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10-Cast Iron
10-Cast Iron
Introduction
►Family of ferrous alloys
►Cast into desired shape not worked
►2-4% C & 1-3% Si
►Properties & microstructures affected by chemical
composition, solidification rate, heat treatments
►Low cost
►Good hardness, wear resistance
►Better corrosion resistance than plain carbon steel
effect of alloying elements
►Better damping property than steel presence of
graphite
Structures
► Matrix ferritic, bainitic, pearlitic
► Graphite Graphitization
► Graphitization : Fe3C 3Fe + C
► Graphite
Layered hexagonal structure with covalent bonding of atoms in each layer
Density: 2.25 grams/cm3 at 20°C
Layers easily slide against each other and make graphite a solid lubricant
Soft and low strength
Classification
►White Cast Iron
►Gray Cast Iron
►Malleable Cast Iron
►Ductile Cast Iron
►High Alloy Cast Iron Special purpose
Classification
Irregular
shape
nodule
/rosette
Classification
Classification
Effect of chemical composition
►% C
► % Si
► Cooling rate
Classification
Effect of chemical composition
Classification
Effect of chemical composition & cooling rate
Factor Affecting Graphitization
Factor Affecting Graphitization
►Metal cools across eutectic T from “A” or from
“B” will Fe3C or graphite form?
►γ + eutectic liquid at “A”
fast cooling - γ + Fe3C (white cast iron)
slow cooling - γ + graphite (gray cast iron)
►γ + graphite (gray cast iron) at point “B”
α + Fe3C – pearlitic gray cast iron
α + graphite – ferritic gray cast iron
Factor Affecting Graphitization
►Cast iron Carbon Equivalent: CE = %C +
1/3%Si
CE = 4,3 eutectic
CE < 4,3 hypoeutectic
CE > 4,3 hypereutectic
►Cooling rate
►Gray and nodular cast iron:
higher %C and %Si vs. white and malleable
Effect of Alloying Elements
►Silicon
Silicon is added to cast irons in the range of 1% to 4% in
order to increase the amount of under-cooling required for
the formation of cementite and promote the formation of
graphite during solidification.
Silicon promotes the precipitation of secondary graphite on
the primary graphite during the eutectoid transformation,
which results in large areas of ferrite (commonly called “free
ferrite”) around the graphite particles.
Influence fluidity
Graphitizer agent
Cooling rate control to decomposed carbide eutectic
Effect of Alloying Elements
►Sulfur restrict graphitization promote pearlite
formation
High sulfur tend to reduce fluidity and sometime responsible
for blow hole
►Manganese restrict graphitization promote
pearlite formation
Manganese is carbide stabilizer
►Phosphorus
Increase hardness, wear resistance
Decrease machinability
Transformation of Cast Iron During
Solidification and Heat Treatment
Transformation of Cast Iron During
Solidification and Heat Treatment
Typical Mechanical Properties
White Cast Iron
►White cast iron mempunyai struktur carbida eutectic
►Shows a “white” crystalline fractured surface
►White cast iron terjadi pada laju pendinginan yang
cepat, dan pengaruh paduan yang mendorong
pembentukan carbida eutectic
►Low ductility, high hardness, high wear resistance
low machinability
►Raw material for malleable cast iron
►High compressive stress
►Applications : engine bed, drawing dies, ball mill,
extrusion nozzle
White Cast Iron
Malleable Cast Iron
►Produced by annealing of white cast iron, which
transform eutectic carbides into graphite in ferritic
matrix malleablization
►Malleable irons have good ductility and good strength.
►Matrix microstructure is dependent upon the cooling
rate from the graphitization annealing.
►Before the discovery of nodular irons, malleable irons
were the only ductile class of cast irons.
►Application : Rail road, hand tool, gear casing, farm
part, high pressure part
Malleable Cast Iron
Malleablization
Temper-carbon
nodule graphite
Gray Cast Iron
►Gray cast irons form graphite flakes during
solidification.
►The gray iron microstructure is due to slow
solidification rates and silicon alloying that promotes
graphite formation
►Gray irons get their name from their dull gray fracture
features.
►Gray irons typically have low ductility and moderate
strength, but they have high thermal conductivity
►Excellent vibration damping properties.
Gray Cast Iron
►Great machinability and wear resistance
►Cheap
►Easy to cast, into large complex shape
►Can be alloyed
►Application : gear cover, cylinder blocks,
cylinder bores, piston ring
Gray Cast Iron
Gray Cast Iron
Type of graphite flakes – ASTM A 247
► Type A – uniform distribution and random orientation.
► Type B – rosette groupings and random orientation.
► Type C – superimposed flake size and random orientation.
► Type D – interdendritic segregation and random orientation.
► Type E – interdendritic segregation and preferred orientation
A B C
D E
Gray Cast Iron
Type of graphite flakes – ASTM A 247
► Type A graphite flake structures are generally the preferred
structures.
► Type B graphite flake structures may result when there is poor
inoculation and nucleation.
► Type C graphite flake structures are typically found in
hypereutectic gray irons where the graphite flakes are the first to
precipitate from the melt.
► Types D and E graphite flake structures are typically found
where undercooling of melt is the greatest (edges, parting lines,
thin sections, etc…).
► During melting operation, can be added by innoculant (Ca, Ti,
Al, etc) reduce flake size and improve its distribution
Gray Cast Iron
Microstructures
Nodular Cast Iron
►Ductile Cast Iron, Spherulic Graphite Iron
►Nodular cast irons form graphite spheres during
solidification.
►The nodular iron microstructure is due to slow
solidification rates and magnesium or cerium
alloying that promotes spherical graphite
formation.
►Mg deoxidize & desulphurize molten iron
Nodular Cast Iron
►Graphite spheroid grow directly from the melt
►Nodular irons typically have high ductility and strength.
►Superior machinability, good wear resistance
►Nodular irons were first discovered in the 1940’s.
►Heat treatment :
Stress relieving : remove internal stress
Annealing : increases ductility & machinability
Normalizing & tempering: developing higher strength
Tempering: Quench & tempering, austempering &
martempering
Nodular Cast Iron
Nodular Cast Iron
Microstructures
Nodular Cast Iron
Modified NCI
►Austempered Ductile Iron
Excellent hardness, wear resistance, strength and ductility
matrix: bainitic
Low cost, flexible in design
Alloyed cast iron
Process from austempering treatment
Application : gear, heavy machinery, automotive, etc
New developed material
Confirm to ASTM 897
High Alloy Cast Iron