Difference of gray cast iron and ductile cast ironSearchnscore
Gray cast iron and ductile cast iron basically differ in the type or structure of the carbon contained in them. The making of cast iron is principally, liquefaction of iron by heating, followed by cooling and hence solidification. In case of gray cast iron, the making involves the addition of carbon in the heated beds where the liquefaction of base iron takes place. Whereas, for ductile cast iron, carbon as well as magnesium are added in the hot beds. These added components bind with the solid (cast iron) which is formed thereafter.
'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.
Difference of gray cast iron and ductile cast ironSearchnscore
Gray cast iron and ductile cast iron basically differ in the type or structure of the carbon contained in them. The making of cast iron is principally, liquefaction of iron by heating, followed by cooling and hence solidification. In case of gray cast iron, the making involves the addition of carbon in the heated beds where the liquefaction of base iron takes place. Whereas, for ductile cast iron, carbon as well as magnesium are added in the hot beds. These added components bind with the solid (cast iron) which is formed thereafter.
'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.
This slide show accompanies the learner guide "Mechanical Technology Grade 10" by Charles Goodwin, Andre Lategan & Daniel Meyer, published by Future Managers Pty Ltd. For more information visit our website www.futuremanagers.net
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
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.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfKamal Acharya
The College Bus Management system is completely developed by Visual Basic .NET Version. The application is connect with most secured database language MS SQL Server. The application is develop by using best combination of front-end and back-end languages. The application is totally design like flat user interface. This flat user interface is more attractive user interface in 2017. The application is gives more important to the system functionality. The application is to manage the student’s details, driver’s details, bus details, bus route details, bus fees details and more. The application has only one unit for admin. The admin can manage the entire application. The admin can login into the application by using username and password of the admin. The application is develop for big and small colleges. It is more user friendly for non-computer person. Even they can easily learn how to manage the application within hours. The application is more secure by the admin. The system will give an effective output for the VB.Net and SQL Server given as input to the system. The compiled java program given as input to the system, after scanning the program will generate different reports. The application generates the report for users. The admin can view and download the report of the data. The application deliver the excel format reports. Because, excel formatted reports is very easy to understand the income and expense of the college bus. This application is mainly develop for windows operating system users. In 2017, 73% of people enterprises are using windows operating system. So the application will easily install for all the windows operating system users. The application-developed size is very low. The application consumes very low space in disk. Therefore, the user can allocate very minimum local disk space for this application.
Automobile Management System Project Report.pdfKamal Acharya
The proposed project is developed to manage the automobile in the automobile dealer company. The main module in this project is login, automobile management, customer management, sales, complaints and reports. The first module is the login. The automobile showroom owner should login to the project for usage. The username and password are verified and if it is correct, next form opens. If the username and password are not correct, it shows the error message.
When a customer search for a automobile, if the automobile is available, they will be taken to a page that shows the details of the automobile including automobile name, automobile ID, quantity, price etc. “Automobile Management System” is useful for maintaining automobiles, customers effectively and hence helps for establishing good relation between customer and automobile organization. It contains various customized modules for effectively maintaining automobiles and stock information accurately and safely.
When the automobile is sold to the customer, stock will be reduced automatically. When a new purchase is made, stock will be increased automatically. While selecting automobiles for sale, the proposed software will automatically check for total number of available stock of that particular item, if the total stock of that particular item is less than 5, software will notify the user to purchase the particular item.
Also when the user tries to sale items which are not in stock, the system will prompt the user that the stock is not enough. Customers of this system can search for a automobile; can purchase a automobile easily by selecting fast. On the other hand the stock of automobiles can be maintained perfectly by the automobile shop manager overcoming the drawbacks of existing system.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
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.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Courier management system project report.pdfKamal Acharya
It is now-a-days very important for the people to send or receive articles like imported furniture, electronic items, gifts, business goods and the like. People depend vastly on different transport systems which mostly use the manual way of receiving and delivering the articles. There is no way to track the articles till they are received and there is no way to let the customer know what happened in transit, once he booked some articles. In such a situation, we need a system which completely computerizes the cargo activities including time to time tracking of the articles sent. This need is fulfilled by Courier Management System software which is online software for the cargo management people that enables them to receive the goods from a source and send them to a required destination and track their status from time to time.
2. • Most widely used structural metals due to their wide
range of mechanical, physical and chemical properties.
• Contains iron as their base metal.
