Material Information

Cast Iron Information

 Cast Iron Information
Iron is a commonly used metal due to its
low cost and high strength.
Cast iron often refers to gray iron, but can
mean any of a group of iron-based alloys
containing more than 2% carbon. Cast iron
is made by remelting pig iron or scrap iron
and removing undesirable contaminants
such as phosphorus and sulfur, which
2 weaken the material.
Carbon content may be anywhere from
2% to 3.5% and silicon content will range
between 1% to 3% depending on the
application. Other elements are then added
before the final cast process.
Mechanical Properties
The mechanical properties of cast iron
vary greatly depending upon the form
carbon takes in the alloy. In addition, these
properties are influenced by:
• Cooling rate, both during and after Gray iron characteristics include:
solidification
• Chemical composition
• Heat treatment
• Design
• Effectiveness of filling and riser gates
Physical Properties of Cast Iron
1. Tensile strength range (dependent on
type of cast iron) - 20,000-60,000 psi
2. Hardness - (Rockwell) B150
3. Yield strength - 8,000-40,000 psi
4. Modulus of Elasticity - 13.5-21.0 psi
x 106
5. Expansion coefficient - 6.7 x 10-6
per ˚F
6. Melting point - 2,797 ˚F
7. Thermal conductivity (at 68 ˚F) -
523 btu/ft2/h/˚F/in
8. Electrical resistivity - 9.71 microhm-
nm at 68 ˚F
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Gray Iron
Gray iron is one of the two most common
types of cast iron. In gray iron, the carbon
exists as fine flakes of graphite, which
results in lower bending and tensile
strength. This is due to the stress-raising
nature of the sharp edged flakes of
graphite.
Silicon is a key component; it transforms
the carbon into graphite, leaving relatively
pure, soft iron. Graphite acts as a
lubricant, which improves wear resistance.
Weak bonding between planes of graphite
lead to a high activation energy for growth
in that direction, resulting in thin, round
flakes. The metal expands slightly on
solidifying as the graphite precipitates.
The sharp edges of graphite flakes tend
to concentrate stress, allowing cracks to
form more easily.
Gray Iron
While gray cast iron has less tensile
strength than ductile iron, both exhibit a
similar compressive strength. More gray
iron is needed per casting to achieve the
same tensile strength exhibited by a
smaller amount of ductile iron. Gray iron
is traditionally used in drainage and other
construction products and it’s known to be
hard wearing and cost effective.
Advantages of Gray Iron
• Corrosion resistant
• Wear resistant
• Maintains its strength
• Absorbs vibrations
• Low-notch sensitivity — easy fracture
• Cost effective
• Long service life
 Ductile Iron

Ductile iron is used when a higher bending

and tensile strength is required than gray
iron. Ductile iron is sometimes referred
to as ‘spheroidal graphite’ (sg) due to the
ball-like structure of the graphite. It is a
more expensive material to produce than
gray cast iron. Ductile iron is stronger in
tensile bending and less iron is needed,
per casting, to exhibit similar strength as
a gray iron casting. Consequently, ductile
iron castings usually exhibit better strength
to weight characteristics than gray iron.

The strength in ductile iron is a result of

adding trace amounts of magnesium just
prior to casting. The magnesium causes
the graphite to form spheres, or nodules,
which greatly increases the toughness
and strength of the iron. These graphite
spheres provide improved tensile bending
mechanical advantages compared to the
graphite flakes in gray iron.

5
Ductile Iron

Ductile iron has many traits similar to gray
cast iron. Both have a low melting point,
good fluidity, are easily cast, and have
excellent wear resistance.
In the construction industry, ductile iron
grates are sometimes paired with gray
iron frames. Frames usually require good
compressive properties rather than
bending/tensile properties required in
grates and covers. Ductile iron grates
and covers are often used in heavy load
areas — airports and industrial facilities,
etc.— where there is a need to avoid
catastrophic failure (gray iron will shatter
rather than bend).
Advantages of Ductile Iron
Ductile iron offers similar characteristics
to gray iron but is significantly stronger in
bending and tensile strength.
• Tougher (non-catastrophic failure) than
gray iron
• High impact resistance
• Ability to withstand heavy loads (e.g.
airports and industrial facilities with
forklift traffic)
• The high strength-to-weight of ductile
iron allows for the manufacture of lighter
weight castings. (Light weight castings
offer cost benefits from transportation
to installation and decrease the chance
of injury when lifting).

