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CAST IRON MATERIAL TEKNIK (MAT) Cecep Ruskandi

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CAST IRON

MATERIAL TEKNIK (MAT)

Cecep Ruskandi

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Cast Iron• Cast iron is a cast ferrous based materials with

the carbon content greater than 2% and also contain elements such as Si, Mn,P and S.

• Cast irons are classified into :

- Gray cast iron (GG / FC)

- Nodular cast iron (GGG / FCD)

- Chilled cast iron (GH)

- Malleable cast iron (GT)

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Gray cast iron (GG/FC)

• It has gray fracture appearance.

• Good machinability and castability

• This cast iron contains flake graphite which cause the iron to be brittle.

• The application : housing engine, crankcase etc.

• Designation :

GG (DIN) or FC (JIS) followed by digits which represent the tensile strength.

example : GG 25

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Flake Graphite

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Gray Cast Iron Products

Exhaust manifoldhousing

Brake drum

rotorArts

Door knocker

Body valve

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Nodular Cast Iron• This cast iron contains spheroidal graphite which

cause the iron to be ductile. so called S.G Iron• High toughness, strength and elongation,

therefore this metal also called ductile iron• This iron also has a good wear resistance• Application : crankshaft, gears, transmission gear,

roll, pump, steering knuckls, valves etc.• Designation :

GGG (DIN) or FCD (JIS) followed by digits which represent the matriks content.example : GGG 70

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Nodular Graphite

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The Group of Ductile Iron

• Ferritic Ductile Iron, which is high impact resistance, relatively good thermal conductivity , high magnetic permeability, good machineability.

• Pearlitic Ductile Iron, which is high strength and hardness, moderate ductility and impact resistance, lower thermal conductivity and magnetic permeability but good machineability

• Ferritic-Pearlitic Ductile Iron, with its properties is in between ferritic and pearlitic ductile iron.

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The Group of Ductile Iron (con’t)

• Martensitic Ductile Iron or quench &tempered iron.

In the "as-cast" condition the alloy is hard andbrittle, and seldom used. However, TEMPEREDMARTENSITE has very high strength and wearresistance. A 930°F (500°C) tempering resultsin 300 HB, a 1110°F (600°C) tempering in 250HB hardness.

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The Group of Ductile Iron (con’t)

• Austenitic Ductile Iron

They are never chosen for strength alone. Theoutstanding features are good corrosion andoxidation resistance, magnetic properties,strength and dimensional stability at elevatedtemperatures. (Also known as Ductile Ni-Resist).

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The Group of Ductile Iron (con’t)

• Austempered Ductile Iron- ADI is almost twice as strong as the regular ASTM grades ofDuctile Iron whilst still retaining high elongation andtoughness characteristics

- It also offer wear resistance and high strength

The remarkable properties of ADI are developed by a closelycontrolled heat treatment operation (austempering) which

develops a unique matrix structure of bainitic ferrite (60%) andretained (high carbon) austenite.

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Application of Ductile Iron

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Malleable Cast Iron (GT –DIN)• Malleable irons are cast white, that is, their as-cast

structure consists of metastable carbide in a pearliticmatrix

• The castings must then be annealed to convert carbides into rossette graphite.

• There are two types of malleable iron, blackheart and whiteheart.

• Malleable irons have a good weldability, machinability and ductility.

• Application : automotive parts, agricultural components, valves etc.

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Whiteheart malleable cast iron (GTW)

• In the whiteheart process, the white, as-cast iron is decarburised during annealing leaving a structure of iron carbide in a metallic matrix.

• Annealing is performed in an oxidising atmosphere improving weldability

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Blackheart malleable cast iron (GTS)

• In the Blackheart process, the white, as-cast iron is annealed to develop graphite cluster.

• Annealing is performed in a non-oxidising atmosphere

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Malleable cast iron products

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Chilled Cast Iron• These irons have a white fracture appearance due to

rapid cooling or very small amount of Si content.

• The microstructure consists of carbide causing the iron has a high hardness but very brittle.

• This irons have a very good wear resistance

• The chilled cast irons are generally applied for components which require a high wear resistance properties such as roll mill, crusher etc.

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Chilled cast iron products

Rolls