• Ferrous alloys are produced as
o Sheet steels for automobiles and containers
o Plates for boilers, ships and bridges
o Structural members – I-beam, bar products, crankshafts, railroad rails.
o Gears, tools, dies and molds
o Fasteners – bolts, rivets and nuts
3. Iron-carbon alloy consist 0.005% C called pure iron.
Characteristics : soft, ductile, low strength
Used in : magnetic device and enameling steels.
Invention of blast furnace made production of iron in large quantities.
3 basic materials used in iron production :
◦ Iron ore
◦ Limestone
◦ Coke
Is one of the most abundant element in world, making up about
5% of the earth’s crust ( in the form of various ores)
4 compositions of iron ores :
Magnetite
Hematite ( an iron-oxide mineral)
Limonite (an iron-oxide containing water)
Siderite (Carbonate iron)
4. Magnetide
Category : Oxide mineral
Colour : black, gray with brownish tint in reflected sun
Hardness : 5 – 6
Hematite
Category : oxide mineral
Colour : metallic gray, dull to bright red
Hardness : 5.5 – 6.5
Limonite
Category : amorphous, mineraloid
Colour : varoius shades of brown and yellow
Hardness : 4 – 5.5
Siderite ( carbonate iron)
Category : carbonte mineral
Colour : yellow, gray, brown, black and sometimes
nearly colourless
Hardness : 3.75 – 4.25
5. Iron ore processing
◦ Crushing into fine particles
◦ Removal of impurities by various means ( such as magnetic
separation)
◦ Pellets, balls or briquettes formation by using water and
binders. ( some iron-rich ores used directly without pelletizing)
6. Obtained from a soft coal rich in volatile hydrocarbons and tarry
matter that are heated in vertical oven and then cooled with water
Functions of coke :
◦ Generating the high level of heat required for the chemical
reactions in iron making to take place.
◦ Producing carbon monoxide ( a reducing gas to removes
oxygen) which is used to reduce iron oxide to iron.
7. Function of limestone:
◦ Remove impurities from the molten iron
◦ Reacts chemically with impurities, acting as flux (flow as
fluid) that causes the impurities to melt at a low
temperature.
◦ Combine with impurities to form slag, which is light, floats
over the molten metal and is removed
8.
9. Iron ore, limestone and coke added into the blast furnace. (charging
process)
The charge mixture is melted in a reaction at 1650˚C, with the air preheated
(to produce sufficient high temperature) to about 1100 ˚C and blasted into
furnace through nozzles (tuyeres)
Oxygen reacts with carbon to produce carbon monoxide.
Produced carbon monoxide reacts with iron oxide and reduces it to iron.
The molten metal accumulates at the bottom of the blast furnace, while the
impurities floats to the top of the metal.
The molten metal in tapped into ladle cars.
The molten metal at this stage is called pig iron or hot metal.
Composition of pig iron : 4%C, 1.5%Si, 1%Mn, 0.04%S, 0.4%P and the rest
is pure iron.
10. an alloy of iron
Carbon content between 0.002% and 2.1% by
weight
Used in : buildings, infrastructure, tools, ships,
automobiles, machines and weapons
Steel can be produced by
Basic Oxygen Furnace
Electric Arc Furnace
Vacuum Furnace
11. Is the fastest steel making process
Processes in BOF :
a) Molten pig iron and scrap charged into vessel
b) Pure oxygen in blown into furnace through lance(long tube)
c) Fluxing agents (lime) are added through a chute
d) Oxygen refines the molten metal by an oxidation process in which iron oxide is
produced
e) The oxide reacts with the carbon in the molten metal, producing carbon
monoxide and carbon dioxide.
f) The furnace is tapped by tilting
g) The slag is removed by tilting the furnace in opposite direction
12. Source of heat : continuous electric arc formed between the
electrodes and the charged metal. (temperature generated :
1925˚C)
Steel scrap, a small amount of carbon and limestone dropped
into the electric furnace through the open roof
Roof closed and electrodes are lowered
Metal melts after around 2 hours the power has been turned on
Current turned off, and the electrodes raised.
Furnace is tilted and the molten metal is poured into a ladle
(used for transferring and pouring molten metal)
13. Carbon composition in iron, steel and cast iron :
Pure iron : up to 0.008% C
Steels : 0.008 - 2.14% C
Cast Iron : 2.14 - 6.67% C ( most cast iron contain less than 4.5% C)
Pure iron experiences 2 changes in crystal structure before it melts at a
temperature of 1537˚C.
At rt, the stable form called ferrite(α iron) has BCC crystal structure.
