Metallurgical and Material Engineering UET, LHR 1

Metallographic study of cast iron structure

1.0. Introduction:
Metallography is the study of the physical structure and components of metals,
typically using microscopy. It is the study of the structure of metals and of metal
alloys through the examination of specimens with a metallurgical microscope. The
structures observed in the microscope are often recorded photographically.

Figure #1 metallographic structure.

1.1. Principles of metallographic Examination:

Metals and alloys are polycrystalline, that is, they are composed of crystals
commonly referred to as grains. The size, shape, and configuration of the grains
within a metal or an alloy are a function of the way in which the metal was
produced and used. The metallographic examination of specimens allows the
metallographic structure of metal to be observe under microscope. Metals and
alloys often contain features other than grains. Such features include pores (from
the evolution of gases and the formation of bubbles in liquid metal as it solidifies
in a mould); non-metallic inclusions such as oxide or sulfide particles or bits of
slag in the metal; fissures or other flaws that may arise when the metal shrinks and
cracks upon cooling; surface and internal corrosion products, and so forth. For
each feature, one normally records the following characteristics:

1. Shape
2. Size
3. Color (in plane polarized light or with crossed polar)
4. Distribution
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Metallographic study of cast iron structure

Figure#2 micro structure of a sample

Metallography of a given sample is taken in different steps and requires different

procedures to follow.

Following are the procedures:

 Cutting metallic samples

 Grinding
 Polishing
 Etching

In metallographic etching is the main step. This is the main step which shows all
the hidden realities in a prepared sample. The chemical react with the grain
boundaries and show light and dark regions.

In etching 2% Nital is used as a chemical reactant thus shows all the hidden
structures.

1.1.1 Nital:
Nital is a solution of nitric acid and alcohol commonly used for etching of metals.
It is especially suitable for revealing the microstructure of carbon steels. The
alcohol can be methanol, ethanol or ethylated spirits.

If sample is over etched than the reaction of nital with grain boundaries expands
and cannot help us to differentiate between different regions. If under etched then
there is no reaction on green boundaries. [1]
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Metallographic study of cast iron structure

Figure#3 Nital solutions

1.2. Cast iron:

Cast iron is a group of iron-carbon alloys with carbon content greater than 2%. Its
usefulness derives from its relatively low melting temperature. The alloy
constituents affect its color when fractured: white cast iron has carbide impurities
which allow cracks to pass straight through, grey cast iron has graphite flakes
which deflect a passing crack and initiate countless new cracks as the material
breaks, and ductile cast iron has spherical graphite "nodules" which stop the crack
from further progressing.
Carbon (C) ranging from 1.8–4 wt% and silicon (Si) 1–3 wt% are the main
alloying elements of cast iron. Iron alloys with lower carbon content (~0.8%) are
known as steel. Cast iron tends to be brittle, except for malleable cast irons. With
its relatively low melting point, good fluidity, castability, excellent machinability,
resistance to deformation and wear resistance, Cast irons have become
an engineering material with a wide range of applications and are used in pipes,
machines and automotive industry parts, such as cylinder heads(declining
usage), cylinder blocks and gearbox cases (declining usage). It is resistant to
destruction and weakening by oxidation. [1]

Figure#4 Showing cast iron products

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Metallographic study of cast iron structure

1.2.1. Types of cast iron:

Cast iron is classified according to the type of carbon flakes in the internal
structure of iron.
These are the types of cast iron
 Grey Cast iron
 White Cast iron
 Malleable Cast iron
 Chilled Cast iron
 Nodular or ductile Cast iron
Grey Cast iron:
Grey cast iron is characterized by its graphitic microstructure, which causes
fractures of the material to have a grey appearance. It is the most commonly used
cast iron and the most widely used cast material based on weight. Most cast irons
have a chemical composition of 2.5–4.0% carbon, 1–3% silicon, and the remainder
iron. Grey cast iron has less tensile strength and shock resistance than steel, but
its compressive strength is comparable to low- and medium-carbon steel. These
mechanical properties are controlled by the size and shape of the graphite flakes
present in the microstructure. In grey cast iron carbon exists in combined form.

