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The Benefits of Iron Casting Science – Cast Iron

Cast iron typically means gray cast-iron, but is identifies a grouping of ferrous alloy which harden with an eutectic.  Iron accounts for over 95% the alloying materials, while the primary alloying elements are carbon and silicon. The quantity of carbon in solid iron is 2.1-4% while ferrous alloys with less carbon are called low carbon steel.

Fe-C-Si alloys

Cast-iron has significant quantity of silicon typically 1.3%. these alloys should be considered ternary Fe-C-Si alloys. Despite this, the rules of solid iron solidification are accepted from the binary iron carbon phase diagram, where the eutectic point lies at 1154 degree Celcius and 4.3 wt% carbon.

Because solid iron has this composition, its softening temperature of 1150 to 1200 degree Celsius is about three hundred degrees less than the softening point of pure iron. Cast-iron has a tendency to be brittle, though the name of certain alloys may suggest opposite.

The colour of a fracture surface might be utilised to spot an amalgamate ; carbide imperfections permit cracks to pass straight thru leading to a smooth “white” surface, while graphic flakes deflect a brief crack and initiate numerous new cracks as the material breaks, leading to a coarse surface that looks gray with its low softening point, good fluidity, castability, fantastic machinability and wear rising resistance, cast irons became an engineering material with a big range of uses like pipes, machine and auto parts.

Production Process of Cast Iron

Cast-iron is produced by remelting pig iron, usually with big quantities of scrap iron and steel and initiating steps to get rid of undesired pollutants like phosphorus and sulfur. Dependent on use carbon and silicon content are reduced to the mandatory levels that may be anywhere from two percent to 3.5% and one percent 3 p.c. respectively.

Other elements are then added to the melt before the last form being manufactured by casting. Iron is often liquified in a little blast furnace called cupola. After softening is over the softened iron is ladled from the forehearth of blast furnace.

Benefits of Cast Iron Process

This system was developed by the Chinese whose inventive concepts brought radical change in field of metallurgy. Before that iron was liquified in an air furnace, which is a sort of reverberatory furnace. Some blessings of cast iron in engineering uses :

A ) A family of metals having capacity of being utilized for engineering and production needs.

B ) You may have it in a large range of mechanical characteristics.

C ) Good strength to weight proportion.

D ) Often less expensive than other competing metals and lower monetary cost per unit of strength compared with other metals.

E ) Smaller density and higher thermal conductivity then steels at similar tensile strength levels.

F ) Simply mechniable, permits high speeds and feeds and less energy due to free graphite being presence.

G ) Many iron castings could be utilised without heat treatment ( as cast ) but when needed might be heat treated to extend overall properties or local property like surface toughness.

H ) Superb damping capacity particularly in gray irons.

I ) Chemical research might be modified to give improved special properties like corrosion resistance, oxidization and wear resistance.

J ) Speedily changes from design to finished products.

K ) Capable of having highly complicated sizes from oz. to one hundred tons.

L ) Of flexible pattern and capacity to enhance appearance for sales appeal.

M ) You can make complex shapes as well as extraordinarily thin to awfully thick sections.

N ) Capable of redesigning and mixing a few parts from metals into a single casting so lessening assembly cost and time.

O ) Capable of being cast with inserts of other metals.

P ) Many casting systems for low, medium or high production.

Q ) Less bent towards residual stress than other competing metals.


Engineer Sheikh Imran is a manufacturing expert of over ten years experience in the field of manufacturing. He did his BE in Industrial Manufacturing from NED University in 2010. Imran has broad knowledge and expertise in the areas of metal cutting and cutting tools and in R & D of manufacturing methodologies. He has worked for more than 8 years about various projects under the following heads: Manufacturing process improvement Boiler Manufacturing Manufacturing system improvement Projects

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