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    Cast Iron Vs Ductile Iron

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    Fekre Razi
    Cast iron and ductile iron are commonly used materials for industrial gearbox housings. Cast iron provides good strength, machinability, and corrosion resistance at a low cost but can be brittle. Ductile iron has a rounded grain structure that gives it higher toughness and fatigue strength, making it better for applications with shock or impact loading, though it has a slightly higher cost. The document discusses specifications and properties of cast iron grades FC200 and FC250 and ductile iron grade FCD450 according to Japanese and American standards.

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    Cast Iron Vs Ductile Iron

    Uploaded by

    Fekre Razi
    170 views2 pages
    Cast iron and ductile iron are commonly used materials for industrial gearbox housings. Cast iron provides good strength, machinability, and corrosion resistance at a low cost but can be brittle. Ductile iron has a rounded grain structure that gives it higher toughness and fatigue strength, making it better for applications with shock or impact loading, though it has a slightly higher cost. The document discusses specifications and properties of cast iron grades FC200 and FC250 and ductile iron grade FCD450 according to Japanese and American standards.

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    The comparison material

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    Cast Iron vs Ductile Iron

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    Cast iron and ductile iron are commonly used materials for industrial gearbox housings. Cast iron provides good strength, machinability, and corrosion resistance at a low cost but can be brittle. Ductile iron has a rounded grain structure that gives it higher toughness and fatigue strength, making it better for applications with shock or impact loading, though it has a slightly higher cost. The document discusses specifications and properties of cast iron grades FC200 and FC250 and ductile iron grade FCD450 according to Japanese and American standards.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    170 views2 pages

    Cast Iron Vs Ductile Iron

    Uploaded by

    Fekre Razi
    Cast iron and ductile iron are commonly used materials for industrial gearbox housings. Cast iron provides good strength, machinability, and corrosion resistance at a low cost but can be brittle. Ductile iron has a rounded grain structure that gives it higher toughness and fatigue strength, making it better for applications with shock or impact loading, though it has a slightly higher cost. The document discusses specifications and properties of cast iron grades FC200 and FC250 and ductile iron grade FCD450 according to Japanese and American standards.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 2

    EDOC1-12-004

    www.smcyclo.com Author: D.Rosseljong; Review: T.Bobak









    The Relative Merits of Cast Iron Housings

    Various grades of cast iron have been widely applied and used in a multitude of industrial machinery for many years. The use of cast iron as
    a housing material in gearboxes of all sizes and configurations has been especially prevalent. That trend continues today, with the majority
    of the medium to large reducer housings being made of cast iron.

    The reasons for the pre-eminence of cast iron, as a reducer housing material, are many, including:
    1) Structural rigidity,
    2) High strength, especially in compression,
    3) Good strength to weight ratio,
    4) High machinability,
    5) Corrosion resistance,
    6) Inherently sound absorbing,
    7) Excellent castability, making it easy to cast into complex shapes with simple and inexpensive patterns and
    8) Relative abundance or raw materials.

    The different grades of iron are named by their chemistry and their strength. For example, in the USA, Grey Cast Iron, Grade 30 is a specific
    chemical composition, processed in a manner to obtain yield strength of 30,000 psi. Cast irons in grades 20 and 30 are the materials most
    frequently specified in the construction of reducer housings.

    Where greater strength for more demanding applications is required, it is possible to adjust the chemistry and the iron making process to
    obtain a much stronger material: Ductile Iron. Ductile iron is typically twice as strong as many grey cast irons, and nearly as strong as
    steel. While ductile iron shares many of the advantages of cast iron, the ductile iron is more difficult to cast, and has a different shrink rate
    than cast iron. This difference means different patterns are required.

    In the case of Sumitomo, because we are a subsidiary of a Japanese company, we
    use a classification system called the Japanese Industrial System (JIS) to classify
    many things including metals. In the Cyclo products, and their derivatives, cast iron
    grade uses is typically FC200 (Figure 1), with the ductile iron being FCD450 (Figure 2).