Ferrite undergoes polymorphic transformation to FCC austenite (γ iron)
at around 912 ˚C.
At 1394 ˚C, austenite reverts back to a BCC phase known as δ ferrite
which finally melts at 1537 ˚C
16. IRON-IRON CARBIDE PHASE DIAGRAM
Fe-C liquid solution
•C is an interstitial impurity in Fe.
•It forms a solid solution with α, γ, δ phases of iron
•Maximum solubility in BCC α-ferrite is limited
(max.0.022 wt% at 727 °C) - BCC has relatively
small interstitial positions
•Maximum solubility in FCC austenite is 2.14 wt% at
1147 °C - FCC has larger interstitial positions
17. γ-austenite - solid solution of C in FCC Fe
• The maximum solubility of C is 2.14 wt % at 1148 °C
• Transforms to BCC δ-ferrite at 1394 °C
• Is not stable below the eutectoid temperature (727° C)
unless cooled rapidly
α-ferrite - solid solution of C in BCC Fe
• Stable form of iron at room temperature.
• The maximum solubility of C is 0.022 wt% at 727˚C.
• Transforms to FCC γ-austenite at 912 °C
•Soft, magnetic at temp below 768 ˚C
δ-ferrite solid solution of C in BCC Fe
• The same structure as α-ferrite
• Stable only at high T, above 1394 °C
• Melts at 1538 °C
727˚C
18. Fe3C (iron carbide or
cementite)
• This intermetallic compound is
metastable
• it remains as a compound
indefinitely at room T, but
decomposes (very slowly, within
several years) into α-Fe and C
(graphite)if heated at 650-700°C
• hard, brittle
Pearlite
•When alloy of eutectoid composition
(0.76 wt % C) is
cooled slowly it forms perlite,
• a lamellar or layered
structure of two phases: α-ferrite and
cementite (Fe3C)
•Prop intermediate between
soft,ductile ferrite and the hard, brittle
cementite
19. Hypoeutectoid
At about 875°C microstructure
consist entirely of grain of the γ
phase
At about 775°C, small α particles
will form along the original γ grain
boundaries
At this point, α particles grown
larger.
As temperature lowered below
eutectoid , point d, all γ phase
transform to pearlite, but there is
no change in α phase.
(pearlite is not a phase!!)
20. Types of carbon steels Carbon content (%) Application
Low-carbon Steel
(Mild Steel)
Less than 0.30% Bolts , nuts, sheets, plate, tubes and for
machine components that do not require
high strength.
Medium-carbon Steel 0.30 – 0.60% Machinery. Automotive, agricultural
equipment parts, railroad equipment and
parts for metalworking machinery.
High-carbon Steel More than 0.60% Cutting tools, cable, springs, cutlery
Remember : The higher the carbon content of the steel, the higher is its
hardness, strength and wear resistance
21. A small increase in carbon has significant impact on
properties of the steel. As Carbon increases the steel:
◦ becomes more expensive to produce and less ductile, more
brittle
◦ becomes harder and less machinable and harder to weld
◦ has higher tensile strength and a lower melting point
22.
23. Alloy Steels
A ferrous alloy that contains alloying elements ( other than C and
residual amounts of Mn, Si, S and P).
These alloying elements are added to improve mechanical and
corrosion resistance properties in steel.
Characteristics : high strength, hardness, creep and fatigue
resistance
Alloy steels are widely used in
o Construction and transportation industry for their high strength.
24. ELEMENT INFLUENCE
Manganese (Mg) Form stable carbide and increasing hardenability.
Silicon (Si) Fluidity and heat resistant.
Copper (Cu) Reduce rusting
Aluminum (Al) Reducing grain size which adds toughness, increase machinability
Boron (B) Increasing hardenability
Chromium (Cr) Stabilize α, Corrosion resistant, heat resistant and increases hardenability
Cobalt (Co) Permanent magnet
Molybdenum (Mo) Increase strength and hardenability.
Nickel (Ni) Stabilize , Grain refiner, corrosion,heat resistant, increase toughness,
strength and impact resistance
Tungsten (W) Stabilize , form very hard carbide, increase toughness and strength and
impact resistance
Vanadium (V) Increase hardenability, increase toughness and strength and impact
resistance
25. Steel alloys Main class Contents (%) Applications
Structural steel Carbon and low
alloy
0.55C, 0.70Mn Gears, cylinders and machine-tool
parts requiring resistant to wear.
