IS : 4771 - 1985 ( Reaffirmed 2005 )

Indian Standard
SPECIFICATION FOR ABRASION-RESISTANT IRON CASTINGS (

Second Revision 1
First Reprint JULY 1991

UDC

669*11-14

: 669.018125

Q Copyrfght 1986
BUREAU
MANAK

OF
BHAVAN,

INDIAN
9 BAHADUR NEW DELHI

STANDARDS SHAH ZAFAR

MARG

110002

Gr 3

Jdy

1986

IS :4771- 1985

Indian Standard
SPECIFICATION FOR ABRASION-RESISTANT IRON CASTINGS (

Second Revision)
SMDC 9
Representing Ductron Castings Ltd, Hyderabad

Pig Iron and Cast Iron Sectional Committee,

Chumnqn
SHRI

B. G. SAsTRY Mmbrrs

SHRI M. S. DALVI ( Alternate to Shri B. G. Sastry ) Mechanical Engineering Research & Development SHSI P. K. ARORA Organization ( CMERI ), Ludhiana Indian Iron & Steel Co Ltd, Burnpur !&RI R. K. BA~ERJEE SHRI R. DAYAL (Altern&) Visvesvarya Iron & Steel Ltd, Bhadravati SHRI K. B. D. BPZRIAH SHRI B. S. UMAPATEY ( Allcrnate ) National Test House, Calcutta SHRI A. M. BIEWAS SHRI K. L. BARVI ( Alfernate ) Indian Institute of Technology, Kharagpur PROF .A.K. CHAKBABORTY Indian Register of Shipping, Bombay SHRI S. CHANDRA SRRI H. K. TANEJA ( Alternate ) CHEMIST & METALLURGIST, E.As- Ministry of Railways TEEN RAILWAYJAMALPUR Hindustan Machine Tools Ltd, Bangalore SHRI P. P. CROPRA SHRI H. S. RAMACHANDRA LAbmate I ) SHRI P. RAMPRASAD ( Alter&e 11 ) I SHRI V. N. VENKATESAN ( Alternatc III ) SHRI A. SHANTARAU ( Alternate IV ) Mercury Iron & Steel Co, Bombay SHRI S. H. COMYISSARIAT Iron 82 Steel Control, Calcutta SHRI B. K. DUTTA Sandur Manganese & Iron Ores Ltd, Mysore SHRI S. Y. GHORPADE Institute of Indian Foundrymen, Calcutta &ax K. N. KINKAX SHRI B. P. Snva~ ( Alternate ) Djrectorate General of Supplies & Disposals ( InsSARI V. B. KEANNA pection Wing ), New D&hi SHRI T. N. UBOVEJA ( Ahrnata ) Electrosteel Castings Ltd, Calcutta SHBI B. V. Ln SH~I S. B. .%NQTJ~TA( Ahmats ) ( C&nud @ f&vi& 1986 on paga 2 )

Thii publication is protected under the Indiun Co&ri&f Act ( XIV of 1957 ) and reproduction whole or in part by any means except with written permission of the in publiier shall be deamd to be an intrigement of copyright under the said Act.

BUREAU OF INDIAN STANDARDS

IS I 4771 - 1985 ( Conhued from pap1 )

