some notes on cast iron
TRANSCRIPT
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8/8/2019 Some Notes on Cast Iron
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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