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August 26, 2022

Introduction
Cast iron is obtained by remelting pig iron with coke and limestone in a furnace called a
cupola. It is mainly an alloy of iron and carbon. The carbon content of cast iron varies
between 1.7% and 4.5%. It also contains small amounts of silicon, manganese,
phosphorus, and sulfur.

Cast Iron has brittle properties and hence cast iron is not preferable for parts that are
subjected to vibration & shocks. Good Casting properties, Low Cost, high compressive
strength, excellent wear resistance & machinability property make it a valuable
engineering material. The compressive strength of cast iron is much greater than tensile
strength. Below is the ultimate strength value of cast iron:

Tensile Strength – 100 to 200 MPa

Compressive Strength – 400 to 1000 MPa
Shear Strength – 120 MPa

Types of Cast Iron

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Cast Iron are of the following types:

Grey Cast Iron

Grey cast iron is a type of iron found in castings. It is known for its grey color and
appearance caused by the graphite crushing of the material. What makes Grey cast iron
“grey cast iron” is the graphite flake structure that forms during the cooling process from
the carbon contained in the component.

The grey color is due to the carbon being in the form of free graphite. It has low tensile
strength, high compressive strength, and no ductility. Grey cast iron has free graphite on
its surface and hence it has lubricative properties. For this reason, it is very suitable for
areas where a gliding effect is required. Grey cast iron is the result of both the materials
used and the processes used to cast the parts.

In other words, the properties of grey cast iron change depending on what kind of
material is melted and poured into the mold and what kind of casting method is used.
With a powerful microscope, you can see the graphite microstructure that makes grey
cast iron very easy to identify. Grey cast iron has small black graphite flakes. These flakes
cause cracks and make the material look grey. The mechanical properties of grey cast
iron are controlled by the size and shape of graphite flakes present in the microstructure.

The popularity of grey cast iron (cast iron) components is due to the fact that grey cast
iron is one of the cheapest types of iron castings that can be produced and has
acceptable ductility, tensile strength, yield strength, and impact strength for most
applications cast iron also has an excellent ability to dampen vibrations, making it ideal
for machine bases and many enclosure applications. Grey cast iron has high thermal
conductivity and conducts heat more easily through the metal. Grey cast iron parts are
often used in machine tools.

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Chemical Composition

Carbon: 3-3.5%, Silicon: 1-2.75%, Manganese: 0.40-1.0%, Phosphorous: 0.15-1%,

Sulphur: 0.02-0.15% and remaining percentage is Iron.

Application

Automobile bodies
Cylinder blocks
Heads, housings
Flywheels
Pipes and fittings
Agricultural equipment

White cast Iron

White Cast Iron

Its white color is due to the fact that it contains no graphite and all the carbon is in the
form of carbide (known as cementite), the hardest component of iron. White cast iron has
high tensile strength and low compressive strength. Because of its hardness, it cannot be
processed with ordinary cutting tools and requires grinding as a molding process. White
cast iron can be cast against a mold or made by regulation analysis. This mold is used
when products such as car wheels, grain crusher rollers, jaw crusher plates, etc. require a
hard, wear-resistant surface.

Chemical Composition

Carbon: 1.75-2.3%, Silicon: 0.85-1.2%, Manganese: Less than 0.40%, Phosphorous:

Less than 0.2%, Sulphur: Less than 0.12% and remaining percentage is Iron.

Application

Mining Crusher parts

Roller Crusher
Oil sand Application
Lifting Bars

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 Slurry Pumps
Cement Mixers
Pipe Fittings.

Malleable Cast Iron

Malleable Cast Iron

The malleable cast iron is a cast iron-carbon alloy that solidifies in the as-cast condition in
a graphite-free structure, i.e. total C% is present in the form of cementite (Fe3C). It is less
brittle & more ductile as compared to grey cast iron. The tensile strength of the malleable
cast iron is usually higher than that of grey cast iron and has excellent machining
qualities. Malleable cast iron is preferable for the machine parts in which a degree of
accuracy is required.

In order to obtain a malleable iron casting, it the first cast into molds of white cast iron. A
suitable heat treatment (i.e., annealing) then separates the bound carbon in white cast
iron into graphite nodules.

There are two methods of malleable solid iron particularly whiteheart malleable solid iron
and blackheart malleable solid iron.

Whiteheart Process

White iron castings are packed in iron or steel cases surrounded by a mixture of new and
used hematite ore. The box is slowly heated to a temperature of 900-950°C and held at
this temperature for several days. During this time some of the carbon from the casting is
oxidized and the remaining carbon is distributed as small patches throughout the
structure. A warming process is followed by a cooling process, which lasts for several
days. The result of this heat treatment is a casting that is strong and withstands heat
treatment without breakage.