&ficmbetJ
SHRIM.h'fOHAN

i?@riscniing Heavy Engineering Corporation Forge Plant ), Ranchi Ltd ( Foundry

SIIHI I. ALI ( Alfcrnals) Tata Engineering & Locomotive Co Ltd, Jamshedpur DR P. S. PATTIBAL SH~I U. M. NAIXAR ( ANcrnafc ) Steel Authority of India Ltd ( Bhilai Steel Plant ), Da G. RAI Bhilai New Standard Engineering Co Ltd, Bombay SIIRI M. M. RAJU SHRI P. M. MUKIIERJEE ( Altcrnnfe 1 Steel Authority of India Ltd ( Bhilai Steel Plant ), SHRI S. V. RAJWADE Bhilai Saar R. R. SARIN ( Alternak ) Shah Malleable Caatinga Ltd. Bombay SHRI C. P. RAMAMURTRY Ennore Foundries Ltd, Madras SHRI D. VASUDEVA RAN Steel cau,r.",rL, ,d- T..saL b&& A...,.,.,:,., I *.""saF..a P.___ D n m .^-^-_ \ la,...-Lair c*n-I "..zV. V. II&Uaa 0uIIci r. r. _bBTU Plant ), Roulbta SHRI S. CHOWBEY ( Alternate) Miniatrr of Railways REPRESENTATIVE Bhagwati Spherocast Ltd., Hyderabad REPREYENTATIVII Development CornmissIoner ( Small Scale InREPREB~NTATIVE dustries ), New Delhi Maruti Udyog Ltd, Gurgaon REPRESENTATIVE Bokaro Steel Plant, Bokaro SH~I A. K. SAHA SIIRI B. P. SINQH ( Aftermale ) Directorate General of Technical Developnrent, SHRI u. SEN New Delhi Joint Plant Committee, Calcutta SHRI K.R. SENCWPTA Kesoram Spun Piper 81 Foundriea, Calcutta SERI P. J. SHENOY SBSI S. C. NARSABIA ( Alfwttefc I Tata Iron 6 Steel Co Ltd, Jarnalntdpur SHUI I. s. P. SIIIIEY SERI T. SIJDHAXAB ( &Umalr ) Ministry of Defence ( DGOF ) SHRI M. P. SINIXi Fertilizer Corporation of India Ltd, Sindri SRRI R. It. SINHA Walchandnagar Indwtry Ltd, Satara SARI P. S. N. Svaoarm Southern Alloy Foundries Pvt Ltd, Madras SHRI S. THIA~HARAJAN SHRI A. THAN~AVIILU ( Al&nab ) Metallurgical Laboratory ( CSIR ), National DR S. K. TIWARY Jamshcdpur Fed?:&,;! Engineering Indmtrier of India, SHRI V. N. UPADRAYA

e
SHRI H. L. BHARDWAJ ( Ahrnatr ) Bharat Heavy Electricals Ltd DR G. VENKATARX~AN SHRI A. K. MITTAL ( Al&n& ) Director General, IS1 ( Ex-o&i0 M~u SHRI K. RAOIIAVENDRAN, Director ( Strut & Met ) ;rcncllIry SHRI S. S. SETHI Joint Director ( Metals ), ISI

( Contintud es m#

10 )

IS r-4771- 1985 Indian

S&m&d

SPECIFiCATIUN FOR ABRASION-RESISTANT IRON CASTINGS (

Second RevisionJ
0.

FOJkEWO_R

) was adopted by the Indian 0.1 This Indian Standard ( Second Revis Standards Institution on 26 December 198 ,after the draft finalized by iang the Pig Iron and Cast Iron Sectional Committee had been approved by the Structural and Metals Division Council. 0.2 This standard. was first published in 1968 and revised in 1972. As a result of further experience gained during these years, the standard has been revised again incorporating provisions in regard to &chemical analysis and making the hardness values mandatory. 0.3 Iron castings included in this standard have good resistance to both low- and high-stress abrasion in the application of mining, millin& earth moving and manufacturing industries. These iron castings are expected to have a microstructure of carbides in a metrix of martensite, bainits and austenite and essentially free from. pearlite. They are expected to be freefrom graphite except where its presence is intentionally desired for specific applications. 0.3.1 Attempts are being made to develop commercially nickel and molybdenum-free abrasion-resistant iron castings which may be included in this standard at a later date. 0.4 For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS : 2-1960*. The number of significant places re\Eainedin the rounded off value should be the same as that of the specified value in this standard. 1. SCOPE 1.1 This castings. standard covers the requirements of abrasion-resistant iron

*Rules for rounding off numerical values ( rcuissd ).

IS t 4771 - 1385
1.2 Iron excluded castings consisting from this standard essentially irrespective of iron carbide of alloy content. and pearlite are

2. GRADE 2.1 Abrasion-resistant 7-j@ la 1b Nickel-chromium iron Nickel-chromium iron iron castings Chemical Name martensitic martensitic white white shall be of the following grades: Designation NiLCr NiLCr NiHCr NiHCr NiHCr wl-Qe CrMoHC CrMoLC HCrNi HCr 301500, 34/550 27/500, 30/550, 34/600 34,500, 28/500 27/4dO, 27/400

2 3

Chromium-molybdenum iron High-chromium

martensitic

white iron

NOTE 1 - The grades under Type 1 are designated by the letters NiLCr and NiHCr to represent nickel containing low-chromium and nickel-csntaining high-chromium iron respectively. The grades under Type 2 are designated by the letters CrMoHC and CrMoLC to represent high carbon and low carbon varieties of chromiummolybdenum irons respectively. The grades under Type 3 are designated by the letters HCrNi and HCr to represent nickel containii and nickel-free high-chromium white irons respectively.
types are further designated by two digits to represent mean N~TB~ -These arbon content of the range and three digits to represent the minimum Brine11 Hardnaa, the example, NiLCr 30/500 means a low-chromium grade with carbon in the range 29-3.3 percent and having a minimum Brine11 Hardness of 500 HBW.

