Metal Casting: (Metallurgy of Cast Iron)

METAL CASTING
(Metallurgy of Cast Iron)
VP PARTHASARATHY
BRAKES INDIA LIMITED

Basis for choosing Casting as
a Process
1. Most intricate shape can be cast
2. Due to their metallurgical nature, some metals
like Cast Iron, cannot be hot worked into bars or
sheets and can only be cast
3. Parts may be cast as a single piece which may
otherwise require assembly or welding of more
than one part
4. Process is highly adaptable for mass production
of large volumes
5. Large and heavy components weighing several
tons can be produced economically by casting
6. More uniform properties in all directions of the
part
7. Can have economic advantage due to
combination of one or more of the above points
Flow diagram of the basic operations for
producing sand castings
New sand
Sand
Pig Iron, Pour Mould
MS Scrap, Binder
CI Borings, Cores
Foundry Furnace Cooling Additives
returns Sand mixer
Shakeout
Sand reclammation
Castings
Scrap Fettling
Cleaning
Heat treatment (Optional)
Inspection
Finishing
Finished casting
Steps involved in making castings
1. Pattern Making
2. Core Making
3. Moulding
4. Melting & Pouring
5. Cleaning
Cope & Drag Pattern with Cores
Induction Furnace
Pouring
Cast Iron Family
1. Grey Cast Iron
2. White Cast Iron
3. Mottled Iron
4. Chilled Cast Iron
5. Malleable Iron
6. Nodular Iron (SG Iron)
Factors Controlling the nature of
Cast Irons
1. Chemical Composition
2. Solidification Process & Cooling Rate
3. Microstructure
Chemical Composition Ranges of Cast Irons
Type of TC% Si% Mn% P% S%

Iron
Grey Iron 2.5 – 4.0 1.5 – 3.0 0.2 – 1.0 0.002 – 1.0 0.02 - 0.25
Malleable 2.2 - 2.9 0.9 – 1.9 0.15 – 1.2 0.02 – 0.2 0.02 – 0.2
(White)
Iron
Nodular 3.0 – 4.0 1.8 – 2.8 0.1 – 1.0 0.01 – 0.10 0.01 – 0.03
(SG) Iron
EFFECT OF CARBON & SILICON PERCENTAGES
Metal Stream Inoculation
IRON-CARBON-SILICON PHASE DIAGRAM
MICROSTRUCTURE OF GREY CAST IRON
Graphite Type & related factors
Temp of Eutectic Type of Structure Other factors
Solidification (Deg C)
1149 – 1115 Type A graphite & High C % & Ladle
Type B at lower inoculation favour
temperatures Type A flakes
1115 – 1075 Increasing Types D & Increased cooling rate

E as temperature & super heating favour
decreases Type D & E
1040 - 1065 Mottled & White Iron Increased cooling rate

and / or Type E flakes (chilling) favours
under cooling and
white iron
Grey Iron Grades & Properties
Grade Tensile Brinell
Strength (MPa) Hardness (HB)
FG150 150 130 -180
FG200 200 160-220
FG220 220 180-220
FG260 260 180-230
FG300 300 180-230
FG350 350 207-241
FG400 400 207-270
Other Properties of Grey Iron
Compressive Strength 3 to 5 times of UTS
Torsional Strength 1.2 to 1.4 times of UTS
Shear Strength 1.0 to 1.6 times of UTS
Modulus of Elasticity 100 to 145 GPa
Endurance Limit 35 to 50 % of UTS

Other Properties of Grey Iron
(contd..)
Wear Resistance Excellent to Sliding friction type of
wear, especially when lubricated
Machinability Good
Heat Resistance Good with respect to retention of

moderate strength; improved with
alloyed grey irons
Damping capacity Good
Corrosion resistance Applications like water mains &

other pipe applications
Ability to be heat treated Responds similar to steel
Effects of Alloying Elements
Alloying Chill Machinability Wear Hardness Strength
Element Propensity Resistance
Silicon Decreases Increases Decreases Decreases Decreases
Manganese ---- ----- ---- Increases Increases
Chromium Increases Decreases Increases Increases Increases
Molybdenum ---- ---- Increases Increases Increases
Nickel Decreases Increases Increases Increases Increases
Copper ---- Increases Increases Increases Increases
Vanadium Increases ---- ---- Increases ----

