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Properties and applications of engineering materials
Published in Alan Darbyshire, Charles Gibson, Mechanical Engineering, 2023
Alan Darbyshire, Charles Gibson
When carbon is added to molten iron in quantities greater than 1.7%, all cannot be absorbed interstitially or as iron carbide. After the mixture has cooled down, the excess is seen to be present as flakes of graphite between the grains. The material is then known as grey cast iron. A carbon content of 3.2%–3.5% and silicon of up to 2.5% is usual which gives the molten metal good fluidity. This enables it to be cast into intricate shapes. It is easy to machine without the use of a cutting fluid since the graphite flakes have a self-lubricating effect. Grey cast iron is strong in compression but tends to be weak and brittle in tension. The graphite flakes also act as vibration absorbers which make it an ideal material for machine beds. A low silicon content coupled with a fast rate of cooling does not allow the graphite flakes to separate out. The material then has a white appearance and is known as white cast iron. This tends to be weak and brittle but it can have its properties modified.
Study and Control of Shrinkage in Gearbox Sand Casting Using Simulation and Experimental Validation
Published in R.S. Chauhan, Kavita Taneja, Rajiv Khanduja, Vishal Kamra, Rahul Rattan, Evolutionary Computation with Intelligent Systems, 2022
Sarabjit Singh, Rajesh Khanna, Neeraj Sharma
Different functional advantages and economic benefits of the casting process make it a better option, when compared to other metal forming methods. Right from the component design stage to the final casting production stage, the casting process offers good flexibility and versatility. Foundries offer good products rage and are normally categorized by ferrous foundries (production of various alloys of cast iron and cast steel) and non-ferrous foundries (production of aluminum-base, copper-base, zinc-base, magnesium, and other non-ferrous castings) (Mocellin et al., 2003). Different forms of cast iron include gray iron, white iron, ductile iron, malleable iron, and mottled iron. On the basis of appearance of fracture surfaces, gray iron and white iron have driven such names. Mottled iron is a variety between gray iron and white iron. Ductile iron has good malleable ductility. The good geometric freedom capability and cost-effectiveness have made sand casting a preferred manufacturing process.
Building from Proof of Concept Design
Published in Bahram Nassersharif, Engineering Capstone Design, 2022
Strength is a measure of the material not failing under some applied stress. The strength in the chart is measured for materials under tension except for ceramics which are measured under compression load. Toughness is proportional to the energy required to propagate a crack through the material. Toughness is a descriptor for materials under an impact force. Material composition and processing significantly affect the strength and toughness of the material, particularly for metals. Metals typically deform under an impact force instead of being brittle, so they are considered tough. Cast iron is typically brittle because of the high carbon content formed in flakes during the casting process. Carbon steel becomes hard but brittle during a quenching process. Quenching and tempering carbon steel increase strength and toughness, making it suitable for applications such as hammers, engine components, and saw blades.
An influence of nickel with heat treatment on the microstructure and fracture toughness of austempered ductile iron
Published in Canadian Metallurgical Quarterly, 2023
Subramanya Raghavendra, J. V. Raghavendra, Manjunatha Kuntanahalli Narayanappa, Chandra Shekar Anjinappa, K. G. Srinivas, B. Manjunatha
Nodular iron, also known as ‘Ductile iron,’ is a kind of cast iron in which the graphite is arranged in the form of well-formed nodules (Spherical) rather than flakes as in typical cast iron. The proportion of carbon in nodular iron ranges from 3.2 to 3.6% [1]. Nodular iron has a wide range of uses in the automotive, industrial, agricultural, and piping industries. The typical austempering method is used to convert nodular iron to austempered structure, where austenite converts to Bainite with certain remaining Austenite. ADI finds its products beneficial in a variety of industrial sectors, including automotive, military, rail road, agricultural, earth moving, power plants, and mining. The microstructure of ADI is unusual, consisting of acicular (Bainitic) ferrite with some preserved stabilised austenite.
Cost reduction for achieving competitiveness through industrial experimentation in SG casting for Automotive application
Published in Canadian Metallurgical Quarterly, 2022
Vasu Ramanujam, K. Narashiman, Rajagopal Ananthasubramaniam
Ductile iron is defined as a high carbon-containing, iron-based alloy in which the graphite is present in compact, spherical shapes rather than in the shape of flakes, the latter being typical of grey cast iron. Higher is the carbon, more is the graphite formed, and lower are the mechanical properties. Carbon lowers the melting point of metal and thus acts as a graphatiser to favour the formation of grey cast iron. As the number of graphite increases in the melt, there is a relatively small decrease in strength, elongation, modulus of elasticity, and density. In GGG-50, ductile iron (ISO Grade) carbon requirement is 3.4%–3.6% in the final casting for sufficient graphitisation (nodules) to take place. In the bath, it should be 3.7%–3.8% carbon to produce the product containing 3.5% carbon, as it is due to the loss taking place in solidification and in carbide formation.
Formation behaviours of blowhole and chill layer by GTAW in cast iron
Published in Welding International, 2018
Toshiyuki Hasegawa, Michinori Okubo
Cast iron, which is easily manufactured and has good wear resistance and vibration damping capability, is widely used in industrial and other transport machinery including construction machinery and automobile parts. Its cheapness and recyclability also mean that it will in all probability be subject to increasing demand, not least because of the requirements for further reductions in the cost of machinery and improvements in the global environment. However, the high-carbon content of cast iron means that it is poorly weldable and welding has long been very limited.