Corrosion
resistant steel
Stainless steel 0.04C, 0.45Mn,
14.00Cr
Kitchen tools (forks and spoons)
Heat resistant
steel
Heat resisting
steel
0.15C, 20.00Cr,
25.00Ni
Conveyers chair and skids, heat
treatment box, recuperator valve, and
other furnace part.
Tool and die
steel
Alloy tool steel 0.35C, 1.00Si,
5.00Cr, 1.50Mo,
0.40V, 1.35W
Extrusion die, mandrels and noses for
aluminum and copper alloy. Hot
forming, piercing, gripping and
heading tools.
Magnetic steel Hard magnetic
material
1.88Ni Electric motor
26.
27. 27
Cast Irons
•Composed of iron, carbon (2.1% ~ 4.5%), and silicon (1% ~
3.5%) – ferrous alloy.
•Cast irons classification according to the solidification
morphology from the eutectic temperature are :
o Gray cast iron or gray iron
o White cast iron
o Black Malleable cast iron
o White Malleable cast iron
o Nodular Cast Iron ( Ductile Cast Iron)
28.
29. Gray Cast Iron
•Composition of 2.5% to 4% carbon and 1% to 3%) silicon.
•Graphite exists largely in the form of flakes.
•Properties of gray iron :
o Low (negligible) ductility
o Weak in tension
o Strong in compression
o Good vibration damping
•Products from gray iron include automotive engine blocks and heads,
motor housings, and machine tool bases.
30. Nodular Cast Iron (Ductile Iron)
• This is an iron with the composition of gray iron in which the molten metal
is chemically( added with magnesium) treated before pouring to cause the
formation of graphite spheroids rather than flakes.
• shock resistant , stronger
and more ductile iron.
• Applications include machinery components requiring high strength and
good wear resistance.
31. White Cast Iron
•Due to large amounts of iron carbide presence, the structure of
white iron is very hard, wear resistance and brittle.
•It is obtained either by cooling gray iron rapidly or by adjusting the
composition by keeping the carbon and silicon content low.
•Products from white iron include railway brake shoes.
32. Malleable Iron
•Obtained by annealing white iron in an atmosphere of carbon monoxide and
carbon dioxide, between 800oC~900oC, for several hours.
•2 types of malleable iron :
•Pearlite malleable(white malleable) – upon fast cooling of white iron
•Ferrite malleable (black malleable) – upon slow cooling of white iron
•The structure has good ductility, strength and shock resistance.
•Typical products include pipe fittings and flanges, railroad equipment parts.
33. Cast Irons Structure Properties Application
Gray Cast Iron Ferrite and Pearlite
with free graphite
flakes
High strength and
hardness.
Pipe, engine blocks,
machine tools
White Cast Iron Pearlite and Cementite Low Machinability and
Brittle
Wear resistant
component such as
rolls for steel
making.
Black
Malleable
Ferrite and fine Carbon
partical
Higher in
machinability, lower
melting point and
higher fluidity.
Hardware, pipe
fitting
White
Malleable
Ferritic structure near
the surface and
Pearlitic structure near
the center.
Higher in
machinability, lower
melting point and
higher fluidity. (Higher
hardness).
Railroad equipment,
couplings
Nodular Cast
Iron
Ferrite and Pearlite
with Spheroidal
Graphite.
Higher strength, reduce
fatigue failure
Pipe, crankshaft,
gears, rolls for
rolling mills
34. Process Variable Condition Influences
Cooling rate
Slow Produced ferrite and large flakes of graphite together with fine flakes
of graphite formed by the decomposition of the cementite after
solidification.
Moderate The structure will consist of flake graphite in a matrix which is
entirely pearlitic.
Fast (Chilling) The structure will consist of pearlite and cementite.
Carbon content
Low to high High quantity of graphite will be produced in cast iron by increasing
the carbon content.
Cross-section
size
Thin to thick Thin cross section will make the solidification rate faster then the
thicker one. Longer solidification time will cause the differences of
mechanical properties and shrinkage effect.
Element content
Silicon Affect the properties in the different of percent in content.
Ferritic gray cast iron: with 3% silicon
Ferritic/pearlitic cast iron: with 2% silicon
Pearlitic cast iron: with 1.5% silicon
Sulphur Stabilizing the cementite and preventing the formation of flakes
graphite. Thus, sulphur harden the cast iron.
Manganese Remove the sulphur. Thus, softens the cast iron.
Phosphorus High phosphorus content produced a great fluidity. Cause hardness
and embrittlement.