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Fe-C Fe-C-2% Si
2 wt. pct. Si
2.5 wt. pct. Si
C-Si Combinations
Gray Iron
Carbon Equivalent
• C.E. = C + (Si + P) / 3
• Properties related to C.E.
– Mechanical
– Hardness
– Damping
– Thermal conductivity
C.E. Effect
Other Important Elements
• Mn, S • Ni
– Mn ≥ 1.7 * S + 0.3 • Sn
• Cr – Strong pearlite former
– Promotes chill • P
• Cu – From pig
– Strength – Forms Steadite
• Mo
– Promotes pearlite
P Effect on Eutectic Temperature
S Effect
Solidification
• Two possibilities
– C as cementite
• Ledeburite
– C as graphite
• Flakes
Ledeburite
Types of Flake Graphite
Type A Flake Graphite
Type A and B Flake Graphite
Type C and A Flake Graphite
Type D Flake Graphite
Type E Flake Graphite
Deep Etched Flake Graphite
Thermal Analysis
• Look at cooling curve
• Determine rough C, Si
• Determine quality of melt/ladle
Thermal Analysis Plots
Cooling Curves
Melting Methods
• Cupola
– Continuous
• Induction
– Batch type
Cupola
Cupola Charging
• Materials added in alternating layers
• Metals
– Steel
• 25-90%
– Scrap iron castings
• As available
– Pig iron
• As needed to dilute tramp in steel
– Alloys
• FeMn, FeSi, etc.
Cupola Charging
• Coke
– Carbon and heat source
– 8-16%
• Flux
– 2-8%
– Limestone (CaO)
– Soda ash (Na2CO3)
• Increases slag fluidity
– Fluorspar (CaF2)
• Maintains slag fluidity
– Calcium carbide (CaC2)
• Deox, raise C, raise T, adds to CaO
Induction Furnace
Induction Melting Materials
• Pig Iron
– 4%C, 2.75%Si, 0.65%Mn, 0.02%S
• Steel
– 0.3%C, 0.3%Si, 0.8%Mn
• Returns
• Alloying additions
– FeSi
– FeMn
– Pyrite
– Others
Inoculants
• Late addition of FeSiCa type alloy
• Typically contain rare earth elements such as
cerium or strontium
• Helps promote small graphite flakes
– Nucleation sites for flakes
• Slows rate of solidification
• Lowers chill tendency
• Deoxidization
Inoculation Practice
• Dry materials
• Start tapping furnace into ladle then add
inoculants
• Add to metal stream entering ladle
• Provide good mixing
• Pour quickly to prevent fade
• In mold
– Prevent fade ladle inoculant
Classifications
• UTS-Tensile bar size
• 25B
• 35A
• 40C
• 30S
• Dimensions
– A – 0.88” x 6”
– B – 1.2” x 9”
– C – 2.0” x 10”
Ductile Iron
C-Si Combinations
What is ductile iron?
• Similar chemistry as gray iron
• Add a nodulizer
– Changes graphite flake into spherical nodule
– Typically Mg
• Significant change in mechanical properties
Preferred Chemistry Range
Composition
• C, Si – Primary elements
• Mn – Promotes pearlite
• S – Combines with Mg and R.E.
• Mg – Causes spheroids, lowers S, O
– 0.02-0.08%
• Cu, Mo, Ni – Promote hardenability
Composition
• Chunky
– Ce, Ca, Si, Ni
• Intercellular Flake
– Bi, Cu, Al, Pb, Sb, Sn, As, Cd
• Deleterious
– Zr, Zn, Se, Ti, N, S, O
Classifications
• UTS-YS-%Elongation
• 65-45-12
• 60-40-18
• 80-55-06
• 100-70-03
• Tensile bar machined from Y-block
– Dimensions based on casting thickness
Microstructure Classification
• Nodularity %
• Nodule Size
• Pearlite Content
• Carbide Content
Nodularity
Nodule Size
Pearlite Content
Carbide
C Float
Magnesium Recovery