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Cast Irons: MSE 206-Materials Characterization I Lecture-6

Cast iron is an alloy of iron and carbon containing 2.1-6.7% carbon. It also contains silicon, manganese, sulfur, and phosphorus. The type of cast iron depends on the carbon and silicon content and the cooling rate. Gray cast iron contains 2.5-4% carbon and forms graphite flakes during slow cooling. It has good vibration damping and wear resistance but is weak in tension. Nodular cast iron forms spherical graphite nodules and has higher strength and toughness than gray cast iron. White cast iron forms cementite and is very hard and brittle. Malleable cast iron is produced by heat treating white cast iron to decompose cementite into graphite roset

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127 views21 pages

Cast Irons: MSE 206-Materials Characterization I Lecture-6

Cast iron is an alloy of iron and carbon containing 2.1-6.7% carbon. It also contains silicon, manganese, sulfur, and phosphorus. The type of cast iron depends on the carbon and silicon content and the cooling rate. Gray cast iron contains 2.5-4% carbon and forms graphite flakes during slow cooling. It has good vibration damping and wear resistance but is weak in tension. Nodular cast iron forms spherical graphite nodules and has higher strength and toughness than gray cast iron. White cast iron forms cementite and is very hard and brittle. Malleable cast iron is produced by heat treating white cast iron to decompose cementite into graphite roset

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Jose Luis Valin Rivera
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CAST IRONS

MSE 206-Materials Characterization I


Lecture-6
Iron-Carbon (Fe-C) Phase Diagram

 Cast Iron is an alloy of iron and


carbon containing 2.1%-6.7% C.
In addition, silicon, manganese,
sulphur and phosphorus are
STEELS contained in varying amounts.

CAST IRONS
 Elements such as nickel,
chromium, molybdenum,
vanadium can be added to
produce alloy cast irons

 Since carbon makes iron brittle, carbon changes between 2.5% to 4% in


commercial cast irons. Additionally, cast irons contain Si as main alloying
element between 1-3 %.
Engineering importance of cast iron

 Cast Irons may often be used in place of steel at considerable


cost savings. The design and production advantages of cast iron
include:

 Low tooling and production cost


 Ability to cast into complex shapes
 Excellent wear resistance and high hardness
(particularly white cast irons)
 High inherent damping capabilities (gray cast irons)

 They are produced by casting because commercially used cast


irons have relatively lower melting points while they are brittle
and hard to fabricate.
Types of cast iron

 White Cast Iron


 Malleable Cast Iron
 Gray Cast Iron
 Nodular (Ductile) Cast Iron
 Chilled Cast Iron

What determines the type of cast iron?

1) %Si & %C content: Increasing Silicon and carbon content


retards cementite formation, stabilizes graphite.
2) Cooling rate: slow cooling favors graphitization.
3) Temperature: At high temperatures (>1000ºC) Fe3C tends to
decompose to form graphite
Fe-C and Fe-Fe3C Systems

 For Gray cast irons Fe-C system is used, whereas Fe-Fe3C system is used for
white cast irons
White Cast Iron

 In low-silicon cast irons with high cooling rates, most of the


carbon exists in cementite instead of graphite
 Such alloys have a white appearance on their fracture surface
and therefore called White Cast Iron (WCI)
 Matrix is always cementite for these alloys
Cementite:
white phase
pearlite
White Cast Iron: Properties and Applications

 Used in applications requiring wear resistance:


-Cement mixers, extrusion nozzles, spacers, spools in farm
machinery
-In the textile industry - bearings, mill liners, etc.

 Fe3C makes WCI hard and brittle. White cast irons have high wear
resistance but they are extremely brittle and difficult to machine.

 Most of the WCI is produced to manufacture Malleable Cast Iron.


Malleable Cast Iron
 By malleabilization process white cast iron is converted into Malleable cast iron

 There is a tendency for cementite to decompose into iron and carbon. During
malleabilization heat treatment cementite decomposition occurs.
Fe3C  3Fe + C
Malleabilization Process;

Process contains 2 steps:

Step1-Heat the white cast iron 800-900oC. During holding at this temperature  occurs
and cementite in WCI dissolves (Fe3C  3Fe + C). Graphite nuclei grows in all
directions and appear as irregular nodules and spheroids called temper carbon. After
that the casting is cooled as rapidly as practical to about 760oC.

