Classification of Alloys

Metals Classification

TYPES

Grey Cast Iron

Composition: 1. Sulphur 2. Phosphorous 3. Manganese 4. Silicon 5. Carbon : 0.02 to 0.10% : 0.15 to 1 % : 0.40 to 1.0% :1 to 2.8% : 2.5 to 3.8% &

Remaining Percentage is Iron. Grey colour is due to carbon is present in the form of Free Graphite

Properties:
1. High Compressive strength. 2. Low tensile strength.

3. No ductility.
4. Easily Machined to get a good finish. 5. Good fatigue resistance.

6. High Fluidity and ability to make sound castings(Low

Shrinkage) 7. Melting Point around 1130 to 1250 degrees. 8. Able to absorb vibrations.

Applications
1. Where sliding action is required this material is Used. 2. Machine tool bodies (bed, frame) 3. Automotive cylinder blocks, heads, Housings, Flywheels. 4. Water Pipes for underground purposes. 5. Piston rings.

6. Frames for electric motors.

7. Manhole covers.

Microstructure

Characteristics
Gray iron is basically is an alloy of carbon & silicon with Iron.

It is easy to cast into a desired shape in sand mould.

Length of flakes vary from 0.05mm to 0.1mm. When fractured, gray iron gives gray clour appearance.

High resistance to wear.

Low ductility and Low strength when compared to steel. It has a shrinkage of 1mm in 100mm.

WHITE CAST IRON

White Cast Iron

It shows White fracture when it fractured. 1. Sulphur : Less than 0.12% 2. Phosphorous : less than 0.2% 3. Manganese : less than 0.40 4. Silicon : less than 1% 5. Carbon : 1.75 to 3.6%. The White colour is due to fact that is no graphite and whole of the carbon in the form of carbide (Cementite). Which is Hardest Constituent of iron. White Cast Iron is Produced by Chilling (Cooling rapidly)

Properties..
White cast irons are formed with silicon less content and

rapidly cooling rate resulting in carbon existing in cementite instead of graphite and the fracture surface appears as white and are termed as white cast iron.
High Tensile Strength.

Low compressive strength.

It cannot be machined with ordinary cutting tools, it requires

Shaping process. Abrasion resistant. Brittleness can be reduced by reducing carbon content. Because of more cementite present, the white iron is very hard and brittle.

MICROSTRUCTURE:

Malleable Cast Iron

Malleable cat iron is one which can be

hammered & rolled to obtain different shapes. It is obtained from Hard and Brittle white iron through a controlled heat conversion process. An alloy malleable cast iron contains chromium and Nickel which possesses high strength and corrosion resistance. It possess high yield strength.

High Youngs modulus and low coefficient

of thermal expansion. Good wear resistance and vibration damping capacity. It can be used from -51 degrees to 649 degrees Moderate cost

Malleable Cast Iron

It is a ductile and may be bent without breaking or

fracturing the material. Tensile strength is higher. Excellent Machining Qualities. It is used for machine parts for which steel forgings would be too expensive and in which the metal should have a fair degree of accuracy. It is Separated by using Whiteheart Process and Blackheart Process.

Malleable Cast iron Microstructure

Applications
Rail Road

Conveyor chain links

Automotive Industry

Camshafts Wrenches
Spanners

Crankshafts

Nodular Cast Iron (or) Ductile (or) Spheroidal Cast iron

By adding small amount to Magnesium (Mg) (or) Cerium

(Ce) to gray Cast iron before casting produces a microstructure having Nodule (or) Sphere like structure instead of flakes. The matrix surrounding these spherical particles may be pearlite or Ferrite depending on heat treatment and it is normally pearlite for cast piece.

Properties
More Stronger and Ductile than Grey cast iron. Very good machinability. Castability and Wear resistance.

Applications
Pumps and compressors, I.C Engines, Power transmission equipments, Earth moving Machinery. Paper Industries Machinery. Valves and Fittings.

Nodular Cast iron (or) Ductile Cast iron