SG Cast Iron

Effect of alloying elements (Mainly Nickel) on mechanical properties of S G cast iron
Scope This document covers the study of effects of reduction in Nickel content from 0.7% to 0.5% on mechanical properties of Spheroidal Graphite Cast Iron. Introduction Ductile cast iron or SG Iron exhibits good ductility and toughness because of the graphite morphology is spherical. SG Iron has many advantages such as high strength and toughness, high machinability and medium corrosion resistance. The small additions of Mo, Mn, Cu, Ni and Cr changed the as-cast mechanical properties owing to the different as-cast matrix microstructures. The ferrite matrix of Mo and Ni alloyed cast iron exhibits low strength and hardness as well as high elongation and impact energy. The increase in Mo and Ni contents developed some fractions of pearlite structures near the austenite eutectic cell boundaries, which caused the elongation and impact energy to drop in a small range. Adding Cu and Cr elements rapidly changed the ferrite matrix into pearlite matrix, so strength and hardness were significantly increased. Following table shows the chemical composition of different SG cast iron by wt percentage.
Microstructure
Table 1: Chemical Composition of Nodular Cast Iron
Figure 1 shows the as-cast microstructure of SG Cast iron. The micrograph shows that the matrix structure is fully ferrite structure with a small fraction of pearlite near the eutectic cell boundaries. The spheroidal graphite nodules are well distributed within the ferrite matrix. Two types of graphite in size are observed microscopically.
Ferrite Phase*
Pearlite Phase**
Graphite Nodules Figure 1 Microstructure of Spheroidal Graphite Cast Iron
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*Ferrite Phase: It is generally a soft constituent, but it can be solid solution hardened by silicon. The ferrite matrix is readily machined but exhibit poor wear resistance. **Pearlite Phase: A combination of ferrite and cementite, it consists of alternate layer of ferrite and iron carbide. It is very strong and tough. The hardness, strength, machinability and wear resistance of pearlite matrices vary with the fineness of its lamination.
Image analysis of volume fraction, nodule count, nodularity and average diameter of graphite on the different alloyed ductile cast irons are given in Table 2. Increase in nodularity percentage/count, higher the ductility of the cast iron.
Table 2: Characteristics of Spheroidal Graphite Cast Iron
Effect of alloying elements on SG Cast Irons The result of chemical analysis indicates the alloying elements obtain a mixture of ferrite and pearlite in the matrix microstructure. The ferritic-pearlitic and fully pearlitic matrix obtained by the reaction with manganese and phosphorus. Each alloying elements are kept at appropriate levels to obtain the microstructures and mechanical properties required by ductile iron standards. Manganese functions as an alloying element, increasing the hardness and strength of ferrite, stabilizing and refining the pearlite. Increase in manganese content, results in significant increases in tensile and yield strength. Nickel is weak pearlite promoter and strengthens ferrite phase. The contribution of nickel to hardenability is significantly enhanced by additions of molybdenum. It helps in increasing the strength without affecting the impact values. Due to the high cost it is generally present as traces in the matrix. Copper is strong pearlite promoter, It is commonly used to develop pearlitic microstructures, Copper decreases the ferrite content in favor of pearlite formation and increases strength and hardness through increased pearlite formation. Chromium is a pearlite promoter in ductile iron but its reaction depends up on the nodule count. Nickel, copper and molybdenum have to be carefully added because they influence on the matrix microstructure with severity when are added to the cast, Besides, they have important effects on hardness, strength and on corrosion. Mechanical Properties of as-cast SG Iron Below figure 2 shows the variation of tensile strength and elongation of nodular cast iron having different alloying contents. With the increase in the amount of Mo and Ni additions, tensile strength is slightly increased while elongation is decreased. The strength of Mo and Ni alloyed ductile cast iron is mainly dependent on the solid solution hardening of ferrite matrix. It was also considered that the decrease in elongation was caused by the increase in pearlite formation. 02 of 03
Figure 2 : Tensile and Elongation Properties
Figure 3 shows the variation in hardness and impact energy with different alloying additions. As more alloying contents are added, the Brinell hardness of Mo and Ni alloyed ductile cast iron is linearly increased, but that of Cu and Cr alloyed ductile cast iron increased very steeply. The Brinell hardness of ductile cast iron refers to the resistance of the matrix and graphite to plastic deformation. The variation in hardness with the alloying element is strongly determined by the as-cast microstructures. Generally, the hardness of cast iron is increased by the volume fraction of pearlite structure. In this study, the addition of Mo and Ni slightly increased the matrix hardness via solid solution hardening. As more Cu and Cr element is added, the hardness increased significantly owing to the high fraction of pearlite.
Figure 3: Hardness and Impact Properties
The Charpy impact energy of Mo and Ni alloyed iron is gradually decreased, but that of the Cu and Cr alloyed iron begins to decrease fast. This indicates that ferrite matrix provides highly ductile cast iron while pearlite yields highly strong cast iron. Mo was found to reportedly segregate at cell boundaries and aggravate the toughness of ductile cast iron. However, the toughness of ductile cast iron was more dependent on the area fraction of ferrite than the area fraction of intercellular carbide-like phases. Conclusion: 1) Reduction in Ni content from 0.75% to 0.50% will increase the percentage elongation upto some extent. Tensile strength of ductile cast iron depends upon the C & Mo content. 2) Hardness decreases and charpy impact energy (toughness) increases as Ni content decreases from 0.75 to 0.50%. 3) Ni addition is week pearlite promoter and strengthen ferrite phase. As the pearlite phase increases the hardness increases and ductility decreases. 4) Higher the percentage of graphite nodules (> 90%), higher the ductility and toughness.
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SG Cast Iron

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How does the addition of different alloying elements affect the microstructure and mechanical properties of SG cast iron?

How does the percentage of pearlite phase present in the matrix influence the hardness and impact energy of SG cast iron?

Effect of alloying elements (Mainly Nickel) on mechanical properties of S G cast iron

Table 1: Chemical Composition of Nodular Cast Iron

Graphite Nodules Figure 1 Microstructure of Spheroidal Graphite Cast Iron

Table 2: Characteristics of Spheroidal Graphite Cast Iron

Figure 2 : Tensile and Elongation Properties

Figure 3: Hardness and Impact Properties

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