This document discusses different types of cast iron including their composition, microstructure, properties, and applications. Grey cast iron contains graphite flakes and is inexpensive and easy to cast but brittle. White cast iron contains cementite and is very hard and brittle. Malleable cast iron is produced by heat treating white cast iron to form graphite nodules, giving it ductility. Spheroidal graphite cast iron contains spherical graphite nodules added with magnesium which improves its ductility. These cast irons are widely used in automotive and machinery applications due to their strength, castability and corrosion resistance.
this ppt is useful for understanding the concept of heat treatment process in steel.
it gives the idea about the various stages of heat treatment process in details
this ppt is useful for understanding the concept of heat treatment process in steel.
it gives the idea about the various stages of heat treatment process in details
various types of steel basically low carbon steels and alloy steels and how the alloying elements alter the various properties of steels , a detailed study & analysis
various types of steel basically low carbon steels and alloy steels and how the alloying elements alter the various properties of steels , a detailed study & analysis
CONTENTS
Ferrous metal
Type of ferrous metal
Pig iron
Cast iron
Working of cupola furance
Wrought iron
Steel
Stainless steel
Tools steel
Application of ferrous metal in automotive
Merits and Demerits of ferrous metal materials in automotive
'Iron seemeth a simple metal but in its nature are many mysteries’. Many, but not all,of these mysteries have been solved over the past three hundred years using the combined skill of the foundryman and the knowledge of the scientist to provide today's design engineer with a family of casting alloys that offer a virtually unique combination of low cost and engineering versatility.
The various combinations of low cost with castability , strength,
Machinability , hardness, wear resistance ,corrosion resistance, thermal conductivity and damping are unequalled among all casting alloys and It makes Cast Iron most widely used metal in engineering purpose .
What is cast iron, its process, properties and applicationsSearchnscore
Cast Iron is a ferrous alloy consisting of 2 to 4.5 % of Carbon, 0.5 to 3 % Silicon and small amount of Sulphur, Manganese and Phosphorous. It is generally cast as soft and strong or as hard and brittle iron. Usually made from Pig Iron, cast iron is formed by liquefying it, followed by pouring it in a mould and allowing it to cool.
I hope You all like it. I hope It is very beneficial for you all. I really thought that you all get enough knowledge from this presentation. This presentation is about materials and their classifications. After you read this presentation you knowledge is not as before.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
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Event Management System Vb Net Project Report.pdfKamal Acharya
In present era, the scopes of information technology growing with a very fast .We do not see any are untouched from this industry. The scope of information technology has become wider includes: Business and industry. Household Business, Communication, Education, Entertainment, Science, Medicine, Engineering, Distance Learning, Weather Forecasting. Carrier Searching and so on.
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Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Quality defects in TMT Bars, Possible causes and Potential Solutions.PrashantGoswami42
Maintaining high-quality standards in the production of TMT bars is crucial for ensuring structural integrity in construction. Addressing common defects through careful monitoring, standardized processes, and advanced technology can significantly improve the quality of TMT bars. Continuous training and adherence to quality control measures will also play a pivotal role in minimizing these defects.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
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2. COMPOSITION
• GREATER Than 2 % of carbon
• And also Small amounts of ALLOYING
ELEMENTS (Silicon, Sulphur, Manganese and
phosphorus).
• Cast irons are least expensive of all metals. Because
of plenty of resource available.
• Molten cast iron can be cast in to any complex
shapes and can be easily machined.
3. Composition of cast iron
• Carbon- 3.0 - 4.0%
• Silicon- 1.0% - 3.0%
• Manganese- 0.5% - 1.0%
• Sulphur and phosphorus- up to 1.0%
4. Cast iron Features
• Most widely used cheap metal
• Using casting methods we can produce
complicated shapes.( Easy Castability)
• Easy to machine.
• Good mechanical rigidity
• Good strength in compression
• Example --- spheroidal graphite iron are
strong , malleable cast irons are tough
7. Effect of composition elements on
Cast Iron
1. CARBON ( 3 – 4 %)
– Its present in the form of flakes of Graphite or
cementite ( i.e. brittle iron carbide)
Note
– When the cast iron having cementite Structure ---
results poor mechanical property.
– so for application point of view its require to have
carbon in the form of flakes of graphite.
8. 1.carbon
• If the iron having more
cementite, it looks silvery
white in the broken area.
(cementite is a silvery
white component)
• We call it as white cast iron
• If the iron having the
presence of flakes of
graphite the broken area
looks grey colour --- this is
called as grey cast iron
9. 2.Silicon
• This will some extent governs the form in
which carbon is present in cast iron.
• Silicon causes cementite (unstable), so that it
decomposes, thus releasing free graphite.
• Therefore high silicon iron tends to be a grey
iron, whilst a low silicon iron tends to be a
white iron.
10. 3.Sulphur
• Sulphur tends to stabilize cementite. Thus
helps to produce white iron.
• It gives brittleness property to iron, so we
have to keep this percentage as low.
11. 4.Manganese
• It gives toughness and strength to iron.
• It also control the harmful effect(Reactions)
of sulphur in metal
12. 5.Phosphorus
• It gives the property of fluidity (in melting)
for cast iron.
• It also give brittleness like sulphur. For that
we have minimize the percentage level.
15. FACTOR -2----------Heat treatment
• Prolonged heating (700 degree celcius) of white
cast iron causes graphitization to occur.
