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Iron Classification Codes and Characteristics

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Iron Classification Codes and Characteristics Iron Alloys Joseph S. Santner, American Foundry Society, Schaumburg, Illinois George M. Goodrich, Professional Metallurgical Services, Buchanan, Michigan ron castings are produced by a variety Iof molding methods and are available with a wide range of properties. Cast iron is a generic term that designates a family of metals. To achieve the best casting for a particular application at the lowest cost consistent with the component’s require- ments, it is necessary to have an under- standing of the six types of cast iron: • gray iron; • ductile iron; • compacted graphite iron (CGI); • malleable iron; • white iron; • alloyed iron. Table 1 lists the typical composition ranges for common elements in fi ve of the six generic types of cast iron. The classification for alloyed irons has a wide range of base compositions with major additions of other elements, such as nickel, chromium, molybdenum This gray iron manifold for wheel loaders was developed by the casting supplier and cus- or copper. tomer from concept-to-casting in less than one month. The new design cut the processing The basic strength and hardness of time of the component in half. all iron alloys is provided by the metallic structures containing graphite. The prop- shape (sphericity) and volume fraction of oxidation and corrosion by developing erties of the iron matrix can range from the graphite phase (percent free carbon). a tightly adhering oxide and subscale those of soft, low-carbon steel (18 ksi/124 Because of their relatively high sili- to repel further attack. Iron castings are MPa) to those of hardened, high-carbon con content, cast irons inherently resist used in applications where this resistance steel (230 ksi/1,586 MPa). The modulus provides long life. Resistance to heat, of elasticity varies with the class of iron, oxidation and corrosion are appreciably enhanced with alloyed irons. Properties of the cast iron family can be adjusted over a wide range and enhanced by heat treatment. Annealing readily produces a matrix of soft machin- able ferrite. In limited situations, this annealing can be accomplished at sub-critical temperatures. Heating above this critical temperature takes the carbon from the graphite and places it in the matrix. This engineered material can Pictured is a dual de- livery seed and fertilizer be through-hardened and tem- tool for use in the agricul- pered using conventional heat treat- tural industry. The sand cast ing or surface hardening. These adjust- component features a ductile iron knife body and a high-chrome point. ments create the cast iron family. Gray iron—Flake graphite provides gray iron with unique properties (such Table 1. Composition Range for Un-Alloyed Cast Irons as excellent machinability) at hardness Iron Family Carbon Silicon Manganese Sulfur Phosphorus levels that produce superior wear-resistant Gray 2.5-4.2 1.0-3.0 0.15-1.0 0.02-0.25 0.02-1.0 characteristics, the ability to resist galling Ductile 3.0-4.0 1.8-3.0 0.1-1.0 0.01-0.03 0.01-0.1 and excellent vibration damping. CGI 2.5-4.0 1.5-3.0 0.10-1.0 0.01-0.03 0.01-0.1 Ductile iron—An unusual combina- tion of properties is obtained in ductile Malleable 2.2-2.8 1.2-1.9 0.15-1.2 0.02-0.2 0.02-0.2 iron because the graphite occurs as spher- White 1.8-3.6 0.5-2.0 0.15-0.8 0.02-0.2 0.02-0.2 oids rather than as fl akes. The different 2006 CASTING SOURCE DIRECTORY ENGINEERED CASTING SOLUTIONS 17 grades are produced by controlling the trolling the matrix structure as-cast or to iron at a given level of ductility. ADI can matrix structure around the graphite provide response to heat treatment. have strength in excess of 230 ksi (1,586 either as-cast or by heat treatment. Only The high-strength grades can be MPa); however, its modulus is 20% lower minor compositional differences (to pro- quenched and tempered to form a bainite- than steel with a comparable strength. mote the desired matrix microstructure) like matrix produced by austempering. Compacted Graphite Iron (CGI)—In exist among the regular grades. Alloy Austempered ductile iron (ADI) provides CGI, graphite locally occurs as intercon- additions may be made to assist in con- twice the strength of conventional ductile nected blunt fl akes. This graphite structure Table 2. Iron Specifi cations, Characteristics & Applications Standard Specifi cations Characteristics Applications • ASTM A48: gray iron castings Several strength grades; Automobile engine blocks & • ASTM A74: cast iron soil & pipe fi ttings vibration damping; low heads; manifolds for internal • ASTM A126: gray iron castings for valves, fl anges & pipe fi ttings rate of thermal expansion & combustion engines; gas • ASTM A159: automotive gray iron castings resistance to thermal fatigue; burners; machine tool bases; • SAE J431: automotive gray iron castings lubrication retention; and dimensionally stable tooling sub- • ASTM A278 & ASME SA278: gray iron castings for pressure-containing parts good machinability. jected to temperature variations, for temperatures up to 650F (343C) such as