3. SUPPLY

OF MATERIAL iron

3.1 General requirements relating to the supply of abrasion-resistant castings shall be as laid down in IS : 1387-1967*.
4. MANUFACTURE

4.1 The castings 5. CHEMICAL

shall be made

by any suitable

melting

process.

COMPOSITION
grades of abra-

5.3 The chemical composition of the metal for different sion-resistant iron castings shall be as given in Table 1. 6. CHEMICAL 6.1 Chemical
casting

ANALYSIS
constituents in

analysis for the determination of various shall be done in accordance with IS : 228-1959t.

*General requirements tMethods of chemical rteels ( rmisrd ).

for the supply of metallurgical materials (&t rr~isia ). analysis of pig iron, cast iron and plain carbon and low alloy
4

TABLE

CHRMICAL

COMPOSITION

OF ABRMXON-RESXSTANT

IRON

CASTINCg

( PERCENT

CONSTITUENT

---_*--7 NiLCr 30/508 (2) 33

TYPE IA NiLCr 341550 (3) 32 to 36 83 to 86 0.3 to 06 NiHCr 271500 (4) 25 to 29 l-5 to 22 83 to 86 40 to 60

TYPE 1B NiHCr 30/550 (5) 28 to 3.3 I.5 to 22 03 to 86 40 to 60 8.0 to 180 85 Max 815 83 NiHCr 341600 (6) 3.2 to 36 15 22

TYPE 2 A___--CrMoHC CrMoLC 281500 341508 (7)

TYPE 3 w-L---, HCrNi HCr 271480 271400 (9) 23 S-0 (10)

(1) Total Silicon Manganese carbon

(8)
24 to 31 83 to 88 89 to 0.4 85 h&W 140 to 180 25 to 35 8.1: 8.

2-7 to

3-l to
3.6 83 to 88 d:9 85 Max 146 to 180 2.5 to 3.5 0.15 93

to

2.3 to 3.0 82 to 1.5 1.5 Me* 85 Max 240 to 280 86 Max 615 63

0.3 to 06

to

82 to 1.5 1.5 Mar 1.2 Max 240 to 280 86 Max 815 0.3

m
Nickel Chromium Molybdenum Sulphur, Max Max

:ssto
15 to 25 od Max 0.15 0.3
c_----

83 to 86 40 to 60 7.5 to 95 05Max 815 83

I5 10 25 V5M8# 815 03

180

8-o to

85 Max 015 0.3

-_--

Phoephonu.

Remainder
sections.

~q~~~y~o~_---_-----_-_----_-_--_------_

NOTE 1 - For Types

High-nickel, Toughness Resistance

la.and lb, low-nickel, high-silicon and low-chromium low-silicon and high-chromium con~nts are preferred and resistance to abrasive to repeated wear increases as carbon content increases.

contents are preferred for the for the heavier sections. decreams.

smaller

NOTE2 NOTE3 -

shock increase as carbon content

IS : 4771.1985 7. WORKMANSHIP AND FINISH

7.1 The castings shall be accurately moulded in .accordance with the pattern or working drawings supplied by the purchsaer, with the addition of such letters, figures and marks as may be specified. 7.2 The drawings shall specify tolerances oxi all important dimensiona.

8. MICROSTRUCTURE 8.1 Castings or suitable examination if agreed Location of test samples by mutual agreement of test samples may be subjected to metallographic to between the purchaser and the manufacturer. and area used for examination shall be decided the purchaser and the manufacturer. irons depend on cooling

8.2 The microstructures of all abrasion-resistant rate and are therefore sensitive to section size. 9. HEAT-TREATMENT

9.1 Castings shall be supplied either in the as-cast or heat-treated condition at the discretion of the manufacturer to meet the hardness requirements specified in 10.1 or as specified by the purchaser. 9.2 If required, Type la castings shall be heat-treated for 12 to 16 hours at 200 to 275C followed by air or furnace cooling. Where optimum properties are required, particularly under severe conditions of repeated impact, a double heat-treatment for 4 to 8 hours at 425 to 475C followed by air cooling and holding 12 to 16 hours at 200 to 275C shall be preferred. 9.3 If required, Type lb castings .shall be heat-treated for 6 to 12 hours at 775 to 825C, followed by air or furnace cooling. This heat-treatment conditions the austenite for transformation to martensite and bainite to develop a good combination of hardness, strength and resistance to repeated impact. At the request of the purchaser, or at the discretion of the~manufacturer, these grades may be subsequently tempered at 200 to This heat-treatment toughness the iron and increases 350C for 4 hours. resistance to spalling. the manufacturer shall 9.4 When specified by the purchaser, castings of Type 2 and Type 3 grades to provide a maximum hardness of 380 HBS before givining hardening treatment.
NOTE - A recommended ir described below: b) Hold at this temperature c) Furnace-cool d) Further annealing procedure for castings of

