ME 293: Engineering Materials

CAST IRON
 Definition
• Cast Iron is an iron-carbide alloy together with small amount
of Si, Mn, S and P.

• The carbon content Varies from 2 to 6.67%

Composition of Cast Iron:

Carbon - 2.5 to 3.7%

Silicon - 1.0 to 3.0%
Manganese - 0.5 to 1.0%
Phophorus - 0.1 to 0.9%
Sulphur - 0.07 to 0.10%
 Applications
Cast iron is used in a wide variety of structural and decorative
applications, because it is relatively inexpensive, durable & easily
cast into a variety of shapes.
• Construction of machines and structures (High Tensile
Strength)
• As Columns, balusters & Arches (High Compressive Strength)
• Used for Decorative purposes

Decorative gate design Arches in bridge Decorative pattern Door

 Applications
• Machine and car parts like cylinder heads, blocks, gearbox cases, cookware, pipes, etc.
• Vehicles engine (High thermal conductivity and specific heat capacity)
• Stoves Cookware (Good fluidity,elasticity)

Swing Machine
Stoves

Different Machine Components

Ball Mills
Car Engine
 Disadvantages:
Cast Iron Weight

Cast iron is very heavy, and consequently is much harder to install than regular
PVC/ABS sewer pipe.

Brittleness

• It is quite brittle and if accidentally knocked will easily break.

• Its strength and stiffness deteriorate when subjected to high heat, such as in
a fire.

Weak in tension and bending, so can’t be used as beams.

Can not overcome from Environmental causes Or can not absorb sudden
shocks.
 Cast Iron Content
C (Carbon 2.5 to 4.5%) : Makes the iron easier to cast and machine .

Si (Silicon 1.0 to 5%) : Softens the iron and helps grain size higher %'s give heat stability.

Mn (Manganese 0.8%) :Counteracts some impurities and strengthens & hardens.

S (Sulphur) : In normal iron but not wanted in Spheroidal Graphite Iron.

P (Phosphorus) : Used to assist the flow of metal in drainpipe production, weakens the iron.
Increase fluidity.

Cu (Copper) : Strengthens the metal and forms finer grains.

Mg (Magnesium) : Converts flake graphite to spheroidal graphite giving strength & ductility.

Ni (Nickel): Strengthens and in larger (18-22%) quantities provides corrosion resistance.

Cr (Chromium) : Mixed with Ni 2% and Cr 22-28% very hard wearing.

 CUPOLA FURNACE
• A cupola furnace is a melting device used in
foundries that can be used to melt cast iron.
• For many years, the cupola was the primary method
of melting used in iron foundries.

• The cupola furnace has several unique

characteristics which are responsible for its
widespread use as a melting unit for cast iron.
• Cupola furnace is employed for melting scrap metal
or pig iron for production of various cast irons.
• It is also used for production of nodular and
malleable cast iron. It is available in good varying
sizes.
• The main considerations in selection of cupolas are
melting capacity, diameter of shell without lining or
with lining, spark arrester
 HISTORY OF CUPOLA FURNACE

Cupola furnaces were first built in china as early as the Warring States period
(403-221 BC).

A Cupola furnace was made by RENE-ANTOINE FERCHAULT DE

RESUMUR around in 1720.

During the Han Dynasty (202 BC – 220 AD), most, if not all, iron smelted in
the blast furnace was remelted in a cupola furnace; it was designed so that a cold
blast injected at the bottom traveled through tuyere pipes across the top where the
charge (i.e. of charcoal and scrap or pig iron) was dumped, the air becoming a hot
blast before reaching the bottom of the furnace where the iron was melted and
then drained into appropriate molds for casting..
 Different Zones of Cupola Furnace
Well

• The space between the bottom of the Tuyeres and the sand bed.
• Molten metal collected in this portion.

Combustion Zone

• The combustion zone is also known as oxidizing zone.