Step2- The part is cooled from 760oC to room temperature at different cooling rate. (slow,
fast, moderate)
Malleable Cast Iron
Slow cooling Moderate cooling

pearlite

ferrite graphite rosettes


Ferrite (white regions)
Gray Cast Irons

 Most widely used group of cast irons

 Most gray cast irons are hypoeutectic alloys containing


between 2.5 and 4% C

 In high-silicon , high carbon cast irons with slow cooling rate


carbon occurs in the form of graphite.

 To examine phase transformations in gray cast irons Fe-C


equilibrium phase diagram is used.
Gray Cast Irons:
Hypoeutectic Alloys Microstructures

Hypoeutectic Gray Cast Iron with pearlitic microstructures

Graphite flakes pearlite


Gray Cast Irons

Advantages
 Graphite acts as a chip breaker and a tool lubricant.
 Very high damping capacity.
 Good thermal conductivity
 Good dry bearing qualities due to graphite.
 Good corrosion resistance in many common engineering environments.

Disadvantages:
 Brittle (low impact strength) which severely limits use for critical applications.
 Graphite acts as a void and reduces strength. Maximum recommended design
stress is 1/4 of the ultimate tensile strength. Maximum fatigue loading limit is 1/3
of fatigue strength
 Changes in section size will cause variations in machining characteristics due to
variation in microstructure
 Higher strength gray cast irons are expensive to produce...
Chilled Cast Irons

It is made by casting the molten metal against a metal chiller


(results WCI region near the surface and GCI region in interior
parts)

WCI
GCI

Surface: Hard abrasion resistance


Interior : Relatively softer

 The structure is obtained by carefull control of alloy


composition and cooling rate.
Chilled Cast Irons

During production metal liners (chills) are placed on the


surface of the mold.

Thin metal plates mold

The depth of WCI layer is controlled by adjusting the amount of


metal plates

 Thin WCI layer is obtained by using thin metal plates, while


thicker WCI region is obtained by heavier metal plates.
Nodular Cast Irons

 Known also as ductile iron, spheroidal graphite iron, spherulitic iron


 Graphite is present as tiny balls and spheroids

 Has higher strength and toughness than gray cast iron

 NCI
GCI


Nodular Cast Irons

 Gray cast irons are mechanically weak and brittle due to sharp tips and
brittleness of graphite flakes which act as stress concentration points and
produce “notch-effect”.

Production of Nodular cast iron

To form graphite as sphere like particles:


Calcium Carbide addition to molten Iron to lower the S content to
suppress graphite flake formation.
Mg or Ce addition to impede directional growth and lead to isotropic
growth.
Nodular Cast Irons
 The surrounding matrix will be ferritic upon very slow cooling because all
carbon in the matrix diffuses to the nodules resulting in Ferritic nodular cast
iron
 At moderate or high cooling rates matrix will be pearlitic and at even higher
cooling rates it may be bainitic or martensitic.

Ferritic Nodular Cast Iron Pearlitic Nodular Cast Iron


Production of Cast Irons: Summary

Adapted from Fig.11.5, Callister


& Rethwisch 8e.

18
Properties of Cast Irons: Summary
Adapted from Fig.
11.3(a) & (b),
Gray iron Callister &
Rethwisch 8e.
• graphite flakes
• weak & brittle in tension
• stronger in compression
• excellent vibrational dampening
• wear resistant

Nodular (Ductile) iron


• add Mg and/or Ce
• graphite as nodules not flakes
• matrix often pearlite – stronger but less
ductile
Properties of Cast Irons: Summary
Adapted from Fig.
11.3(c) & (d),
White iron Callister &
Rethwisch 8e.
• < 1 wt% Si
• pearlite + cementite
• very hard and brittle

Malleable iron
• heat treat white iron at 800-900ºC
• graphite in rosettes
• reasonably strong and ductile
Typical Applications of Cast Iron

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