anneal surface
3

Type 2 and Ty+e

a) Heat slowly to 920 to 9750, for not less tban I hour; rate not to exceed 40%/h; to 810 to 815%;

cool in furnace to 590 to 645C, cooling

and

e) Cooling below 590C may be in furnace or still Sr. 6

IS : 4771.1985
by the purchaser, the manufacturer shall harden the castings of Type 2 and 3 by heating to a suitable temperature for a minimum of 1 h/250 mm of section thickness, but in no case for less than 1 hour, followed by air cooling. The austenitizing temperature for this hardening treatment shall be between 950 and 1 OlOC for the Type 2 irons and between 980 and 1 120C for Type 3 irons. The same procedure may also be used for hardening annealed and machined castings. 9.6 Both annealing and hardening treatments shall not be specified for castings of Type 2 and Type 3 grades. If annealing is specified for these grades, it is expected that the purchaser will carry out both machining and hardening operations. 10. HARDNESS

9.5 When specified

10.1 The
Table 2.

material

shall

conform

to the

requirements

stipulated

in

TABLE 2
CONDITION

MINIMUM BRINELL HARDNESS VALUES (HBW) ABRASION-RESISTANT IRON CASTINGS

TYPE 1B c----~---NiHCr NiHCr NiHCr 271500 301550 341600 TWE 2 #--_~_--~ CrMoHC CrMoLC 34/500 20/500

OF

TWE IA C--h--T NiLCr KiLCr 30/500 341550 (2) (3) 550 -

TYPE3 ,-.-y HCrNi HCr 271400 27/W

(1) Sand-cast Hardened Annealed

(4) 500
-

(5)
550 -

(6)
600 -

(7)
500 600 380 I&x

(81
500 550 380 &f#?#x

(9)
400 550 -

(?a
400 550 380 _i_ Maw

500
-

\NOTE - Minimum hardness values up to 50 Brine11 pointr lower than those specified in thir table shall be permitted in castings with section thickness greater than 125 mm.

10.1.1 The hardness test shall be carried IS : 1500-1983* using tungsien carbide ball. 11. SAMPLING

out

in

accordance

with

il.1 FOP quality control during production, use of control chart technique is recommended to the manufacturer for which reference is invited to IS : 397 ( Ptirt 1 )-1972t or IS : 397 ( Part 2 )-1975t. The results of such
Method *Method for Brine11 hardness test for metallic materials ( sdwlJ r&ion ). for statistical quality control during production: Part 1 Control charts for variables (jrst nuGoa ). Part 2 Control charts for attributes and count of defects ( jbst mkiea ).

IS : 4771- 1985 tests done at the place of manufacture along with may be made available, to enable the purchaser ability. the material supplied to judge its accept-

11.2 Sampling for Chemical Analysis - Chemical analysis shall be carried out either on finished casting or test bar representing each melt. In the case of continuous melting, samples shall be provided at the rate of one sample per hour of production. 11.3 Sampling for Hardness Test - If specified by the purchaser, test shall be carried out either on finished casting or test bar representing each heat-treatment batch; at least one test shall be carried out from each meit in case the castings from two or more meits are heat-ireated in one batch. In the case of continuous melting, sufficient number of samples shall be provided to ensure at least one test per hour of production. 12. RETEST 12.1 Chemical ,Analysis - If a sample selected under 11.2 fails to meet the requirements given in Table 1, the purchaser shall select two If both the samples satisfy the further samples from the same lot. specified requirements, the castings represented shall be accepted. If either of the samples fails, the castings represented shall be deemed as not complying with this standard. t2.2 Hardness Test - If a sample selected under 11.3 fails to meet given in Table 2, two further samples shall be selected \ he requirements 4 rom the same lot and in case the castings have been heat-treated from The consignment shall be considered to the same heat-treatment batch. conform to the requirements if both the additional tests are satisfactory. Should either of the samples fail, the castings represented shall be deemed as not complying with this standard. If the castings are supplied in the heat-treated condition, the manufacturer shall have the right to reheattreat the product, if he so desires, in any suitable manner before two Should the two tests satisfy the fresh samples are taken for testing. requirements of this standard, the lot shall be accepted. Should either of the samples fail, the castings represented shall be taken as not complying with this standard. 13. MARKING 13.1 Where practicable, each casting shall be legibly marked with an identification mark by which it can be traced to the melt and the batch of heat-treatment, where applicable, from which it was made. 13.2 By agreement between the purchaser and the manufacturer, ings complying with the requirements of this standard, may, inspection, be legibly marked with an acceptance mark. 8 castafter

IS : 4771- 1985
13.3 The castings may also be marked with the ISI Certification Mark.

