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Home Matter Index Iron-steel Page Cast Irons
Introduction
Cast Irons are a family of ferrous metals with a wide range of properties produced by being cast into shape as opposed by being formed. Cast Irons contain 2% to 4% Carbon and 1% to 3% Silicon. Other elements are used to control specific properties. Cast irons have a wide range of mechanical properties which make them suitable for use in engineering components. The wide spread use of cast iron is as a result of its low cost and versatile properties. A iron-carbon liquid containing over 2% C cooled very slowly will result in a graphite (pure carbon) and iron crystallising out to form cast iron. In the practice at normal cooling rates the metastable cementite Fe 3C is formed. High carbon content metals can, under controlled conditions, solidify as stable iron-graphite systems or metastable iron-carbide systems. Rapid cooling discourages the nucleation graphite and encourages the formation of metastable iron carbide. Longer holding times at higher temperatures and slower cooling and the addition of certain alloying elements encourage the formation of stable iron-graphite phase. Cast iron contains significant amounts of silicon in addition to the high carbon content. Cast irons are therefore really iron-carbon-silicon alloys. The presence of silicon in iron carbon alloys promotes the formation of graphite. The true (equilibrium /stable ) phase diagram for iron-carbon is similar to the metastable one on the carbon steel page ( Phase diagram ) . The phase diagrams for iron-carbon-silicon is similar but the eutectic/eutectoid points are moved to the left. A diagram for one containing 2% silicon is shown below.
Cast Iron
Cast Iron
graphitisation) then the grey cast iron resulting will have graphite flakes in a ferritic matrix. If however 0,5% to 0,8%of the carbon remains in the form of Fe 3C the the resulting grey cast iron matrix will be pearlitic and the cast iron will be stronger and harder. Sulfur is present in cast iron and generally is is kept low . Manganese is often present and combines with the sulfur as a precipitate. Both elements on their own restrict the formation of graphite. The mechanical properties of grey cast iron result from the effects of chemical composition and the cooling history. In general as the combined equivalent of carbon and silicon is reduced the strength of the cast iron is increased. When tensile strengths above 350MPa are required, for thicker sections, alloying additions of chromium, nickel or molybdenum are required.
Wear Resistance
Grey cast iron has outstanding resistance to sliding friction wear and has been used very successfully,throughout the twentieth century,for sliding surfaces including cylinder bores, piston rings and slideways on machine tools. Because of the effect of the graphite flakes grey cast iron has and excellent resistance to galling and seizing and has a low coefficient of friction.
Machinability
Grey cast iron is one of the easiest iron alloys to machine. The ferrite-graphite cast iron is the easiest the fine pearlite matrix cast iron is more difficult.
Damping Capacity
Grey cast irons have an excellent capacity for absorbing vibration energy and thus damping vibrations. This property is most evidenced with a high percentage of graphite flakes.
White Cast Iron Standard..BS EN 1562:1997: Founding. Malleable cast irons ...
UTS 600-800 MPa, Elongation 2-3%... Has a structure of pearlite in a cementite matrix making it hard, brittle and difficult if not impossible to machine. It has limited applications in industry, it is used for wear resisting components such as extrusion dies and cement mixer liners. Fracture surfaces have light-coloured appearance.
Cast Iron
1. Whiteheart..UTS 250-400 MPa, Elongation 4-10%... This is heat treated white iron compound producing an outer ferrite layer and a ferrite/pearlite core Easy to cast in thin sections, which have a tough core.... 2. Blackheart...UTS 290-340 MPa, Elongation 6-12%... Soaked at high temperature to cause the cementite to break down, then slowly cooled to give ferrite and graphite 3. Pearlite... UTS=450-550 MPa, Elongation 6-12%... Similar to blackheart but faster cooling to produce a pearlite structure with higher strength
Malleable iron is preferred over ductile iron for thin-section castings and for components as listed below: Components that are to be pierced, coined, or cold formed Components parts requiring maximum machinability Components that must retain good impact resistance at low temperatures Components requiring wear resistance (martensitic malleable iron )