UNIT - 3

CAST IRON
10 MARKS
CAST IRON PG - 455

o Cast Irons are basically the

alloys of Carbon & Iron in
which the carbon varies
between 2.0 to 6.67% i.e. more
than the solubility limit of
carbon in austenite and less
than the carbon content of
cementite.
CAST IRON PG - 455

o Because of the poor ductility &

malleability, they can not be
forged, rolled, drawn or pressed
into the desired shape but are
formed by melting and casting
to the required shape and size
and hence the name “cast iron”.
C I - CHARACTERISTICS PG-455
o They are cheapest amongst the
commercial alloys.
o They are easier to melt because of
their low melting temperature
(1150-1250°c) as compared to steels
(1350-1500°c).
o They have excellent castability due
to high fluidity of melt & low
shrinkage during solidification.
C I - CHARACTERISTICS PG-455
o Their corrosion resistance is fairly
good.
o By proper alloying and suitable
heat treatment the properties of
any type of CI can be easily
adjusted over a wide & useful
range.
o In general they are brittle and
their mechanical properties are
C I - CLASSIFICATION PG-456
1. On the basis of furnace
used in their
manufacturing.
I. Cupola CI
II. Air furnace CI
III. Electric furnace CI
IV. Duplex CI
C I - CLASSIFICATION PG-456

2. On the basis of composition

& purity.
I. Low carbon, low silicon CI
II. High carbon, low sulphur
CI
III. Nickel alloy CI
C I - CLASSIFICATION PG-456

3. On the basis of microstructure

& appearance of fracture.
i. White CI
ii. Malleable CI
iii. Gray CI
iv. Nodular CI
v. Chilled CI
WHITE C I
• All the carbon is in the combined
form i.e. as cementite & there is
no free carbon i.e. Graphite.
• The fracture appears white.
• All white CI are hypoeutectic.
• Composition –
C=2.5%, Mn=0.4%, Cr=17%,
Si=1.3%, Ni+Cu=1.5%,
P=0.15%, S=0.15%, Mo=0.5%.
WHITE C I
• Due to the presence of large amount
of cementite it is hard, brittle &
difficult to machine.
• It is used in ball mills, drawing dies,
extrusion nozzles etc.
• Microstructure -
 MALLEABLE C I
• They contain free carbon i.e.
Graphite in the form of irregular
spheroids also called as rosettes.
• They are produced from White CI by
a heat treatment called
malleablization.
• Composition –
C=2-2.65%, Si=0.9-1.4%, Mn=0.25-
0.55%, P=Less than 0.18%,
MALLEABLE C I
• It is used in pipe fittings, chain hoist
assembly, railroad equipments etc.
• Microstructure –
 GRAY C I
• The CI containing graphite in the
form of flakes are called Gray CI.
• They fracture appears gray in
colour.
• Properties –
• Excellent machinability
• Good compressive strength
• Good bearing peoperties
• Fairly good corrosion resistance
 GRAY C I
• Composition –
C=3.2-3.7%, Si=2-3.5%, S=0.06-0.1%, P=0.1-
0.2%, Mn=0.5-1.0%.
• Microstructure –
 White CI
Fracture appears White in
Colour.
Melting point is lower than
Gray CI.
It is harder than Gray CI.
Machining is difficult.
Silicon content is between
0.1-0.5 %.
Widely used in industry.
Gray CI
Fracture appears Gray in
Colour.
Melting point is higher than
White CI.
It is softer than White CI.
Better machinability than
white CI.
Silicon content is between
0.5-3.5 %.
Has limited applications.
 NODULAR C I

• These CI contain graphite in the

form of nodules or spheroids.
• This increases tensile strength,
ductility & toughness.
• They are also called as spheroidal
graphite cast iron (SGCI) or
ductile CI.
 NODULAR C I
• They are produced from Gray CI by
the addition of small quantity of
certain elements called nodulising
elements such as magnesium,
calcium, barium etc.
• The common addition is Mg which is
usually added in ladle just prior to
pouring into the moulds.
 NODULAR C I
• Microstructure –
 CHILLED CI
• This type of CI shows white structure at
the surface & gray structure at the
centre.
• Due to this good properties of White CI
(hardness & wear resistance) and Gray
CI (machinability, damping capacity,)
can be coupled together .
• Generally carbon content varies from
3.3 – 3.5% with silicon content between
 CHILLED CI
• The depth of chill i.e. the thickness of
white layer can be controlled by
controlling the carbon & silicon
contents.
• Chilled CI are used for crushing rolls,
grinding balls, road rollers, hammers,
dies etc.
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