1. The American University in Cairo Mechanical Engineering Department MENG 426: Metals, Alloys & Composites Interactive MENG 426 Lab Tutorials Experiment (6) Cast Iron Prepared by Eng. Moataz M. Attallah Fall 2002

2. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens ResultsOutline  Introduction: steel and cast iron  Cast iron properties  Cast iron types  Specimens  Lab report

3. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens Results Ferrous Alloys

4. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens Results Steel Alloys Low carbon (Mild) steel 0.3% C Medium carbon 0.3-0.6% C High-carbon >0.6% C High strength low-alloy HSLA Austenitic Ferritic Martensitic Ppt. Hard. CARBON STEELS STAINLESS STEELS ALLOY STEELS

5. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens Results Effect of Carbon Content

6. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens Results Cast Iron  Carbon content ranging from 2-4.3%  Castable, hard & strong  Wide range of types depending on: 1.The chemical composition of the iron; the existence of certain alloying elements. 2.The cooling rate of the casting in the mould. 3.The type of graphite formed and its percent composition.

7. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens Results Cast Iron Types  Gray (graphite flakes) CI  Malleable CI  Nodular (ductile/spherulitic) CI  White CI

8. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens Results CI Compositions ElementGray CIWhite CIMalleable CIDuctile CI C 2.5-4.01.8-3.62.0-2.63.0-4.0 Si 1.0-3.00.5-1.91.1-1.61.8-2.8 Mn 0.25-1.00.25-0.80.2-1.00.1-1.0 S 0.02-0.250.06-0.200.04-0.180.03 max P 0.05-1.00.06-0.180.18 max0.1 max

9. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens Results Gray (Graphite Flakes) CI  Gray fracture surface  Maximum C%  C precipitate as flakes  High Si% forms flakes  Good wear resistance, vibration damping machineability Pearlitic matrix Graphite flakes

10. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens Results Ductile (Nodular/spherulitic) CI  C precipitates in black nodules  High fluidity/castability Good machineability Wear resistance  Alloy elements produce nodules Pearlitic matrix Spherulites

11. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens Results Nodular Cast Iron  Desulfurization  Nodules formation  Inoculation

12. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens Results White CI  Iron carbide forms instead of iron and graphite  Iron carbide in pearlite  White fracture surface Pearlitic matrix Cementite

13. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens Results Malleable CI  Initially formed as white CI  Heat-treated in malleablizing furnace to dissociate Fe 3 C to iron and graphite  Good wear resistance Ductility Fluidity Pearlitic matrix Graphite clump

14. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens Results Compact CI

15. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens ResultsObjectives 1.Focus on the cast iron zone in the iron-iron carbide system. 2.Get acquainted with the different types of cast irons, and the differences between them in microstructure, mechanical & physical properties. 3.Study the different microstructures of the different types of cast iron.

16. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens ResultsSpecimens  Gray cast iron  Nodular cast iron  Malleable cast iron  Common grinding and polishing  Etching using 3ml of HNO 3 + 100 ml of CH 3 OH (methyl alcohol), etched by immersing for 15 seconds.

17. Ferrous alloys Steels Cast Iron Types Composition Gray Ductile White Malleable Objectives Specimens ResultsResults  Sketch and describe the microstructure