PERMANENT MOULD IRON
 Poured in Metal Moulds
 Hyper Eutectic Iron (CE > 4.3%)
 High Phosphorous Iron
 Excellent Machinability & good surface finish
 Typical Chemistry:
TC% 3.40 – 3.75 Si% 2.30 – 2.70
Mn% 0.40 – 0.80 P% 0.60 max
S% 0.12 max
 Microstructure: Type D flakes (Under cooled graphite)

Microstructure of Permanent Mould
Iron
Limitations:
 Low strength (125 MPa)

 Suitable for small solid castings only
 Castings must preferably with out core
 Castings must be annealed as a rule
 Castings prone for Hot Cracking
 Poor Wear Resistance & Heat discipation
Chemical Composition Ranges of Cast Irons
Type of TC% Si% Mn% P% S%

Iron
Grey Iron 2.5 – 4.0 1.5 – 3.0 0.2 – 1.0 0.002 – 1.0 0.02 - 0.25
Malleable 2.2 - 2.9 0.9 – 1.9 0.15 – 1.2 0.02 – 0.2 0.02 – 0.2
(White)
Iron
Nodular 3.0 – 4.0 1.8 – 2.8 0.1 – 1.0 0.01 – 0.10 0.01 – 0.03
(SG) Iron
Microstructure of SG Iron
Mechanical Properties of SG Iron
Grade Tensile 0.2% Proof Elongation (%) Hardness (HB)
Strength (MPa) Stress (MPa)
SG 350 / 22 350 220 22 <150
SG 400 / 18 400 250 18 130 – 180
SG 400 / 15 400 250 15 130 – 180
SG 450 / 10 450 310 10 160 – 210
SG 500 / 7 500 320 7 160 – 240
SG 600 / 3 600 370 3 190 – 270
SG 700 / 2 700 420 2 225 – 305
SG 800 / 2 800 480 2 245 – 335
SG 900 / 2 900 600 2 280 - 360
Other Properties of SG Iron
Machinability Superior to grey iron at
equivalent hardness
level & better than steel
Corrosion resistance Equivalent to grey iron &
superior to steel
Wear Resistance Equivalent to grey iron &
superior to steel
Ability to be heat treated Responds similar to
steel
CASTING DEFECTS
1. CRACK
2. CARBON FLOATATION (KISH)
3. SLAG & INCLUSIONS
4. SWELL
5. GAS DEFECT
6. HARD SPOTS / CHILLED AREAS
7. MIS RUNS / COLD SHUT
8. OPEN GRAIN STRUCTURE
9. SHORT POURED
10. ROUGH SURFACE
11. SHRINKAGE
12. POROSITY
13. PIN HOLES / BLOW HOLES
CRACK
INCLUSION DEFECT
GAS DEFECT
Blow Hole
HARD SPOTS / CHILLED AREAS
MISRUNS & COLD SHUT
OPEN GRAIN / POROSITY
SHRINKAGE
SHRINKAGE
Poor Microstructures in SG Iron

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METAL CASTING

(Metallurgy of Cast Iron)

BRAKES INDIA LIMITED

4. Melting & Pouring

2. Solidification Process & Cooling Rate

Type of TC% Si% Mn% P% S%

1115 – 1075 Increasing Types D & Increased cooling rate

1040 - 1065 Mottled & White Iron Increased cooling rate

Torsional Strength 1.2 to 1.4 times of UTS

Shear Strength 1.0 to 1.6 times of UTS

Modulus of Elasticity 100 to 145 GPa

Endurance Limit 35 to 50 % of UTS

Heat Resistance Good with respect to retention of

Damping capacity Good

Corrosion resistance Applications like water mains &

Manganese ---- ----- ---- Increases Increases

Chromium Increases Decreases Increases Increases Increases

Molybdenum ---- ---- Increases Increases Increases

Nickel Decreases Increases Increases Increases Increases

Copper ---- Increases Increases Increases Increases

Vanadium Increases ---- ---- Increases ----

 Microstructure: Type D flakes (Under cooled graphite)

 Low strength (125 MPa)

Type of TC% Si% Mn% P% S%

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