some notes on cast iron

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  • 8/8/2019 Some Notes on Cast Iron

    1/3

    R.Michael,PE 11/25/08

    SomenotesonCastIron/CastSteel(refChapter15BudinskiText):Overview:Ironcarbonwithmorethan2.11%(butusuallylessthan4%)carbonexperiencetheeutecticreaction

    during

    cooling

    and

    are

    known

    ascastirons

    .

    Class

    80

    50

    means

    tensile

    strength

    is

    80

    ksi

    and

    yield

    is

    50

    ksi. Castingprocessesinclude:sandcasting,investmentcasting,resinshell,etc.. (diecastingdifficult

    duetotemp).

    Advantagesinclude:

    Lowliquidustemperature Readilycasttoformusefulshapes Inexpensive Dampingproperties(goodforvibrations)

    Disadvantages(vs.

    machined):

    Tolerances(+/ 0.06typicalforascastdimensions) Surfacefinish(2501000intypicalforsandcast) Sizelimitations Shrinkage/draft Fatigue Brittle! (Elongationcanbequitelow,especiallyforGrayIron)

    3Maintypesofcastings:Gray(cheapest),Malleable,Ductile(most$$)1. GrayIronistheleastexpensiveandthemostcommonvariety. Typicalcarbonrangesare2.5%to4%. Themicrostructurehasmicroflakesofgraphitedispersedinamatrixofferrite. Flakes

    haveNOstrengthsotheyactasvoidsinthestructure. Thepointedendsoftheflakesactas

    notchesandcrackinitiationsites. Thereforethematerialisverybrittleandextremelylow

    ductility. Generallysoldbyclass(20,30,40upto80relatingtoitstensileorultimatestrength).

    Applicationsincludelargemachinerypartswithintricateshapes,generalpurposecastiron,

    sewerpipes(duetobettercorrosionresistancethanmoststeels)

    CharacteristicsofGrayIron:

    BHN=150 Elongation

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    R.Michael,PE 11/25/08

    Machinabilityisgood LOWCOST

    2. MalleableIroncoolingrateisincreased. Irregularspheroidalgraphiteparticlesinferriteorpearlitematrix. Applicationsincludeaxlehousings,pipefittings,brakedrums. 23%carbon,

    leastcommon,smallthinparts,canbeheattreated. Typicaldesignation325010means32500

    minyieldand10%elongationin2.

    CharacteristicsofMalleableIron:

    Elongationrangefrom1020%(i.e.malleable) BHN=110150 Modulus=24E6psi Tensilestrength=5056ksi Wearresistanceispoor Corrosionispoor Weldingisnotdoneheatoftheweldwouldruinmalleableproperties,onlyalongtermannealingwillrestorethem. Brazingcanbedoneat1700Fsoitisapreferred

    methodofrepair.

    Machinabilityisfair Castabilityisgood Moreshockresistantthanductileiron

    3. DuctileIronaddmagnesium(butonly1poundperton). Spheroidalgraphiteparticlesinferriteorpearlitematrix. Applicationsincludestructural(loadcarrying)parts,valves,pump

    bodies,crankshafts,gears.

    CharacteristicsDuctileIron:

    Strongestofthe3w/goodelongation Canbeheattreated Elongationfrom1020% BHN140300 Modulus=24E6psi Tensile=65150ksi Wearispoor Corrosionispoor Weldabilityispoorbutcanbeweldedwithnickelandironelectrodes Machinabilityisfairtoexcellent Castabilityisgoodtoexcellent Grade5(604018)=Su=60ksi,Sy=40ksi,%elongation=18% Grade1(1209002)

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    R.Michael,PE 11/25/08

    Alsohavegrade1,2,3,4 Material:DUCTILECASTIRONPERASTMA536GRADE3