1. Presentation on Cast Iron Material Science and Metallurgy (2131904) Guided by Mr. Pankaj Sharma Submitted by: (130770119001)/3 rd ME A (130770119002)/3 rd ME A (130770119003)/3 rd ME A (130770119004)/3 rd ME A SILVER OAK COLLEGE OF ENGINEERING

3. ORE Blast Furnace PIG IRON CUPOLA FURNACE CAST IRON

4. CAST IRONS Grey CI Ductile CI White CI Malleable CI Alloy CI Good castability  C > 2.4% Malleabilize Stress concentration at flake tips avoided

5.  Gray cast iron is characterized by its graphitic microstructure, which causes fractures of the material to have a gray appearance.  Most cast irons have a chemical composition of 2.5 to 4.0% carbon, 1 to 3% silicon, and the remainder is iron.  Gray cast iron has less tensile strength and shock resistance than steel.  Its compressive strength is comparable to low and medium carbon steel.

6.  A low cost material that can be used for many purposes

7. Characteristics: 1) Gray Iron basically is an alloy of carbon and silicon with iron. 2) It is readily cast into a desired shape in a sand mould. 3) It contains 2.5-3.8% C, 1.1-2.8%Si, 0.4-1%Mn, 0.15% P and 0.10% S. 4) It is marked by the presence of flakes of graphite in a matrix of ferrite, pearlite and austenite. 5) Graphite flakes occupy about 10% of the metal volume 6) Length of flakes may vary from 0.05 mm to 0.1 mm 7) When fractured, a bar of Gray Cast Iron gives gray appearance.

8. 8) Gray iron possesses lowest melting point of the ferrous alloys. 9) G.C.I. possesses high fluidity and hence it can be cast into complex shapes and thin sections. 10) It possesses machinability better than steel. 11) It has higher resistance to wear 12) It possesses high vibration damping capacity 13) G.C.I. has a solidification range of 2400 – 2000°F 14) It associates low cost combined with hardness and rigidity.

9. 1) Machine tools and structures (bed, frame and details) 2) Gas or water pipes for underground purpose 3) Manhole covers 4) Cylinder blocks and heads for I.C. engines 5) Tunnel segments 6) Frames for electric motors 7) Ingot moulds 8) Sanitary Wares 9) Piston Rings

10. Nodular (ductile) iron: the dark graphite nodules are surrounded by an -ferrite matrix.

11.  Nodular or ductile cast iron. Tiny amounts of magnesium or cerium added to these alloys slow down the growth of graphite precipitates by bonding to the edges of the graphite planes.  Along with careful control of other elements and timing, this allows the carbon to separate as spheroidal particles as the material solidifies.  The properties are similar to malleable iron, but parts can be cast with larger sections.

12. 1) Paper industries machinery 2) I. C. engines 3) Power transmissions equipment 4) Farm implements and tractors 5) Earth moving machinery 6) Valves and fittings 7) Steel mills rolls and mill equipment 8) Pipes 9) Pumps and compressors

13. White iron: the light cementite regions are surrounded by pearlite, which has the ferrite–cementite layered structure.

14.  With a lower silicon content and faster cooling, the carbon in white cast iron precipitates out of the melt as the metastable phase cementite, Fe3C, rather than graphite.  It is difficult to cool thick castings fast enough to solidify the melt as white cast iron all the way through.  However, rapid cooling can be used to solidify a shell of white cast iron, after which the remainder cools more slowly to form a core of grey cast iron.

15.  The resulting casting, called a chilled casting, has the benefits of a hard surface and a somewhat tougher interior.  White iron is too brittle for use in many structural components, but with good hardness and abrasion resistance and relatively low cost.

16. 1) For producing malleable iron casting 2) For manufacturing those component parts which require a hard and abrasion resistant material.

17. Malleable iron: dark graphite rosettes (temper carbon) in an –ferrite matrix

18. Characteristics: 1) M.C.I. is one which can be hammered and rolled to obtain different shapes. 2) M.C.I. is obtained from the hard and brittle white iron through a controlled heat conversion process. 3) (i) A ferritic M.C.I. has Ferrite matrix (ii) A pearlitic M.C.I. has pearlite matrix (iii) An alloy M.C.I. contains chromium and nickel and possess high strength and low corrosion resistance. 4)M.C.I. possess high yield strength. 5)High young’s modulus and low coefficient of Thermal expansion.

19. Malleable Iron Ferritic Matrix Pearlitic Matrix Fully Malleabilized Iron  Complete Ferritizing Anneal 10  m Partially Malleabilized Iron  Incomplete Ferritizing Anneal Pearlite (grey) Graphite (black) Ferrite (White) Graphite (black)

20. 1) Automotive Industry 2) Rail Road 3) Agricultural implements 4) Electrical line Hardware 5) Conveyor chain links 6) Gear case 7) Universal joint yoke 8) Rear axle banjo housing 9) Automotive crankshaft.