Blackheart Process

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The castings used are free of carbon and sulfur. They are packed in a neutral substance
like sand and the reduction of sulfur helps speed up the process. The castings are heated
to a temperature of 850-900°C and held at this temperature for 3-4 days. In contrast to
the White Heart process, this process turns carbon into globules. Castings made with this
process are more malleable

Types of Malleable Cast Iron

Black malleable iron
It is obtained after annealing in an inert atmosphere and exhibits black fracture. The
microstructure developed in the casting should have a matrix of ferrite with essentially
tempered carbon and no flake graphite.

Pearlitic malleable iron

It is obtained after heat treatment and has a homogeneous matrix consisting essentially
of pearlite or other transformation products of austenite. Graphite is in the form of lumps
of charcoal. The microstructure must not contain flake graphite.

White malleable iron

It is obtained after annealing in a decarburizing atmosphere and has a silvery grey

fracture surface with a dark grey to the core of black. The microstructure that develops in
a cut depends on the size of the cut. Small section castings are mainly ferrite with some
perlite.

Chemical Composition

Carbon: 2.16-2.90%, Silicon: 0.90-1.90%, Manganese: 0.15-1.25%, Phosphorous: 0.02-

0.15%, Sulphur: 0.02-0.20% and remaining percentage is Iron.

Application

Hubs of wagon wheels

Small fittings for railway rolling stock
Brake supports
Parts of agricultural machinery
Pipe fittings
Door hinges
Locks.

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 Nodular Graphite Cast Iron

Nodular Graphite Cast Iron

This type of cast iron is obtained by adding a small amount of magnesium (0.1-0.8%) to
the molten metal. The addition of magnesium causes the graphite to take the form of
small nodules or spheres instead of the usual angular flakes. It has excellent fluidity,
castability, tensile strength, toughness, wear resistance, pressure resistance, weldability,
and machinability. Commonly used for castings that require impact resistance and good
machinability.

Chemical Composition

Carbon: 3.60-3.70%, Silicon: 2.20-2.40%, Manganese: Less than 0.3%, Phosphorous:

Less than 0.03%, Sulphur: Less than 0.020% and remaining percentage is Iron.

Application

Hydraulic cylinders
Cylinder heads
Rolling mill rolls
Centrifugal casting products
Valves & Fittings
IC Engines
Steel Mill Rolls

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 Chilled Cast Iron

Chilled Cast Iron

White cast iron is made by quenching hot metal. Cast iron produced using quenching is
called chilled cast iron. All castings are skin cooled by the contact of molten iron with cold
sand in the mold. However, in most castings, this hardness penetrates to a very shallow
depth (less than 1mm). Castings can be intentionally cooled or inadvertently cooled to a
great depth. Targeted cooling is achieved by inserting iron or steel inserts (tremblers) into
the mold. When the molten metal comes in contact with the mold, its heat is easily
dissipated and a hard surface is formed. Radiators are used on all surfaces of castings
that are resistant to wear and friction.

Chemical Composition

Carbon: 3.30-3.50%, Silicon: 2.20-2.50%, Manganese: 0.91%, Nickel: 1.49%,

Molybdenum: 0.84%, Chromium: 0.75%, and remaining percentage is Iron.

Application

Air Blast machine

Used for Surface preparation
Ballast

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 Mottled Cast Iron

Mottled Cast Iron

A product between gray cast iron and white cast iron in composition, color, and general
properties is mottled cast iron. This is obtained in castings with specific wear surfaces
that are cooled.

Chemical Composition

Graphite: 1.75%, Combined Carbon: 1.75%, Iron: 93.5%, remaining slag.

Application

Manhole covers
Pipes
Fire Plugs

Alloy Cast Iron

Alloy Cast Iron

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Cast Iron containing Silicon, Manganese, Sulphur, and Phosphorous is called Plain Cast
Iron. Alloyed cast iron is created by adding sufficient amounts of alloying elements such
as nickel, chromium, molybdenum, copper, and manganese. These alloying elements
increase strength and lead to improved properties. Alloyed cast iron has special
properties such as increased strength, high wear resistance, corrosion resistance, and
heat resistance. Alloy cast iron is widely used in automotive parts such as gears,
cylinders, pistons, piston rings, crankcases, crankshafts, camshafts, sprockets, wheels,
pulleys, brake drums, shoes, crusher and grinder parts, etc.

Chemical Composition

Carbon: 0.02-0.03%, Silicon: 0.02-0.10%, Manganese: 0-0.02%, Phosphorous: 0.05-

0.25%, and remaining percentage is Iron.

Application

Brake Drums
Disks
Automotive applications.

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About the Author

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Noaman Adenwala
Mechanical Engineer with strong knowledge of design tools, technologies, automobiles
etc. Sharing insightful knowledge to help people.

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