Ferrous materials:

Cast Iron

Courtesy: Professor Dr. A.K.M. Bazlur Rashid

 Learning Objectives

Knowledge &
Knowledge about different Cast Irons
Understanding

Skills & Abilities Ability to know the character and potential use of Cast Irons

Values &
Aware of the importance and limitation of use of Cast Irons
Attitudes

Resources
1. S H Avner (1974), “Introduction to physical metallurgy,” Tata McGraw-Hill, Ch-09.
2. R A Higgins (1977), “Materials for the engineering technicians,” Arnold, Ch-13.
Outline of this lecture
 Cast Iron
 Classification of Cast Iron
 Introduction
 Cast iron is mainly an alloy of Fe and C with addition of Si.

 Range of C ( 2- 6.6%), Si (up to 3%)

 High C  brittleness

- Commercially used types contain 2.5 to 4 % C

 The ductility of cast iron is very low

- Cannot be rolled, drawn, or worked at room temperature

 However, they melt readily and can be cast into complicated shapes .

 Casting is the only suitable process applied to these alloys, they are known
as cast irons.

 Wide variation in types and properties are achieved maintaining conditions

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 Introduction
 Cast irons are the largest tonnage of cast-to-shape products of foundry
industry in the world

 Cast irons have tremendous range of properties at low cost

•Strength and hardness
•Wear and abrasion resistance
•Machinability
•Corrosion resistance
 They also have excellent foundry properties
•Fluidity
•Yield
•Shrinkage
•Ease of production
•Casting soundness

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Uses of Cast Irons

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 Forms of Carbon in Fe-C alloys
 C can be said to be in a combined form such as intermetallic iron carbide
compound
 Carbon can also be present in either graphitic form (pure C, hexagonal
structure)

Iron – Iron Carbide Phase Diagram Iron – Graphite Phase Diagram

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Solidification process 1. liquid to austenite (A) dendrites
transformation begins

2. eutectic transformation begins

L E (A + G)  grey/nodular iron
L E (A + C)  white iron

3. eutectic transformation ends

 End of solidification structures:

A + G  grey/nodular iron
A + C  white iron
•between 3 and 4, ppt. of carbon (as G or C)
from austenite takes place

4. solid state transformation begins

 very complex; some examples are:

simplified Fe-C-Si ternary diagram showing A F + G ferritic GI or NI

approx. temperature ranges for solidification A P + F + G pearlitic GI or NI
and graphitization in cast irons
A P  white iron

5. solid state transformation end

 Classification of cast irons
1. Gray cast iron
2. White cast iron
3. Malleable cast iron
4. Ductile/nodular cast iron

Gray cast iron

White cast iron Malleable cast iron Nodular cast iron

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 Chemical Composition of Cast Irons
 Influence of chemical composition on properties and uses of cast irons is
largely related to the two alloying elements, carbon and silicon, and their
influence on the process of graphitization.

Fe3C = Fe + 3C
 Presence of C, especially above 2.0%, increases the graphitization process
 Presence of Si causes cementite to become less stable (thus promotes
graphite formation)
 Other elements helping graphitization process (graphite stabilizers): Cu, Ni
 Elements inhibiting graphitizing process (carbide stabilizers): Mn, S, P, Cr, V,
Mo
 Elements having dual effects: Al, Ti (actual effect depends upon composition)
 Elements other than C and Si (e.g., Mn, Cu, Ni, Cr, Mo) added mainly to
control the matrix microstructure; have small effects on solidification
microstructures
Chemical Composition of Cast Irons
 Composition of cast irons are described
in terms of both carbon and silicon
percentages.
 Thus the term carbon equivalent, CE,
has been adopted.
CE = %C + %Si/3
 CE > 4.3% hypereutectic alloy
(ductile irons)
 CE < 4.3% hypoeutectic alloy (grey,
white, malleable irons)

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 Role of Si and Other Alloyants

Addition of Silicon (Si) :

1) reduces the eutectic and

eutectoid carbon levels (e.g., for
2% Si, eutectic = 3.6%C, eutectoid
= 0.6%C)
2) increases austenite instability
and reduces austenite zone; widen
ferrite area
3) Graphite Stabilizer

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 Role of Si and Other Alloyants

 2.75 % C and 1.5 % Si

 maximum tensile strength .

 Pearlitic gray cast iron

 Ferritic gray and white cast iron

Sulphur (S) Relation of tensile strength to carbon and silicon

 Adverse effect: stabilize carbide

 Forms thin film layer of FeS, low melting temperature
 Red shortness (high temperature)

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 Role of Si and Other Alloyants
Manganese (Mn)
 In presence of Mn, MnS or complex manganese-iron-sulphides forms
are, usually randomly distributed.
 Mn above that necessary to react with the sulphur will help in retaining
the pearlitic microstructure.
 In view of attaining desired microstructure, the sulphur-manganese
relationship is expressed as below:
a) % S x 1.7 = % Mn; Chemically equivalent S and Mn percentage to form
MnS considering no effect from iron.
b) % S x 1.7 + 0.15 = Mn; the Mn percentage which will promote a
maximum of ferrite and a minimum of pearlite.
c) % S x 3 + 0.35 = Mn; the manganese percentage which will develop a
pearlitic microstructure.

