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Microstructural Characterization of grey cast iron

Conference Paper · June 2013

DOI: 10.13140/RG.2.1.5019.6880

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Arul Mozhi Varman J P

The University of Queensland
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 Microstructural Characterization of Grey Iron
JP Arul Mozhi Varman1
1
Research Scholar, Department of Metallurgical and Materials Engineering,
Indian Institute of Technology*-Madras, Chennai - 600 036, India
e-mail: aruliitm2010@gmail.com.

Keywords: Cast iron, microstructure, phases, characteruzation, etc.

ABSTRACT

Typical grey cast iron of DIN GG 25 with a pearlitic matrix was developed for high wear resistance applications. This grey
iron was cast by shell casting process by optimizing the process parameters. Experiments were done with ELKEM and
GARGI based inoculation to evaluate the microshrinkage and graphite flake distribution, and an unique etching method is
developed for differentiating the steadite and ferrite microconstituents precisely. Characterization was done by Optical
emission spectrometer, light microscope, and mechanical testing. This paper depicts scientific approach to develop the grey
cast iron material in a shell casting process and also to quantify the microconstituents.

INTRODUCTION

Typical pearlitic grey cast iron was developed for high wear resistance applications. Shell casting route was followed because
of its outstanding surface finish and greater dimensional stability than the green sand molding process. Also, this reduces
machining operation and product cost by contributing to energy saving. As a result, shell casting enables the foundry industry
to operate in an economical and efficient way to get benefited.
Shell casting involves preparation of shell mold which is made up of thermosetting resin binders such as phenol
formaldehyde resin in a quartz sand mixture. This mixture will be poured on a heated metal pattern where resin gets cured
and results in good bonding between sand grains and forms a sturdy shell which replicates the casting geometry of one half of
it.. Similarly the another part is made and core can be inserted if required for hollow section in the shell mold, and fastening
will be done for rigidness so that the shell would not get collapsed at the time of pouring.
The microstructure(5) of the casting depends on the chemical composition, carbon equivalent, type and method of inoculant,
degree of superheating and supercooling and the pouring temperature.

MICROSTRUCTURAL CHARACTERIZATION

The difficulty in the metallography of grey cast iron lies in the differentiation of ferrite and iron phosphide eutectic (steadite)
microconstituents using normal etchants like nital & picral and both these phases appears as bright under normal light
microscope. Hence, it is difficult to find out relative amounts of phases, either photo micrographically or using an image
analysis software. In general, the samples are etched with 2% to 3% nital for quantification of ferrite, steadite, pearlite, and
carbides under light microscope. This method of inspection requires high skill to differentiate the ferrite and iron-phosphide
eutectic (steadite) microconstituents and also sometimes it leads to misinterpretation.

*Project supported by WABCO-INDIA LIMITED (Chennai) under the guidance of P.Kannan, Head, Six Sigma & Quality
Hence, a new etchant, Selenic(3) was developed for differentiating the ferrite and steadite microconstituents precisely under
light microscope. The Selenic etchant reagent is prepared as per the following proportionate.
  

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