• It is located between the upper of tuyers & a theoretical level above it.
• The total height of this zone is from 15cm to 30cm.
• The combustion takes place due to free oxygen completely from the air blast
& generate tremendous heat
• The heat is further evolved also due to oxidation of silicon & manganese.
• The temperature achieved is about 1540 ˚C to 1870˚C.
• Few exothermic reactions takes place in this zone are represented as:
 Different Zones of Cupola Furnace
Reducing Zone

Reducing zone of Cupola is also known as protective zone.

It is located between the upper level of combustion zone & the upper level of coke bed.
In this zone CO2 changes to CO through an endothermic reaction.
Due to which temperature falls from combustion zone to 1200˚C at the top of this zone.

 The important chemical reaction takes place in this zone is :

Melting Zone

The lower layer of metal charge above the layer of coke bed.
The metal charge starts melting in this zone & trickles down through coke bed and
collected in the well.
Sufficient carbon content picked up by the molten metal in this zone is represented
by the chemical reaction given as :
 Different Zones of Cupola Furnace

Pre Heating Zone

Pre heating zone starts from the upper end of the melting zone & continues upto
the bottom level of charging door.
This zone contains a number of alternate layer of coke bed, flux & metal charge.
The main objective of this zone is to preheat the charges from room temperature
to about 1090˚C before entering to the melting zone.
The pre heating takes place in this zone due to the upward movement of hot
gases.

 During the pre heating process, the metal charge in solid form picks up some
sulphur content in this zone.

Stack

The empty portion of cupola above the preheating zone is called as stack.
It provides the passage to hot gases to go to atmosphere from the cupola furnace.
 MANUFACTURING PROCESS
Cast iron is manufactured by remelting pig iron
with coke and limestone. This is done in a furnace
known as cupola furnace. The cupola furnace is
worked intermittently and it is open at the top.

The raw materials are fed from the top .

After raw material is placed, furnace is fired and

blast of air is forced.

The blast of air is cold as the impurities in pig-

iron are removed by the oxidation.

The impurities of pig iron is removed and pure

iron is taken in the molten stage from the bottom
of furnace.

The slag is also removed from the top of the cast

iron. At regular intervals.

Molten cast iron are led into moulds of required

shapes to form what we known as casting.
 Operation of Cupola
Preparation of cupola
• Slag and metal adhere to the cupola lining from the previous run is removed and lining
of cupola is remade.
• The bottom plates are swung to closing position supported by prop.
• The sand bed is then prepared with molding sand such that its slopes to towards the tap
hole.

Firing the cupola.

• The cupola is fired by kindling wood at the bottom.

• This should be done 2.5 to 3 hours before the molten metal is required.
• On the top of the kindling wood a bed of coke is built.
• The height of the coke bed is may be vary from 50cm to 125cm according to the size of
cupola.

Soaking of Iron

• When the furnace is charged fully it is maintain for about 45 minutes.

• The charge is slowly heated.
• During the stage the air blast is shut off and iron is soaked.
 Operation of Cupola
Opening of blast air

• At the end of the soaking period the air blast is opened.

• The taping hole is closed by a plug when the melting proceeds and molten metal is
collect at the bottom.

Pouring of molten metal

• When the sufficient amount of metal has collected in the hearth the slag hole is opened
and the slag is removed.

• Then taping hole is opened and molten metal is flows out in the table.

• The same procedure is repeated until the charge is melted and the operation is over.

Closing the cupola

• When the operation is over the air blast is shut off .

• The bottom of furnace is opened by removing the prop.
 Advantages of Cupola Furnace
It is simple and economical to operate.

A cupola is capable of accepting a wide range of materials without reducing melt quality.
Dirty, oily scrap can be melted as well as a wide range of steel and iron. They therefore play
an important role in the metal recycling industry.

Cupolas can refine the metal charge, removing impurities out of the slag.
From a life-cycle perspective, cupolas are more efficient and less harmful to the
environment. This is because they derive energy directly from coke rather than from
electricity that first has to be generated.