gear blanks & forming • ASTM A319: gray iron castings for elevated temperatures for die covers; cylinder liners for non-pressure-containing parts internal combustion engines; • ASTM A823: statically cast permanent mold castings intake manifolds; soil pipes; • ASTM A834: common requirements for iron castings for general industrial use counterweights; and enclosures & housings. Gray Iron Gray Iron Standard Specifi cations Characteristics Applications • ASTM A395 & ASME SA395: ferritic ductile iron pressure-retaining castings for Several grades for both Steering knuckles; plow use at elevated temperatures strength & ductility; high shares; gears; automotive & • ASTM A439: austenitic ductile iron castings strength, ductility & wear truck suspension components; • ASTM A476 & ASME SA476: ductile iron castings for paper mill dryer rolls resistance; contact fatigue brake components; valves; • ASTM A536 & SAE J434: ductile iron castings resistance; ability to pumps; linkages; hydraulic • ASTM A571 & ASME SA571: austenitic ductile iron castings for withstand thermal cycling; components; and wind pressure-containing parts suitable for low-temperature service and production of fracture- turbine housings. • ASTM A874: ferritic ductile iron castings suitable for low-temperature service critical components. • ASTM A897: austempered ductile iron castings Ductile Iron Ductile Iron Standard Specifi cations Characteristics Applications • ASTM A842: CGI castings A compromise of properties Diesel engine blocks & between gray & ductile iron. frames; cylinder liners; brake discs for trains; CGI power generators; exhaust manifolds; pump housings; and brackets. Standard Specifi cations Characteristics Applications • ASTM A532: abrasion-resistant white iron castings Extremely hard & Crushing & grinding wear-resistant. applications; and Iron White grinding balls. Standard Specifi cations Characteristics Applications • ASTM A47 & ASME SA47: ferritic malleable iron castings Soft & extremely ductile. Chains; sprockets; tool parts • ASTM A197: cupola malleable iron & hardware; connecting rods; • ASTM A220: pearlitic malleable iron drive train & axle components; Iron • ASTM A338: malleable iron fl anges, pipe fi ttings & valve parts for railroad, and spring suspensions. marine & other heavy-duty service up to 650F (343C) Malleable • ASTM A602 & SAE J158: automotive malleable iron castings Standard Specifi cations Characteristics Applications • ASTM A436: austenitic gray iron castings Corrosion resistant; Parts for chemical processing • ASTM A518: corrosion-resistant high-silicon iron castings retains strength & plants; petroleum refi ning; food dimensions during handling & marine service; Iron elevated-temperature control of corrosive fl uids; and Alloyed exposure; and ability to pressure valves. withstand thermal cycling. 18 ENGINEERED CASTING SOLUTIONS 2006 CASTING SOURCE DIRECTORY Table 3. Property Comparisons for Gray Iron Classes Property Class 25 Class 30 Class 30 Class 35 Class 40 (as-cast) (as-cast) (annealed) (as-cast) (as-cast) Brinell Hardness 187 207 109 212 235 Tensile Strength 29.9 ksi (206 MPa) 33.7 ksi (232 MPa) 20.6 ksi (142 MPa) 34.8 ksi (240 MPa) 41.9 ksi (289 MPa) Modulus of Elasticity 16.6 Msi (114 GPa) 17.0 Msi (117 GPa) 14.5 Msi (100 GPa) 18.0 Msi (124 GPa) 18.2 Msi (126 GPa) Tensile Poisson’s Ratio 0.29 0.19 0.21 0.22 0.24 Compression Poisson’s Ratio 0.27 0.28 0.26 0.28 0.23 Compression-to-Tensile Strength Ratio 3.68 3.84 4.05 3.63 3.71 ADI’s high strength-to-weight ratio has resulted guidelines for their own capability in in widespread use in automotive applications. dimensional control, these controls are Shown below is an 8.5-lb. rear control arm for the Ford Mustang Cobra. typically established through concurrent engineering based on the requirements of the application. Material Properties vs. Cast- ing Processes The properties of all metals are infl u- enced by the manner in which they solidify and cool. The individual design of a casting (the molding process, the way the molten metal is introduced into the cavity and the pouring temperature) determines the rate of cooling in the various parts of a casting. The cooling rate in any particular section factors heavily into the mechanical and the resulting properties are interme- properties of the iron. Therefore, a series diate between gray and ductile irons. The quirements (actual strength, dimensional of standard test bars of increasing size has compacted graphite shape also is called tolerances and surface fi nish) cannot be been established specifi cally for gray iron. quasi-fl ake, aggregated fl ake, semi-nodular stated in a general specifi cation. One of these bars should be selected to and vermicular graphite. Table 2 gives iron specifi cations, char- determine the cooling rate in the critical White iron—White iron is hard and acteristics and applications. There are sections of the casting. essentially free of graphite. The metal so- no generally accepted standards for the lidifi es with a compound called cementite, surface fi nish, machining allowances or Types of Specifi cations which is a phase that dominates the mi- dimensional tolerances.
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