products such as door keys, gear wheel, and crank levers
WEC
42

16/05/11

Austempered ductile iron (ADI)

Austempered ductile iron (ADI)

ADI has emerged as a significant engineering material ADI, undergoes a special austempering heat treatment to modify and enhance its properties

Compared to conventional as-cast ductile iron, it offers nearly double the strength at the same level of ductility.

Combines the ability to cast intricate shapes with strength,

fatigue, and wear-resistance properties, similar to those of

heat-treated steel.
16/05/11

WEC

44

Austempered ductile iron (ADI)

Compared to steel, offers an 8 to 10% reduction in density (so strength to weight ratio is excellent) and enhanced damping capability, both due to the graphite nodules, poorer machinability and lower elastic modulus (about a 20%).
WEC
45

but generally it has

16/05/11

What is Austempering?
Austempering is a hardening process to

promote better mechanical properties.

Properties include:

Higher ductility Higher resistance to shock Uniform Hardness

16/05/11

WEC

46

The Austempering Process

The metal is heated into the austinite region and then immediately quenched in a "salt bath"

or heat extraction medium between

temperatures of 357-385C.

The metal is held here until the austenite turns to bainite.

16/05/11

WEC

47

Typical Heat Treatment to produce ADI

Austenitizing temperature = 816 - 824 C, Austenitizing time = 1.5 to 2 hrs Quenching to 357-385 C soaking time = 30 to 45 min Air cooling to room temperature

16/05/11

WEC

48

Advantages of Austempering

Less Distortion Greater Ductility Parts have clean surface from the salt quench Uniform and consistent Hardness

Tougher and More Wear Resistant

Higher Impact and Fatigue Strengths Resistance to Hydrogen Embrittlement Uses

Chases, wheel hub etc

WEC
49

16/05/11

Applications of Austempered ductile iron (ADI)

Construction and Mining Components Agricultural

Gears
Heavy Truck and Bus Components include

suspension components such as spring hanger brackets, shock brackets, u-bolt plates, wheel hubs, brake calipers and spiders, and gears for trailer landing gear.

16/05/11

Powertrain related ADI heavy truck and bus components include engine brackets and mounts, timing gears, cams, annular gears, differential gears and cases, clutch collars, accessory brackets and WEC pulleys.

50

Use of Austempered ductile iron (ADI)

16/05/11

WEC

51

Use of Austempered ductile iron (ADI)

16/05/11

WEC

52

Compacted graphite cast iron (CGI)

16/05/11

WEC

53

16/05/11

WEC

54

Compacted graphite cast iron (CGI)

CGI is produced by addition of an Mg-Ce-Ti

CGI is characterized by a graphite structure that is intermediate to the flake graphite of gray iron and the nodular graphite of ductile iron, and
possesses some of the desirable properties and characteristics of each.

16/05/11

WEC

55

Properties of CGI

Properties of CGI bridge the gap between Gray and Ductile irons

Strength,

stiffness,

and

ductility

are

greater than those of gray iron,

While,

castability,

machinability,

thermal

conductivity, and damping capacity all

exceed those of ductile.

16/05/11

Impact and fatigue properties are good

WEC
56

Typical Properties of Pearlitic Gray, Compacted Graphite, and Ductile Cast Irons
Property Tensile strength (MPa) Elastic modulus (Gpa) Elongation (%) Thermal conductivity (w/mk) Relative damping capacity (Gray = 1) Gray 250 105 0 48 1 CGI 450 145 1.5 37 0.35 Ductile 750 160 5 28 0.22

16/05/11

WEC

57

16/05/11

WEC

58

Fracto-graphs of cast irons

16/05/11

WEC

59

Cast Iron

Cast Iron usually contains 2 to 4% carbon and 1 to 3% silicon and other alloys to control other specific properties. The advantage of cast iron is low cost and ease of casting.

They are used for engine blocks, heads, camshafts, piston rings and crankshafts.
White Cast Iron: carbon and silicon content are low white fracture surface on breaking. Used for grinding balls, farm equipment, and roller dies. Grey Cast Iron: Grey when broken. Have excellent machinability and are used for machine bases. Malleable Cast Iron: White cast iron heated to a high temperature. Stronger and more ductile. Used in automotive differential housings. Ductile Cast Iron: Used in automobile engine crankshafts because of high strength and toughness. High Alloy Cast Iron: Large amounts of alloy for special properties. 30% chromium for corrosion resistance used in mining and agricultural applications. High silicon content for corrosion resistance used in acid containers and chemical pumps.

Cast Iron

Cast iron is defined as an iron alloy with more than 2% carbon as the main alloying element. In addition to carbon, cast irons must also contain from 1 to 3% silicon which combined with the carbon give them excellent castability.

Cast iron has a much lower melting temperature than steel and is more fluid and less reactive with molding materials. However, they do not have enough ductility to be rolled or forged.
The precipitation of carbon (as graphite) during solidification is the key to cast iron's distinctive properties. The graphite provides excellent machinability (even at wearresisting hardness levels), damps vibration, and aids lubrication on wearing surfaces (even under borderline lubrication conditions).
16/05/11

WEC

62

Thanks

Joining cast iron

Joining cast iron

Welding Braze-welding Brazing Soldering Mechanical connections

16/05/11

WEC

65

Weldability

White cast iron - not weldable

Small attachments only Welding largely restricted to salvage and repair

Grey cast iron - low weldability

Ductile and malleable irons - good weldability (inferior to structural steel)

Welding increasingly used during manufacture

WEC
67

16/05/11