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 Cast Iron Resistance Chart Reagent Cast Iron Reagent Cast Iron
Acetic Acid ✗ Copper Nitrate ✗
The resistance information contained
Acetone ✓✓ Copper Sulfate 5% ✗
within this table is for guidance only.
Alcohol (Ethyl) ✓ Cresol ?
Alcohol (Methyl) ✓✓ Cyclohexanone ✓
Please contact ACO if further information Cyclohexane
Aluminium Chloride ✗ ✓
is required of specific material suitability.
Aluminium Sulfate ✗
Ammonia 10% ✓✓ Diethylamine ✓
ACO can arrange for tests to be Dimethyaniline ~
Ammonium Chloride ✗
undertaken with the reagent to establish
Ammonium Hydroxide ✗
the chemical resistance of the materials, Ethyl Acetate
Ammonium Nitrate ✓ ✓✓
at independent test houses. Ethylene Chloride ~
Ammonium Phosphate (Dibasic) ✗
Ammonium Sulfate ✗ Ethylene Glycol ✓✓
Legend Amyl Chloride ✓✓
✓ ✓ — Excellent Aniline ? Fatty acids ?
✓ — Good; Minor Effect - slight Ferric Sulfate ✗
corrosion or discoloration Barium Chloride ? Fluorine ✗
? — Fair; Moderate Effect - not Barium Hydroxide 10% ✗ Formaldehyde 40% ✓
recommended for continuous Barium Sulfate ✓ Formaldehyde 100% ?
use; softening, loss of strength, Barium Sulfide ✗ Formic Acid ✗
swelling may occur Beer ✗ Freon 12 ✓✓
✗ — Bad; Severe Effect; not Beet Sugar Liquor ✓✓ Fruit Juices ✗
recommended for ANY use Benzene ✓✓ Furfural ✓
~ — Information Not Available Benzoic Acid ✗
Bleach Liquors ~ Gasoline (Unleaded) ✓✓
Boric Acid ✗ Glucose (Leaded, ref. ✓✓
Bromine ~ Glycerine ✓✓
Butane ~ Hydrobromic Acid 20% ✗
Hydrochloric Acid 100% ✗
Calcium Carbonate ~ Hydrocyanic Acid ✗
Calcium Chloride ? Hydrogen Peroxide 10% ?
Calcium Hydroxide ✓✓ Hydrogen Peroxide 100% ✓
Calcium Hypochlorite ✗ Hydroquinone ~
Calcium Sulfate ✓✓
Carbolic Acid ✗ Iodine ✗
Carbon Bisulfide ~
Carbon Dioxide (wet and dry) ✗ Kerosene ✓✓
Carbon Monoxide ✓✓
Carbon Tetrachloride ✗ Lactic Acid ✗
Carbon Tetrachloride (dry) ~
Carbon Tetrachloride (wet) ? Magnesium Chloride ✗
Chlorine (Dry) ✗ Magnesium Sulfate ✓✓
Chlorine (Anhydrous Liquid) ✗ Maleic Acid ✓✓
Chloroacetic Acid ✗ Methyl Chloride ✗
Chlorobenzene (mono) ✓ Methyl Ethyl Ketone ✓✓
Chloroform ✓ Milk ✗
Chromic Acid 50% ✗ Mineral Spirits ✓
Chromic Acid 10% ✗
Citric Acid ✗ Nickel Chloride ✗
Copper Chloride ~ Nickel Sulfate ✗
Copper Cyanide ✓✓

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Reagent Cast Iron Reagent Cast Iron
Oleic Acid ~ Trichloroethylene ?
Oleum 25% ~ Triethylamine ✓✓
Oleum 100% ~ Trisodium Phosphate ~
Oxalic Acid ? Turpentine ~

Palmitic Acid ~ Urea ~

Perchloric Acid ~ Urine ✓✓
Petroleum ~
Phenol 10% ✗ Vinegar ✗
Phosphorous Trichloride ~
Photographic Solutions ~ Water (Deionized) ✗
Picric Acid ✓✓ Water (Distilled) ✗
Potash ✓ Water (Fresh) ✗
Potassium Bicarbonate ✓✓ Water (Salt) ✗
Potassium Chloride ✓✓ Whisky and Wines ✗
Potassium Cyanide ✓
Potassium Dichromate ✓✓ Xylene ✓
Potassium Hydroxide ✓
Potassium Permanganate ✓✓ Zinc Chloride ✗
Potassium Sulfate ✓✓ Zinc Sulfate ✗
Propane liquefied ✓✓
Propylene ✓✓

Sea Water (Natural) ✗ Corrosion Resistance

Silver Nitrate ?
Sodium Bicarbonate ? In the initial cast state (after cooling), cast
Sodium Bisulfite ✗ iron appears a burnt black color. Most
Sodium Carbonate ✓ castings are shot blasted to remove this
Sodium Cyanide ✓✓ visual state, leaving a dull silver color.
Sodium Ferrocyanide ~ When exposed to any degree of moisture,
Sodium Hydroxide 20% ✓✓ cast iron’s surface will oxidize, creating a
Sodium Hydroxide 50% ✗ thin reddish ‘crust’ which inhibits further
Sodium Hypochlorite 100% ✗ corrosion (unlike mild steel, which will
Sodium Sulfate ✓ corrode through).
Sodium Sulfide ?
Sodium Sulfite ✓✓ Cast iron can be protected by surface
Sodium Thiosulfate ? finishing. The most common option is the
Stannous Chloride ~ use of a painted finish. For most of the
Stearic Acid ? castings used in the construction industry,
Sulphur Chloride ✗ the painted finish is merely cosmetic and
Sulphur Dioxide (Dry) ✓✓ will fade/wear off over a period of time,
Sulphur Dioxide ~ depending on its use and exposure to the
Sulfuric Acid <10% ? elements.
Sulfuric Acid 10%-75% ✗
Sulfuric Acid 75%-100% ✗ Cast irons can be galvanized.

Tannic Acid ~
Tanning Liquors ~
Tartaric Acid ?
Toluene ✓✓ Typical iron grates used with ACO trench drainage
products.

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P.O. Box 245
Chardon, Ohio 44024
Tel: (440) 285-7000
Toll free: (800) 543-4764
Fax: (440) 285-7005
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© August 2006 ACO Polymer Products, Inc.

All reasonable care has been taken in compiling the information in this document. All recommendations and suggestions on the use of ACO products are made without guarantee since the conditions of
use are beyond the control of the Company. It is the customer’s responsibility to ensure that each product is fit for its intended purpose and that the actual conditions of use are suitable. ACO Polymer
Products, Inc. reserves the right to change products and specifications without notice. Re-order # AQ004