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Department of Materials Science and Engineering,
Khulna University of Engineering & Technology,

Khulna.
Name Mushfiqur Rahman
Roll 2127021
Group A-7
Course No. MSE-2206
Course Title Compositional and Microstructural Analysis
Exp No. 08
Exp Name Compositional and Microstructural Analysis of an

Unknown Cast Iron Sample
Course Teacher Fatema-Tuz-Zahra, Lecturer, Dept. of MSE
Md. Mafidul Islam, Lecturer, Dept. of MSE
Date 19-11-2024
Objectives:
From this experiment, we learned:
• The process of identifying the microstructure of an unknown cast iron sample.
• Methods to analyze its composition, focusing on carbon content, and classify its type
based on the structure.
• The relationship between the microstructure of cast iron and its strength, properties, and
applications.
• Ways to compare the results with known cast iron types to determine its potential uses
and performance.
Introduction:
Cast iron is a group of carbon-rich alloys containing 2-4% carbon, along with varying amounts
of silicon and manganese. It also includes impurities like phosphorus and sulfur. Cast iron is
made by reducing iron ore in a blast furnace, where the primary material, pig iron, is derived
from smelted iron ore. This pig iron is further processed to create cast iron, either directly from
molten pig iron or by remelting it, often with additional materials such as iron, limestone, steel,
or coke.
Although it can be melted in a specialized blast furnace called a cupola, modern production more
commonly uses electric induction or arc furnaces. The cupola furnace, similar in design to a blast
furnace, is cylindrical, typically 1 meter in diameter and 5 meters tall, and is used to remelt pig
iron, limestone, and coke for cast iron production.
There are four main types of cast iron, differentiated by their composition and processing
methods:
1. Gray Cast Iron:
The most common type, gray cast iron, gets its name from the gray color of its fractured
surface, which results from the presence of graphite flakes. It is known for its excellent
compressive strength, good machinability, and thermal conductivity, though it is less
ductile compared to other types. It is widely used in engine blocks, pipes, and cookware.
2. White Cast Iron:
White cast iron has a distinctive shiny white appearance due to its high carbon content,
which forms cementite (iron carbide) instead of graphite. This gives it exceptional
hardness, wear resistance, and high compressive strength. However, it is brittle, making it
suitable for applications like mill liners and grinding balls that require durability under
intense wear.
3. Malleable Cast Iron:
Malleable cast iron is created by heat-treating white cast iron to transform its carbon
structure into irregular nodules. This process improves ductility, toughness, and
malleability while reducing brittleness. It is easily machined, welded, and shaped, making
it ideal for pipe fittings, automotive components, and agricultural equipment, especially
where flexibility and strength are essential.
4. Nodular Cast Iron (Ductile Cast Iron):
Nodular cast iron, also called ductile cast iron, is made by adding a small amount of
magnesium (about 0.2%) to molten iron. This causes the graphite to form into spherical
nodules, enhancing ductility and thermal cycling resistance. It is widely used in water and
sewer systems, crankshafts, gears, heavy-duty suspensions, and brakes, thanks to its
strength and ability to endure thermal variations.
Apparatus:
1. Emery papers (grit-120,220,400,600,800,1000,1200 and 1500)
2. Wrought Iron
3. Watch glass
4. Polishing machine
5. Optical microscope
6. Stereoscope microscope
Chemical used:
1. Al2O3 powder for polishing
2. Etching reagent: Nitral solution (2%HNO3,98%CH3CH2OH)
Methodology:
There are a total of 5 steps for the structural analysis of a material. These steps are described
chronologically below-
(1) Sectioning: Sectioning refers to cutting the sample material through its section. It can be done
in two ways- (a) Longitudinal sectioning & (b) Transverse sectioning. The grain boundaries are
more visible when the sectioning is done longitudinally. That is why the sample is normally
sectioned longitudinally.
(2) Mounting: The sample can often be very small for human fingers to hold on to. Working with
this kind of samples can be difficult and the final result could be hampered. That is why
polymers (usually raisins) are used to hold the material. This is known as mounting.
(3) Grinding: The grinding process is done to smoothen the surface of the material. Emery paper
is used for the grinding. There are 9 grades of emery paper (120, 220, 400, 500, 600, 800, 1000,
1200, 1500). Grade means the amount of silica particle in 1 sq ft. The higher the grade, the finer
particle size that grade of paper has. We have to rub the sample with all the gradings starting
from 120 to 1500. We have to rotate the sample by 90 degrees after finishing working with any
grade of paper, before we can start working with a new grading of paper. This is for creating new
depth over the old ones easily.
(4) Polishing: Polishing is done to make the surface shiny as we will observe the sample under
optical microscope and a shinier surface will make it easier for light to reflect and not scatter.
Diamond paste is used to polish the surface of the sample material. We need to polish it along
the direction that is vertical to the direction along which we worked with the 1500 graded emery
paper.
(5) Etching: The main goal of etching is to create a differentiating factor between the grain and
the grain boundaries. A nitral solution is created with 2% nitric acid and 98% ethanol. When the
surface of the sample is dipped into this solution, the grain boundaries react with the solution
before the grains. So, the grain boundaries can be easily identified. If it is then observed under
the microscope, we can see the grain boundaries. It is usually dipped for 2-3 seconds. If the
grains react too, it is called over etching. If the grain boundaries don’t react properly, it is called
under-etching.
Fig: Microstructure of the unknown sample at 20X and 40X
Result:
The microscopic analysis of the sample showed a microstructure consistent with nodular cast
iron, with rounded graphite nodules distributed within a ferrite matrix. Comparing it to standard
reference images, the sample's features closely match the typical properties of nodular cast iron.
Therefore, we conclude that the unknown sample is most likely nodular cast iron.
Fig: Microstructure of Nodular Cast iron
Discussion
After preparing the unknown sample through grinding, polishing, and etching, microscopic
examination revealed features typical of nodular cast iron. The microstructure showed rounded
graphite nodules within a ferrite matrix, which is characteristic of nodular (ductile) cast iron.
This structure is distinct from other cast irons, such as gray cast iron, which contains graphite in
a flake-like form.
Conclusion:
After grinding, polishing, and etching the unknown sample, microscopic analysis showed
features typical of nodular cast iron. The microstructure revealed rounded graphite nodules
embedded in a ferrite matrix, which matches the usual structure associated with nodular cast
iron. This form of graphite gives the material greater strength and flexibility compared to other
cast irons, such as gray cast iron, which has flake-like graphite inclusions. The improved
ductility and durability of nodular cast iron make it suitable for a wide range of applications,
including automotive parts, pipes, and heavy machinery. Based on these findings, we conclude
that the sample provided is nodular cast iron, commonly chosen for its balance of toughness and
machinability.

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Department of Materials Science and Engineering,

Khulna University of Engineering & Technology,

Name Mushfiqur Rahman

Course No. MSE-2206

Course Title Compositional and Microstructural Analysis

Exp Name Compositional and Microstructural Analysis of an

Fig: Microstructure of the unknown sample at 20X and 40X

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