Non - The use bf the IS1 firtification Mark is governed by the provisions of the Indian Standarda Institution ( Certification Marks ) Act and the Ruled and Regu14ons made thereunder. The IS1 Mark on products covered by an Indian Standard conveys the assurance that they have been produced to comply with the requirements of t&t rt~ndard under a w&defined ryqtem of inspection, testing and uality control which ia denied and supervised by IS1 and operated by the producer. 851 marked products are also continuously checked by IS1 for conformity to that mndard as a further nfeguard. Details of conditions under which a licence for the un of the IS1 CertiCcation Mark may be grpnted to manufacturera or proceuom, may be obtained from t4e Indiin Standards Institution.

IS : 4771- 1985
( Continwdfrom page 2 )

Alloy Cast Iron Subcommittee,

CoaDmet SHRI P. P.

SMDC

9 :6

CHOPRA

Hindustan Machine Tooh Ltd, Pinjore Best and Crom ton, Bangaloro Mahindra & b.fahindra, Bombay

fiwm

Mmbm

REPIUCSENTATIVE REFTWSMTATIVE

10

BUREAU
Headquarters

OF

INDIAN

STANDARDS

: hianak Bhavan, 9 Bahadur Shah Zafar Marg, NEW Telephones : 331 01 31

331 13 75 Offices :

DELHI 1lOOOZ

Telegrams (Common

: Manaksanstha
to all Offices) Telephone 331 01 31 ! 331 13 75 37 86 62 21843 41 29 16 6 32 92 95

Regional Central * Eastern Northern Southern t Western Branch

: Manak Bhavan, 9, Bahadur Shah Zafar Marg.

NEW DELHI 110002 : . l/l4 C.I.T. Scheme VII M. V.I.P. Road, Maniktola, CALCUTTA 700054 : SC0 445-446, Sector 35-C, CHANDIGARH 160036 : C.I.T. Campus, IV Cross Road, MADRAS 600113 : Manakalaya, E9 MIDC. Marol, Andheri (East), BOMBAY 400093 Offices : 380003

Pushpak, Nurmohamed Shaikh Marg, Khanpur, AHMADABAD t Peenya Industrial Area, 1st Stage, Bangalore-Tumkur Road. BANGALORE 560058 Gangotri Complex, 5th Floor, Bhadbhada Road, T.T. Nagar. BHOPAL 462003

2 63 48
39 49 55 55 40 21 5 36 27 2 67 05 8-71 19 96 3 31 77 231083 6 34 71 .-I. ,-.n Th LI oo I0 5 55 07 6 23 05 6 21 04

Plot No. 82/83, Lewis Road, BHUBANESHWAR 751002 Kalai Kathir Building, 6/48-A Avanasi Road, COIMBATORE 641037 Quality Marking Centre, N.H. IV, N.I.T., FARIDABAD 121001 Savitri Complex, 116 G. T. Road, GHAZIABAD 201001 5315 Ward No. 29, R.G. Barua Road, 5th By-lane, GUWAHATI 781003 5-8-56C L. N. Gupta Marg, ( Nampally Station Road ) HYDERABAD 500001 RI4 Yudhister Marg, C Scheme, JAIPUR 302005 __-..__ _ 11 I/418 6 Sarvbdaya Nagar, KANPUR 208005 Plot No. A-9, House LUCKNOW 226005 Patliputra Industrial No. 561/63, Estate, PATNA Sindhu 800013 Bagh-e-Ali Maidan. Nagar, Kanpur Road

District Industries Centre Complex, SRI NAGAR 190011 T. C. No. 14/1421, University THIRUVANANTHAPURAM inspection Offices (With

P. 0.. Palayam. 695034

Sale Point)

:
52 51 71 5 24 35

Pushpanjali, First Floor, 205-A West High Court Road. Shankar Nagar Square, NAGPUR 440010 Institution of Engineers (India) Building, 1332 Shivaji Nagar. PUNE 411005 *Sales Dfflce Calcutta is at 5 Chowringhee P. 0. Princep Street, CALCUTTA t Sales Offlce is at Novelty is at Unity Chambers, Building, $ Sales Office BANGALORE Approach. Grant Road, BOMBAY Square,

27 68 00 89 65 28 22 39 71

Narasimharaja

Printed at Dee Kay Printers, New Delhi,

India