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    Cast Iron

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    Thulasi Ram
    This document discusses types of cast iron, their characteristics, microstructures, and welding procedures. It addresses various cast iron alloys including gray, white, malleable, and ductile iron. Key points covered include preheating requirements to prevent cracking, filler metal selection based on strength and properties, and repair welding techniques for cast iron components.

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    Cast Iron

    Uploaded by

    Thulasi Ram
    357 views43 pages
    This document discusses types of cast iron, their characteristics, microstructures, and welding procedures. It addresses various cast iron alloys including gray, white, malleable, and ductile iron. Key points covered include preheating requirements to prevent cracking, filler metal selection based on strength and properties, and repair welding techniques for cast iron components.

    Original Description:

    WELD PRocedure in Cast iron

    Original Title

    Cast iron

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    This document discusses types of cast iron, their characteristics, microstructures, and welding procedures. It addresses various cast iron alloys including gray, white, malleable, and ductile iron. Key points covered include preheating requirements to prevent cracking, filler metal selection based on strength and properties, and repair welding techniques for cast iron components.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    357 views43 pages

    Cast Iron

    Uploaded by

    Thulasi Ram
    This document discusses types of cast iron, their characteristics, microstructures, and welding procedures. It addresses various cast iron alloys including gray, white, malleable, and ductile iron. Key points covered include preheating requirements to prevent cracking, filler metal selection based on strength and properties, and repair welding techniques for cast iron components.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
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    At a glance
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    The key takeaways from the document are the different types of cast iron, their characteristics and considerations for welding cast iron.

    The different types of cast iron mentioned are gray cast iron, white cast iron, malleable cast iron, ductile cast iron, Ni hard cast iron, Ni resist cast iron and Mehanite cast iron.

    Some characteristics of cast iron mentioned are carbon range of 1.7-4.5%, ability to form intricate shapes and sizes, damping capacity, excellent wear resistance, self lubricating properties, poor elongation and low ductility.

    TYPES OF CAST IRON PROBLEMS & WELDING PROCEDURES

    MACHINE BEDS

    AUTOMOTIVE ENGINE CYLINDER BLOCKS


    CRANK SHAFTS

    FORMING DIES
    IMPELLAR BLADES

    ROLLERS
    PUMP, TURBINE, COMPRESSOR CASINGS

    CHARACTERISTICS OF CAST IRON


    CARBON RANGE - 1.7 - 4.5 % CASTINGS - INTRICATE SHAPE & SIZE DAMPING CAPACITY EXCELLENT WEAR RESISTANCE SELF LUBRICATING PROPERTIES POOR ELONGATION & LOW DUCTILITY GRAPHITE FORMATION (Si, Al, Ti, Cu)
    3

    TYPES OF CAST IRON


    WHITE CAST IRON

    GRAY CAST IRON


    MALLEABLE CAST IRON

    DUCTILE CAST IRON (SG IRON)


    Ni HARD CAST IRON

    NI RESIST CAST IRON


    MEHANITE CAST IRON

    GRAY CAST IRON ASTM A48, A159


    Carbon Manganese Phosphorus 2. 50 - 4. 00 0. 25 - 1. 00

    0. 05 - 1. 00
    0. 02 - 0.25 1. 00 - 3. 00

    Sulphur
    Silicon

    GRAY CAST IRON A159 - G4000


    Ultimate Tensile Strength
    Hardness

    276 MPa
    217 - 269 HB

    WHITE CAST IRON


    Carbon Manganese Phosphorus 1. 80 - 3. 60 0. 25 - 0.80

    0. 06 - 0.18
    0. 06 - 0.20 0. 50 - 1.90

    Sulphur
    Silicon

    Malleable Iron from White Iron

    Malleable Iron : Structure - Cooling rate

    MALLEABLE IRON
    - HEAT TREATMENT OF WHITE CAST IRON

    ASTM A602, M3210


    Yield Strength
    Ultimate Tensile Strength

    224 MPa
    345 MPa

    Hardness
    Elongation

    156 HB
    10 %

    DUCTILE CAST IRON (SG CAST IRON)


