Materials engineering. Cast Irons

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1 Materials engineering Cast Irons

2 Outline Properties of cast irons Microstructure Mechanical properties Types Gray cast iron White cast iron Nodular cast irons Malleable cast irons

3 Properties Cast Iron C = 2.1 ~ 6.67% Properties depend on 1) Carbon content 2) Cooling rate of the casting 3) Alloying elements

4 Carbon content 1) Degree of solution T = C% (Si%+P%) T>1 Hypereutectic Ledeburite + Pr. Cementite T=1 Eutectic Ledeburite T>1 Hypoeutectic Ledeburite + Perlite

5 Cooling rate 2) Cooling rate Slow cooling rate section size > 10 mm Iron + Graphite Quick Cooling rate section size < 10 mm Iron + Cementite

6 Cooling rate 2) Cooling rate Fe - graphite Fe - cementite

7 Alloying elements Graphite producing elements Co, P, Cu, Ni, Ti, Si, C, Al Carbide producing elements W, Mn, Mo, S, Cr, V, Mg, Ce The microstructure depends on: - Carbon and Silicon content - Section size (cooling rate)

8 Maurer diagram Gray cast iron (Stable) Ferrite + Graphite White cast iron (metastable)

9 Microstructure Hypoeutectic white cast iron Perlite and ledeburite Hypereutectic white cast iron Primer cementite and ledeburite Gray cast iron Ferrite and graphite Gray cast iron Ferrite, perlite and graphite

10 C + Si % Greiner - Klingenstein diagram At a given C+Si% the graphite producing elements effects increases with increasing section size Ferrite + Graphite Perlite + Graphite Ledeburite+ Perlite L + P + G Wall thickness (mm) Typical chamical compossition for gray cast iron: C % Si % Mn % S % P % <0.1 <0.3

11 Tensile Strength Mechanical properties of cast iron Ferritic microstructure Perlitic microstructure Graphite s effect on Tensile strength - graphite produces notch effect - graphite excludes parts in the matrix

12 Mechanical properties of cast iron Disadvantage of cast iron - gray cast iron has low strength - gray cast iron has no plastic strain = brittle Graphite forms in gray cast iron

13 Mechanical properties of cast iron Advantage of cast iron - Good compressive strength - high damping capability (tool machines) - good machinability - good wear resistance (graphite as lubricant) - lower cost

14 Utilization of gray cast iron Machine stands, engines, etc

15 Increasing the strength of cast iron a) Increase the perlite amount in the matrix b) Modify the shape and distribution of the graphite flakes c) Alternating the graphite s geometry from flake to spheroidal graphite

16 Increasing the strength of cast iron Increase the perlite amount in the matrix Ferrite + Graphite ASTM A438 TS (ksi) TS (MPa) T Class

17 Increasing the strength of cast iron Modify the size and distribution of graphite flakes FeSi and CaSi as centers of crystallization (nucleation) Method: Overheating the molten iron and alloy - finer flakes - higher strength FeSi ~0.5% CaSi 0.5~1% ASTM A438 TS (ksi) TS (MPa) T Class

18 Ferrite + Graphite flakes Ferrite + spheroidal gr. + Graphite flakes Si % Increasing the strength of cast iron Alternating the graphite s geometry from flake to spheroidal graphite Ductile or Nodular cast iron Mg and Si alloying Mg alloying by Fe-Cu-Mg and Fe-Ni-Mg F + Sph + Graphite flakes C=3.5% 400 F + P +Sph + Graphite flakes F + P + Sph. 100 F + Sph. + Carbides Mg %

19 Microstructure Ductile cast iron Ferrite and spherical graphite 20 µm spherical graphite in gray cast iron Ductile cast iron Ferrite, Perlite and spherical graphite

20 Utilization of ductile cast iron Machine parts, gears, pipes, crankshaft, etc

21 Increasing the strength of cast iron Ductile or nodular cast irons ASTM A395 TS (MPa) YS(MPa) El (%) structure Grade Ferrite Elongation (%) Yield Stress (ksi) Tensile strength (ksi) Grade F + P Grade P (AQ) Grade M (Q+T)

22 Malleable cast iron Convert iron-carbibe to temper carbon increases the ductility

23 T (ºC) Black heart malleable cast iron Ferritic structure with temper carbon ASTM A47 TS (MPa) YS(MPa) El (%) Grade ºC neutral atmosphere Ledeburitic-perlitic structure Iron carbide dissociates to Fe and C Austenite transforms to ferrite and graphite Ferrite + temper carbon hours time

24 T (ºC) White heart malleable cast iron Ferritic structure with low carbon content ASTM A47 TS (MPa) YS(Mpa) El (%) Grade Grade Grade Grade ºC oxidizing atmosphere hours Ledeburitic-perlitic structure C = ~ 3% Iron carbide dissociates to Fe and C Carbon diffuses to the surface and burns there. Ferritic structure, low carbon C = ~ 0.1% time

25 Microstructure Black heart cast iron Temper-carbon in ferrite matrix

26 Utilization of malleable cast iron Machine parts, machine stands, etc

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