The continuous rather than batch process suits the demands of a repetition foundry.
High melt rates
Ease of operation
Adequate temperature control
Chemical composition control
Efficiency of cupola varies from 30 to 50%.
Less floor space requirements comparing with those furnaces with same capacity
Disadvantages
• Since molten iron and coke are in contact with each other, certain elements like Si,
Mn are lost and others like sulphur are picked up. This changes the final analysis of
molten metal.
• Close temperature control is difficult to maintain
 Cast Iron: Typical properties
High Hardness and brittleness
Low ductility
Cannot be cold worked/deformed at room
temperature
Easily melt and can be cast to the desired
shape
Cheapest alloy
 Classification of Cast Iron
Depends on :

1. Carbon content
2. Presence of alloying elements
3. Cooling rate before and after casting
4. Heat Treatment

Types of Cast Iron:

• White Cast Iron

• Grey Cast Iron
• Malleable Cast Iron
• Nodular/ductile Cast Iron
• Alloy Cast Iron
Types of Cast Iron

7-7
Gf, flake graphite;
Gr,graphiterosettes;
Gn, graphite nodules;
P,pearlite;
α, ferrite.

8
Classification of Cast Iron

7-10
 White Cast Iron
 These are iron-carbon alloys
having more than 2.14% carbon.
 All the carbon is present in the
combined cementite form, which
makes the fracture of these alloys to
have dull and white colour, and that
is the reason of their name as white
cast irons.
 Heat treatment to 800– 900℃ causes
decomposition of Fe3C graphite Composition:
clusters form. C = 2.5%, Ni+Cu = 1.5%,
 It is used to produce malleable cast Mn = 0.4%, P = 0.15%,
iron Cr = 17%, S = 0.15%
Si = 1.3%, Mo = 0.5%
White Cast Iron  Malleable Cast Iron
To Increase Ductility
 Properties of White Cast Iron
 White cast iron is hard but brittle. It has lower silicon content and
low melting point. The carbon present in the white cast iron forms
large particles that increase the hardness of the cast iron.
 It is abrasive resistant as well as cost-effective.
 Hard and wear resistant. The hardness and brittleness increases as
the carbon content increases. So, Extremely difficult to machine
 Hardness Brinell 375 to 600.
 Tensile strength 20000 to 70000 psi.
 Compressive strength 200000 to 250000psi.

Limitations
Because of extreme brittleness and lack of machinability,
"completely white" cast irons are limited engineering
applications.
 Applications White Cast Iron
 Liners For Cement Mixers
 Ball Mills, mill liners
 Rollers in rolling mills
 Certain Types Of Drawing
Dies
 Extrusion Nozzles
 In decorative furniture
 Brake shoes, Extrusion Nozzles
 Pump impellers

Liners for Cement Mixers Ball Mills Decorative Furniture

 Grey Cast Iron
Grey is the most versatile and widely used cast iron. The
presence of carbon leads to formation of graphite flakes that
does not allow cracks to pass through, when the material
breaks. Instead, as the material breaks the graphite initiates
numerous new cracks.

The fractured cast iron is greyish in colour, which also gives it

the name. The graphite flakes make the grey cast iron exhibit
low shock resistance. They also lack elasticity and have low
tensile strength.

However, the graphite fakes gives the cast iron excellent

machinability, damping features as well as good lubricating COMPOSITION:
properties making them useful in many industrial applications.
Total carbon : 2.4—3.8%
The graphite microstructure of the cast iron has a matrix that Silicon : 1.2—3.5%
consists of ferrite, pearlite or a combination of two. The Manganese : 0.5—1.0%
molten grey iron has greater fluidity and they expand well Sulphur : 0.06—0.12%
during the solidification or freezing of cast iron. This has Phosphorus : 0.1—0.9%
made them useful in industries like agriculture, automobile,
textile mills, etc.
 Properties Grey Cast Iron
1. Low cost of production

2. Low melting point: (1150°—1250°C) of cast irons, several hundred degrees less than
steel.

3.Good Castability: Cast irons have excellent fluidity and take good mould-impressions easily.
Graphite having low density is voluminous. Its large volume compensates for the shrinkage.
Gray iron, thus, does not need shrinkage allowance at all to take almost exact casting
impressions.