    - INOCULENTS : CERIUM & MAGNESIUM ARE USED TO CONTROL THE SHAPE OF GRAPHITE 3. 54 - 3. 60 Carbon 0. 40 - 4. 90 Manganese
    Phosphorus 0. 01 - 0. 02 0. 02 - 0.25 2. 26 - 2. 40 0. 56 - 1. 20 0. 15 - 0. 20

    Sulphur
    Silicon Nickel Copper

    723 C

    Iron - Iron carbide phase diagram

    ALLOYING ELEMENTS
    MANGANESE MAGNESIUM

    CERIUM
    NICKEL COPPER

    CHROMIUM
    TITANIUM

    SILICON & ALUMINIUM PROMOTE GRAPHITE FORMATION

    Effects of elements on Cast iron


    Phosphorous: solution harden, corrosion resistance, better machining Silicon: removes oxygen, increases oxidation resistance

    Titanium: forms carbides, age hardening possible Chromium: corrosion resistance, does not promote graphite formation
    Nickel : used with Cr, low temperature strength, toughness

    Effects of elements on Cast iron


    Manganese: along with S forms as MnS, improves machining Molybdenum: MoC provide abrasion resistance, improves corrosion resistance, improves hot strength Tungsten: Similar to Mo, delays tempering to higher temperatures

    Ferrite + Pearlite

    Malleable cast iron

    Gray cast iron

    Ni-Hard cast iron

    Microstructure constituents in cast iron


    Ferrite - BCC, low carbon solubility Graphite - Most stable form of carbon in iron, More carbon means more Graphite Pearlite - Mixture of ferrite and cementite More carbon means less Pearlite Austenite - FCC
    Cementite - Iron carbide with good toughness Martensite - Rapidly cooled by quenching

    Retained Austenite

    23

    Heat affected zone (HAZ) - PMZ

    24

    Top half of Casing. Cracked Regions - Ductile iron

    Welding Procedures
    Weldable or non weldable, Repair weld Skip weld technique Preheating Inter pass Temperature Suitable electrode selection Machineable or Non machineable Depositing short weld length

    Welding Procedures
    Use stringer beads

    Use very low heat input Buttering on crack edges


    Steel filler is not recommended for machineable repair weld deposits

    Welding Precautions
    Cracking tendency is very high Higher Preheat is applied for
    Allowing more time for H2 escape Reduces the cooling rate Reduction of hardness in HAZ Avoid the risk of martensite formation

    Welding Precautions
    PWHT / Stress Relieving Furnace cooling

    Reduce residual stresses - Block welding - Depositing short weld lengths

    Broken Part

    Crack 1

    Crack 2

    Carbon Equivalent
    % C EQ = C + (Si/3) + (P/3 ) Used for determining the weldability Preheat is decided by the C EQ

    Increasing CE lowers Tensile Strength

    Carbon Equivalent vs Tensile strength

    Preheat Range for welding cast iron


    TYPE
    GRAY IRON MALLEABLE MALLEABLE DUCTILE DUCTILE FERRITIC PEARLITIC FERRITIC PEARLITIC

    MICROSTRUCTURE

    PREHEAT C
    20 - 300 20 - 150 20 - 300 20 -150 20 - 300

    Turbine Side Crack 1 Crack 2

    Bottom Half View of Casing

    Selection of filler metal


    Based on strength
    Hardness Abrasion resistance

    Special properties - ductility - impact strength - wear resistance

    Weld metal / Electrode


    Steel, Stainless steels Nickel base alloys, Cast iron AWS A5.15 Standard The mechanical properties of weld metal are affected by Weld metal Chemistry (C,Ni, Si) Thermal cycle experienced (CR)

    Nickel Iron Electrodes


    Nickel - Iron electrodes compared to Nickel

    Lower cost
    Stronger & More Ductile

    Advantages of Nickel filler


    Low risk of cracking High ductile weld Minimum contraction stresses Minimum Hardness

    Enlarged view of Crack

    Bend Test of BM

    Lamellar Tear

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