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 Role of Si and Other Alloyants
Phosphorus (P)

 In presence of P, Fe3P forms

 Steadite, a eutectic of iron and
iron phosphide of low melting
point forms
 Steadite is brittle

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Cast iron microstructures
 Type of cast iron (white / nodular / grey) is largely established during the freezing
process.
 The room-temperature microstructure reflects the entire freezing and cooling of the
iron.

Properties and applications of cast irons

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 White cast iron
 All of its carbon is present in a chemically combined form as
cementite(iron carbide).
 White iron presents a white crystalline surface when fractured.

White cast iron

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 Malleable Cast Iron
 Carbon is present as irregular nodular-shaped aggregates of graphite,
called tempered carbon
 It is produced by heat-treating (malleableizing) white iron of suitable
composition to impart ductility, or malleability in the casting
 If conditions are suitable cementite breaks up into iron and graphite
 Fe3C  Fe (α) + C (graphite)

Malleable iron showing Pearlitic malleable iron showing Ferritic malleable iron
tempered carbon. tempered carbon in ferrite- showing tempered carbon in
Unetched pearlitic matrix. Etched ferrite matrix. Etched 18
Malleable Cast Iron

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Malleable Cast Iron

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 Malleable Cast Iron
 0-1 denotes slow heating period.
 On heating, pearlite and part of cementite transform to austenite.
 During long time holding period (1-2) cementite phase is converted to
graphite, which exists in the form of clusters or rosettes around austenite.
 In the next step when this structure is cooled, where cluster form of graphite
does not change, but the austenite transforms to either pearlite or ferrite
depending on cooling rates.
 For faster cooling (2-3), pearlitic malleable cast iron is formed.
 if the cooling rate is very slow (2-3‟), more carbon from austenite will come
out and rest of the austenite transforms to ferrite, which is called ferritic
malleable cast iron.

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 Gray Cast Iron
 A large portion of its carbon is
distributed throughout the
casting as free or graphitic
carbon in flake form.

 Grey iron always presents a

grey sooty surface when
fractured.

 High carbon, high temperature

and high amount of silicon

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Ferritic and Pearlitic Gray Cast Iron

Alloy Addition
Silicon
 Fluidity
 Changes diagram
 Relation of structure

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Heat Treatment of Gray Cast Iron

 Residual stress –cooling rates

 Reduce properties
 538-5700C for minimum carbide decomposition

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 Heat Treatment of Gray Cast Iron
Annealing of Gray cast iron
 Temperature 740-780 0 C
 Slow cooling
 Iron carbide to ferrite and graphite
Normalizing of Gray cast iron
 Temperature 900-1000 0 C
 Air cooling
 Pearlitic Gray Cast Iron
Quenching of Gray cast iron
 Temperature 900-1000 0 C
 Fast/Rapid Cooling (Quenching), Martensite matrix forms
 Tempering
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 Nodular Cast Iron
 Also known as ductile cast iron, or spheroidal graphite cast iron
 A large proportion of its carbon to occur as regular spheroids or
nodules.
 Small percentage of magnesium, cerium, or other agent is added in a
specially prepared liquid iron (spherodizing) to form graphite
spheroids
 Ductility is the highest in these types of cast irons
 When fractured, it presents a bright steely surface

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Nodular Cast Iron

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 Nodular Cast Iron
 Well-known functions of Mg:
1. Acts as deoxdiser and desulphuriser of molten metal
2. Promotes the development of graphite as nodules
3. Prevent nucleation of graphite as flake during freezing
 Actual amount of Mg required depends on S and O2 content of base
iron. Desulphurization of the melt before casting is critical.
 It is critical in making ductile iron that the amount of residual
magnesium present in the melt during solidification be in the range
0.03 to 0.05 weight percent.
 Magnesium contents less than this amount will result in graphite flakes, and
amounts more than this results in the appearance of so called exploded graphites.
 Either type contributes to a degradation in the ductility of the cast iron produced

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 Malleable Iron vs. Ductile Iron
 Malleable iron, like ductile iron, possesses considerable ductility and
toughness because of its combination of nested graphite and a low-carbon
metallic matrix.
 Consequently, malleable iron and ductile iron are suitable for some of the
same applications requiring good ductility and toughness and the choice
between them is based on economy rather than properties.
 However, because ductile iron castings have similar properties to malleable
iron castings, and do not require the long and expensive heat treatment,
malleable iron production has fallen to very low levels, and only a few thin
section castings are made this way today.
 Because solidification of white iron throughout a section is essential in the
production of malleable iron, ductile iron also has a clear advantage when
the section is too thick to permit solidification as white iron.
 Malleable iron castings are produced in thin section thicknesses ranging
from about 1.5 to 100 mm and in weight from less than 30 g to 180 kg or
more.

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Next Class

MME291: Lecture 8
Stainless Steels