4. Good machinability of gray cast iron is due to easy and discontinuous chip
formation due to brittle graphite flakes. Graphite serves as a solid lubricant decreasing
coefficient of friction. It increases the tool life too.(White cast irons, due to high hardness, are
unmachinable).

5.Good wear resistance of gray iron is due to graphite acting as solid lubricant layer, avoiding
thereby metal to metal direct contact. On other hand, white cast irons are wear resistant due to’
their high hardness.
 Properties Grey Cast Iron
6.High damping capacity is due to the graphite flakes, which breaks the continuity of the
metallic matrix, and thus, vibrations are not allowed to transfer from one side of flake to other,
i.e, Gray iron suits thus the machine beds as compared to steels.

7.High compressive strength of gray iron- almost 3 to 5 times of its tensile strength (110-
350 N/mm2), and almost equal to that of steels makes it suitable for applications,where
components are subjected to compression such as machine beds, etc.

8. High thermal conductivity, and have ability to withstand thermal shocks.

9.Good resistance to atmospheric corrosion due to high silicon and perhaps other
factors, than mild steels.

10. The main drawback of grey cast irons are low impact resistance and poor ductility. It has
higher brittleness.
 Applications of Grey Cast Iron
• Internal Combustion Engine
• Pump Housings
• Valve Bodies
• Electrical Boxes
Internal Combustion Engine
• Decorative Castings
• Cast iron cookware
• Disc brake

Pump Housings

Cast iron cookware

Disc brake on a car Decorative Castings
 Malleable Cast Iron
Malleable cast iron is basically white iron that
C is in the form of irregular
undergoes heat treatment to convert the carbide
spheroid
into graphite.

The resultant cast iron has properties that vary

from both grey and white cast iron. In case of
malleable cast iron, the graphite structure is
formed into irregularly shaped spheroidal
particles rather than flakes that are usually present
in gray cast iron.

This make the malleable cast iron behave like

low-carbon steel. There is considerable shrinkage
that results in reduced production of cast iron as
well increased costs. Malleable cast iron can be Components Percentage
identified easily by the blunt boundaries. Carbon 2.00-2.65
Silicon 0.90-1.40
Produced by annealing White Cast Iron at 816 – Manganese 0.25-0.55
954℃ for 50-80hrs (slow cooling to room Phosphorus Less than 0.18
temperature) Sulphur 0.05
Properties Malleable Cast Iron

Similar to ductile iron

Good shock resistance
Good ductility
Good machineability
 Applications Malleable Cast Iron
• Malleable iron is better for thinner castings
• Vehicle components
– Power trains, frames, suspensions and wheels
– Steering components, transmission and differential parts,
– connecting rods

• Railway components
• Pipe fittings Power trains

Wheels

Rail tracks
Pipe fittings
Steering components in car
 Ductile (Nodule) Cast Iron
Ductile cast iron is yet another type of ferrous
alloy that is used as an engineering material in
many applications.

Ductile cast iron is produce by adding

magensium (Mg) / Cerium (Ce) to grey cast iron:
graphite forms as spheres rather than flakes

The magnesium reacts with oxygen and sulphur in

the molten iron leading to nodule shaped graphite
that has earned them the name-nodular cast iron.
COMPOSITION:
Like malleable iron, ductile iron is flexible and
exhibits a linear stress strain relation. It can be
CARBON : 3.3 - 3.4%
casted in varied sizes and into varying thickness.
SILICON: 2.2 - 2.8%
MANGANESE: 0.1 -0.5%
Removing the graphite flakes improves the
MAGNESIUM: 0.03 - 0.05%
tensile strength, toughness and ductility
PHOSPHORUS: 0.005 - 0.04%
SULPHUR: 0.005 T- 0.02%
Properties Ductile Cast Iron

Strength higher than grey cast iron

Higher Ductility
Low cost
Simple manufacturing process makes
complex shapes
Machinability better than steel
 Applications Ductile Cast Iron
• Pipe and pipe fittings: Used for water and sewer
lines.

• Major industrial applications include

--Highway diesel trucks,

--Agricultural tractors,

• Machinery products:

--Oil well pumps.

– Crankshafts,
– Disc brake callipers