Figure#5 Micro structure of grey cast iron

The presence of graphite flakes makes the Grey Iron easily machinable as they
tend to crack easily across the graphite flakes.
White Cast iron:
White cast iron displays white fractured surfaces due to the presence of an iron
carbide precipitate called cimentite. In this type carbon exist in combine State with
a lower silicon content (graphitizing agent) and faster cooling rate. In this type
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Metallographic study of cast iron structure

carbon exist in Free State as flakes, with a lower silicon content (graphitizing
agent) and faster cooling rate, the carbon in white cast iron precipitates out of the
melt as the meta stable phase cemmentate, Fe3C, rather than graphite. The
cementite which precipitates from the melt forms as relatively large particles. As
the iron carbide precipitates out, it withdraws carbon from the original melt,
moving the mixture toward one that is closer to eutectic, and the remaining phase
is the lower iron-carbon austenite (which on cooling might transform
to martensite).
Since carbide makes up a large fraction of the material, white cast iron could
reasonably be classified as cermets. White iron is too brittle for use in many
structural components, but with good hardness and abrasion resistance and
relatively low cost, it finds use in such applications as the wear surfaces of slurry
pumps, shell liners and lifter bars in ball mills and autogenously grinding mills,
balls and rings in coal pulverizes, and the teeth of a backhoe's digging bucket.

Figure#6 Micro structure of white iron

Chilled Cast iron:

In this form carbon in iron exists in Free State. Rapid cooling is used to solidify a
shell of white cast iron, after which the remainder cools more slowly to form a core
of grey cast iron. The resulting casting, called a chilled casting, has the benefits of
a hard surface with a somewhat tougher interior. In this case the cast iron is chilled
by using large chillers.
Malleable Cast iron:
Malleable iron starts as a white iron casting that is then heat treated for a day or
two at about 950 °C (1,740 °F) and then cooled over a day or two. As a result, the
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Metallographic study of cast iron structure

carbon in iron carbide transforms into graphite and ferrite plus carbon (austenite).
The slow process allows the surface tension to form the graphite into spheroidal
particles rather than flakes. [3]

Figure# 7 Microstructure of malleable cast iron

Nodular or ductile Cast iron:

Nodular or ductile cast iron has its graphite in the form of very tiny nodules with
the graphite in the form of concentric layers forming the nodules. As a result, the
properties of ductile cast iron are that of spongy steel without the stress
concentration effects that flakes of graphite would produce. Along with careful
control of other elements and timing, this allows the carbon to separate as
spheroidal particles as the material solidifies. The properties are similar to
malleable iron, but parts can be cast with larger sections. [4]

Figure# 8 Micro structure of ductile cast iron

1.2.2. Application:
Different types of cast irons are used for different applications like
 Iron bridges
 Textile mills
2.0. Experimental work:
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Metallographic study of cast iron structure

2.1. Apparatus:
 Amery papers(200,400,600,800,1000,1200,1400)
 Soap
 Oil
 Nital
 Acetone

2.2. Procedure:
 First of all, a cast iron sample is cut from the long rod.
 Then it grind on grinding wheel to equalize and clean its surface.
 For removing the scratches small stress/energy concentrated areas, Amery
papers (200 t0 1400) are used one by one.
 Now there is further need of removing very small lines due to sand paper
and for polishing its surface, polishing machine of wheel 6 micron meter and
1micron meter one by one.
 To see is that polishing is done, clean it by using soap and observe the
surface in light. If there is no line, its mean polishing is done on it.
 Then the sample is dip in acetone and dry it.
 Now dip the sample in the nital solution for 3-4 seconds. And then
immediately wash it by water.
 Now the sample it completely ready to see the microstructure through
microscope lens.

3.0. Results and Observations:

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Metallographic study of cast iron structure

The microstructures of the sample was seen by using microscope and after
observing the dark colored flakes in the structure, it is concludes that it is a Grey
Cast Iron.

4.0. Discussion:
For seeing the microstructures, the etching is too much important. Because the
nital solution react with the grain boundaries (they are energy concentrated areas)
and reveal the microstructure by darkening the grain boundaries. For the proper
etching the removal of all the scratches is very necessary because there are some
scratches on the surface, then during etching the nital solution also react there
because scratches are stress concentrated areas.
For proper etching, the dipping time of the sample in the nital must be minute.
Because if we dip the sample for longer time nital react too much and
microstructure is not properly reveal. Same case is done with this sample, the
dipping time accidently exceed which is clear in the microstructures

Figure#9 Microstructure of
the sample

The shape of black colored flakes show that it is a gray cast Iron and the structure
is not properly clear because due to the over etching. The dark flakes are the
carbon and the light color shows the ferrite or cementite according the heat
treatment done on it.

5.0. Conclusion:
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Metallographic study of cast iron structure

The given sample is grey cast iron which is minutely over-etched.

6.0. References:
1.  Yaqub, Ejaz; Arshad, Rizwan (2009). "ME-140 Workshop Technology - Slide 25" (images). Air
University. Retrieved 2011-10-30.
2.  http://www.ductile.org/didata/Section2/2intro.htm
3.  Gillespie, LaRoux K. (1988), Troubleshooting manufacturing processes (4th ed.),
4.  "ADI the Material". ADI Treatments Ltd.