• The cementite decomposes into ferrite and
graphite during heating upto 700 degree celcius.
• This decomposed ferrite and cementite will
occupy more space than the original cementite.
16. FACTOR -3 -------------ELEMENTS
• SILICON
• Highest percentage of silicon in iron results
grey cast iron structure.
• Low percentage of silicon results white cast
iron.
17. TYPES OF CAST IRON
• Alloy cast iron --- ( Special Purpose)
1. Grey cast iron --- (General Purpose)
2. White cast iron – ( Heat and wear resistant)
3. Malleable cast iron-- ( Heat treated for
ductility)
4. Spheroidal Graphite cast iron – -(some
ductility)
18. GREY CAST IRON
• Least Expensensive
• Most commonly used
• It is an alloy of carbon and silicon with iron.
Composition:
• Carbon - 2.5 – 4 %
• Manganese – 0.4 – 1%
• Sulphur – 0.02 – 0.15%
• Silicon – 1 – 3 %
• Phosphorus – 0.15 – 1 %
• Remaining iron
19. Grey Cast iron
• Its Consists of graphite flakes ( like potato Chips)
• Graphite flakes are surrounded by alpha ferrite or
pearlite matrix.
• Because of graphite it shows grey in colour
• These flakes not having much strength --- this lead
to crack formation in edges and brittleness.
• The shape, size and distribution of flakes decide the
property of grey cast iron.
20. Characteristics
• Good strength
• Excellent compressive strength
• Good torsional and shear strengths
• Good corrosion resistance
• Excellent fluidity
• Good wear resistance
• Excellent Machinability
• Good vibration damping capacity
21. Applications of Grey cast iron
USED IN
• Machine tool bodies
• Engine blocks
• Engine cylinders
• Brake drums
• Crank shaft
• Pipe and pipe fittings
• Rolling mills
• Agriculture appliances
22. White cast iron
• White cast iron derives its names fact that fracture
surface has a white or silvery appearance
• White iron combined with cementite.
• The broken cast iron area looks like silvery white.
• When the cooling is fast ----- Carbon content
changes to cementite results white cast iron
24. Microstructure
• Cementite is caused by quick cooling of molten
iron it produces White cast iron is very hard and
brittle.
• RAPIDLY COOLED FROM THE CASTING
TEMPERATURE The Cast iron is termed as
“CHILLED IRON”
25. Characteristics of white cast iron
• Very hard and brittle
• Very high resistance to abrasion
• High tensile strength and low compressive
strength
• Cannot be machined because its hard.
26. Applications of white cast iron
• White cast iron is Used as a raw material in the
production of malleable cast iron.
• Used in rolls, wear plates(brakes), pump linings,
balls
• Used in outer surface for car wheels.
27. MALLEABLE CAST IRON and its
MICROSTRUCTURE
• By heat treating the white cast iron we get malleable cast
iron.
• For having malleable and ductile property .
• During heat treatment the cementite breaks into ferrite
and graphite nodules.
• The graphite nodules called as tempered carbon-- it
appears like popcorn.
• This rounded graphite permits a good combination of
strength and ductility
29. Types of Malleable irons
• Ferritic malleable iron,
• Pearlitic malleable iron
30. 1. Ferritic Malleable cast iron
• Here the white iron is heated up to upper critical
(815 ͦ
c to 1230 ͦ
c) temperature and hold it for
prolonged time, so carbon in the cementite
converts in to graphite.
• Subsequently the low cooling through the eutectoid
reaction results in a ferritic matrix
• Finally the cast iron obtained is called ferritic
malleable cast iron.
31. 2.Pearlitic Malleable cast iron
• The Rapid cooling of molten white cast iron in eutectoid
transformation range results pearlitic matrix.
• This is due in fast cooling , the carbon in austenite will have
not enough time to form additional graphite. So its retained
in the pearlite matrix
CHARACTERISTICS:
• It has higher strength and Lower ductility
32. CHARACTERISTICS OF
MALLEABLE CAST IRON
• Good ductility and malleability than grey cast iron
• High yield and tensile strength
• Its not brittle as grey cast iron
• High young’s modulus and low co-efficient of expansion
• Excellent impact strength
• Good wear resistant
• Good vibration damping capacity
• Excellent machinability
33. Applications of Malleable cast iron
USED IN
• Due to their Castability , machinability and shock
resistance it Most widely used in automobile industries
• In brake shoe
• Wheel hub
• Axle housing
• Transmission gears
• Connecting rod
• Levers
• Pipe fittings
• Agriculture machineries and parts
• Switch gear equipments
34. SPHEROIDAL GRAPHITE
OR
NODULAR CAST IRON
• Its also called ductility cast iron
• In the grey cast iron they are adding magnesium
or cerium
• This magnesium converts flakes graphite into
perfect nodules.
• This perfect nodules improves the ductility of
the cast iron. (nearly 20 % increased)
35. Characteristics of
spheroidal graphite cast iron
• Excellent ductility
• Good toughness than grey cast iron
• Good fatigue strength
• Good impact strength
• Good hardness
• High modulus of elasticity
• Good wear resistance
• Good machinability
• Good oxidation resistant
• Excellent castability
36. Applications
Used in
• Valves
• Pump bodies
• Crank shaft ,
• Pinion and gears
• Rollers
• Rocker arm
• Flanges
• Power transmission equipments
• Earth moving machineries