    Casting Materials
    Casting material properties have been standardized by global industrial societies, such as JIS (Japan Industrial Standards) and ASTM
    (American Society for Testing and Materials). Tensile strength is the defining characteristic of (Grey) cast iron and the grade is cited in the
    name of the material (refer to the material properties below to understand the relationship). The two grades that Sumitomo uses are
    identified below.
    > Grey Cast Iron
    FC200 (BBB5 Standard*)
    200 N/mm
    2
    Tensile Strength
    ASTM A48 Class No. 35 (equivalent)
    35,000psi Tensile Strength
    JIS Specification:
    FC250 (equivalent)
    250 N/mm
    2
    Tensile Strength
    Sumitomo Specification:
    ASTM A48 Class No. 40 (equivalent)
    40,000psi Tensile Strength
    * BBB5 Size-Z housing material is tempered die-cast aluminum JIS AC4C-T6(Standard) or ASTM B26-536-T6 (equivalent)

    Each standard has slight variations, and due to conversions, we can say: FC200 < A48 No.35 < FC250 < A48 No.40. Elongation of the material
    or the ability to flex is the defining characteristic of ductile (nodular) iron. Ductile iron grades can be classified from the variations in the
    tensile strength, yield strength, and the elongation. Elongation is the % of stretch of a 2 or 50mm sample and it is important enough to be
    identified in the different material grades (shown as the suffix in each grade). The ASTM (Sumitomo) specification readily identifies the
    tensile, yield and % elongation respectively, in the grade.

    > Ductile Iron
    JIS Specification:
    FCD450-10 (BBB4 Standard)
    10% elongation
    Sumitomo Specification:
    ASTM A536-65-45-12 (equivalent)
    65ksi Tensile; 45ksi Yield; 12% elongation



    Cast Iron vs. Ductile Iron Housing Material
    Figure 1. Cast Iron Example Figure 2. Ductile Iron Example
    Click here to Configure

    EDOC1-12-004
    www.smcyclo.com Author: D.Rosseljong; Review: T.Bobak








    The housing material can be identified directly inside the housing through raised cast lettering. FCD will indicate Ductile Iron and FC
    will indicate Cast Iron (See Figures 1 and 2).

    When the grain is viewed under a microscope, ductile iron has a spheroidal shape where the cast iron reveals a flaky composition.
    Refer to Figures 3 and 4. These rounded shapes allow for more flexibility. The grain structure difference helps to define the strengths
    and weakness of each material.




















    Material Properties Strengths Weakness
    Cast
    Iron
    Tensile
    FC200 200 N/mm
    2
    [29,008psi]
    FC250 250 N/mm
    2
    [36,259psi]
    A48 No.35 35,000psi [241 N/mm
    2
    ]
    A48 No.40 40,000psi [275 N/mm
    2
    ]
    High Strength/Weight
    Low Production Cost
    High Machinability
    Vibration Dampening
    Excellent up to moderate shock loading
    Superior compressive strength compared to
    steel
    Lower tensile strength compared to steel
    More brittle compared to ductile or steel
    when used for shock loaded applications
    Temperatures below 30F/ 0C are
    susceptible to thermal/impact shock and
    brittle failure.
    Ductile
    Iron
    Tensile
    FCD450 450 N/mm
    2
    [65,260 psi]
    A536 65-45-12 65,000psi [448 N/mm
    2
    ]
    Yield
    FCD450 280 N/mm
    2
    [40,610 psi]
    A536 65-45-12 45,000psi [310 N/mm
    2
    ]
    Elongation
    FCD450-10 > 10% A536 65-45-12 > 12%
    High Fracture Toughness (Ability to resist
    fracturing) when compared to cast iron)
    High Fatigue Strength compared to cast iron
    High Machinability
    Vibration Dampening
    Excellent for shock and impact loading
    Similar casting/pouring properties to cast
    iron
    Excellent cost / ratings improvement
    Slightly higher coefficient of expansion than
    cast iron.
    Slightly lower machinability compared to
    cast iron.
    Only slightly higher brittleness from cast
    iron below -25C (-13F)
    References:
    J.R. Davis, ASM Specialty Handbook, Cast Irons, ASM International, 1996 E. Oberg, et.al, Machinerys Handbook, 25th Edition, Industrial Press, Inc. New York, 1996
    H.E. Boyer, T.L. Gall, Metals Handbook, Desk Edition, American Society for Metals, 1985 Metals data book, Japanese Standards Association, Tokyo, Japan, 1984
    Figure 3. Ductile (nodular) Iron Grain Structure
    Figure 4. Grey Cast Iron Grain Structure
    Photos c/o http://physicsarchives.com

    Cast Iron vs. Ductile Iron Housing Material (Continued)
    Click here to Configure

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