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Cast Iron PDF
Cast Iron PDF
Cast Iron PDF
2
1.
2.
(Ferrous metals)
(base metal)
(Nonferrous metals)
(base metal)
2
Ferrous metals
1.
2.
3.
(Fe2O3)
1538
C
Timeline
1.
2.
3.
4.
2900 B.C.
2000 B.C.
1350 1000
B.C.
200 B.C
2. Steel Making
5
1.
(Float)
(Magnetic separation)
(Agglomeration) 1
()
,
,
Magnetite (Fe3O4) 70%
Hematite (Fe3O3) 70%
Siderite (FeCO3) 60%
Pyrite (FeS2)
45%
Limonite (HFeO2) 35%
10
http://www.soes.soton.ac.uk/resources/collection/minerals/minerals/
Magnetite
Magnetite (Fe3O4)
70%
Hematite
Hematite (Fe3O3)
70%
Pyrite
Pyrite (FeS2)
45%
11
http://www.musee.ensmp.fr/mineral//11087x.jpg
http://www.gc.maricopa.edu/earthsci/imagearchive/limonite.htm
Siderite
Siderite (FeCO3)
60%
Limonite
Limonite (HFeO2)
35%
12
2. Process Steelmaking
(% )
Blast furnace
flux CaO CaCO3
13
3.5%
2%,
1.5%,
1%
1%
2
14
3.
(Pig iron)
1600 C
Oxidation
Slag
90%Fe
Mn, Cr, Mo, Ni V
15
:Furnace
1. The basic open-hearth furnace
16
17
www.key-to-steel .com
18
19
20
Radiation
21
22
23
3.
Casting ()
2
1.
2.
Continuous Casting
Ingot Casting
24
25
3.1
3
3.2
27
3.
Low alloy
High alloy
C C C
Plain
Heat
Treatable
28
2
1. (Steels) C 2wt%
2. (Cast Irons) C
2wt%
29
C
Mn
Si
Ni
P
:
:
Yield strength
, 0.25%
, ,
30
S
Sn
Al
Cu
Cr
(Toughness) (Cracking)
Casting (S) Mn , S (Fe)
FeS Hot shortness
(Cracking)
Inclusion
(Castability)
(Edge cracks)
(Corrosion resistance)
,
31
Pb
Nb
V
Mo
Ti
(Intergranular corrosion)
32
Cast Irons
2 % Si
Steels
33
L+
1532 C
910 C
L+
-austenite
1148 C
L + Fe3C
+ Fe3C
727 C
-ferrite + Pearlite
Pearlite + Fe3C
Pearlite
+ferrite
0.025 0.8
Steel
2.08
Fe3C
4.3
6.67 %C
Tensile strength
Elongation
Cast Iron
34
(Gray cast iron)
2. (White cast iron)
3. (Ductile cast iron)
4. (Malleable cast iron)
(Alloys or Special
cast iron)
1.
5.
35
(Pig
Iron) (Blast furnace) C
2 4 wt%
(Graphite Flake)
36
200-250 MPa
37
Graphite flake
Ferrite
C (Fe3C)
39
Pearlite
Cementite (Fe3C) (Ledebulite)
Cementite
Fe3C
Pearlite
40
Carbon atom
graphite
Ferrite
Pearlite
41
Rosette graphite
Ferrite grain
ferrite matrix
42
4. Ductile Iron
4.24.6 wt% Eutectic
ferrite, pearlite
graphite graphite (Nodular)
Nodular graphite Mg
Modulus of elasticity
43
Ferrite grain
Nodular Graphite
44
Ni-Resist
45
46
ASTM Standard
32/35
40/90
28/30
10/18
1/10
6/20
47
Cast iron
Process
Graphite
Matrix
Ductility
White
Ferrite
No
Gray
Ferrite/Pearlite
No
Malleable White+annealing
Flake to
nodule
Ferrite/Pearlite
Good
Nodular
Mg +slow cooling
Nodular
Ferrite/Pearlite
Good
Alloy
alloying element
Carbide
Ferrite/Pearlite
Good
48
1.
2.
3.
4.
5.
Cr and Mn Cementite stabilizers
Si, Al and Ni graphite formers
49
1.
a)
b)
c)
2.
3.
) Mg
) Carbon 2-4wt%
) 1600F 24-48 .
50
Introduction to Solidification
Ingot
billet Ingot
51
Equilibrium
Temperature
Freezing
point
Undercooling
Solidification time
1.
2.
3.
4.
52
Time
1. (Nucleation)
2. (Crystal Growth)
: Equlibrium
53
Cooling curve
At Freezing point, TE :
Embryo (Critical size)
Nucleus
Nucleus
(Hf,
Latent heat of fusion, J/cm3) Freezing
Temperature
54
Undercooling Solidification
TN< TG< TE
55
Temperature
Undercooling
TE
TG
TN
Time
56
Solid Grain
Temperature
Solid+Liquid Liquid
Dendrite tip
TE = Freezing temperature
TG = Growth temperature
TN = Nucleation temperature
TE
TG
TN
X,
Mould
57
6.4 Undercooling
Dendrite structure
(orientation)
Orientation
58
(Crystal
directions) Dendrite
Dendrite arm
59
TE
TG
TN
TE>TG>TN
60
TE
TN
TG
TE>TN>TG
61
Grain refiner
TN
TE
TG
TN>TE>TG
62
Grain Refining
63
(Particles or compounds or elements)
Grain Refiner
64
grain refiner
+ 0.25%Ti
+ 0.1%Ti
+ 0.05%Ti
grain refiner
65
1. (Cooling rate)
2. (Temperature
gradient)
66
2. Temperature gradient
1.1
Equiaxed grain
1.2
columnar grain
67
Mould
Fine Equiaxed grain
Columnar grain
Mould surface
(Mould)
Rapid cooling
slow cooling
Moderate cooling
69