Solid, silver gray in color odor odor threshold vapor density none melting point freezing point specific gravity relative density approximately 2350 f 0 c 7. It is a perfect solution to avoid the problem of corrosion. Metallurgy of cast irons outoffurnace processing of molten cast iron study support doc. Iron melting points of binary eutectic alloys fe iron binary eutectic alloys and melting points. Low s grey irons and ductile irons treated with high re fsm reduce effectiveness. Astm a48 class 30 related standards din gg20, bs 1452 grade 220 is a gray cast iron. Download pdf design of gray iron castings free online new. Comparison of mechanical properties of gray and ductile. Production of gray iron castings asm international. In telco, jamshedpur, the melting of gray cast iron was carried out in induction melting furnace coreless type of mains frequency of capacity 12 t and power of 2,400 kw. Gray iron astm a48 class 30 data sheet penticton foundry. Scraps such as cast iron engine block, foundry returns, ferroalloys and pure metals were melted in a 60 kg rotary furnace at the melting temp of cast iron which is 0. Since 1923, the warsaw foundry company has been providing quality castings from gray iron, ductile iron, and alloy gray iron, to customers in a wide range of industries. Gray iron castings sds sc000041 rev page 3 of 10 sdsgic 1017 when nickel is heated to high temperatures, which may occur during welding and thermal cuttingof this product, it may form nickel oxides.
Specifically, what makes grey iron grey iron, is the graphite flake structure that is created during the cooling process from the carbon that is in the component. It melts about 200kgs per hour but i ran it mostly 40 mins at a time because of the time needed to. In the product as sold, chromium is in the elemental form. While gray iron does not have a measurable yield strength, the range for tensile strength is 20,000 psi 60,000 psi. Both are brittle, but a malleable cast iron produced by a prolonged heat treatment was developed in france in. It is well written, and he has a couple of pictures in the book. For the benefit ofthe purchaser, typical properties of grey cast iron have been added in annex c. Introduction synthetic cast iron melting on the steel scrap base only without the pig iron in solid charge was presented in many previously published papers. Aug 29, 2011 9 cupola melting cast iron scrap for projects in my workshop. Chromium is often added to improve hardness and strength of grey iron, and for this purpose, the chromium level is raised to 0. Pdf experimental investigation of melting gray cast iron. The overall shape is cylindrical and the equipment is arranged vertically, usually supported by four legs.
We specialize in green sand molding with wood, plastic, steel, and aluminum patterns, providing castings from 1 ounce to 150 lbs, in tensile strengths from 25,000 to 100,000 psi. Effect of shakeout time on microstructure and hardness. The widespread use of the grey cast iron can mainly be attributed to its cost efficiency and easy. Ales hanus this study material has been created as a part of the development program called creation of electronic study material for the study programs of fmme in 2008 ostrava 2014. Information to be supplied by the purchaser while ordering grey iron castings according to this specification is given in annex d. It melts about 200kgs per hour but i ran it mostly 40 mins at a time because of the time needed to make moulds and break up scrap so. Cast iron foundry energy use per shipped ton process type iron type electricity kwhton natural gas thermston coke mmbtuton total mmbtuton cupola gray iron 6,061 23.
G iron with free download of seminar report and ppt in pdf and doc format. Fonderie saguenay are a jobbing shop specializing in producing components in materials such as gray iron and ductile iron. Sulfur in gray iron that isnt tied up with manganese will weaken the iron drastically. Now, lets look at the uses of grey cast iron as per its class. A total of thirtytwo different irons from eleven separate foundries have been tested. It is brittle with low tensile strength, but is easy to cast.
Grey cast iron, or grey iron, has graphitic flakes which deflect a passing crack and initiate countless new cracks as the material breaks. In other to ensure total melting of material charge, it was supper heated to 1550. The low cost of production and attractive properties. Astm a48 a48m standard specification for gray iron castings, grades including class no. Inoculation of cast irons an overview 357 combination with 0. Grey cast iron contracts by approximately 1 percent, while white cast iron contracts by between 2 and 2. Metallurgy of cast irons outoffurnace processing of. A cupola or cupola furnace is a melting device used in foundries that can be used to melt cast iron, niresist iron and some bronzes. Cast iron is an iron carbonsilicon alloy, containing from 2 to 4 percent carbon and 0. However, when a small amount of magnesium is added to the melt before casting, the result is a spheroidal graphite iron, in which graphite appears read more. Metallography and microstructures of cast iron janina m.
Cracktipgeometryaffectsstressatthecrack,dependingonaandbofthecrack. Based on the mechanical properties and the wear test, this cast iron is expected to demonstrate a sixtime longer life in service, compared to the currently used. Impact ductile iron has a greater resistance to impacts, and is able to resist a minimum of 7 foot pounds of impact versus 2 pounds of impact for gray iron. Type iron gray class 30, class 35 by request melting 315 ton coreless induction furnaces inside storage for scrap metal molding 1fbo 3 roberts sinto 20 x 26 x 8 over 8 1herman mold master 34 x 44 x 12 over 12 1international jolt squeeze line 34 x 56 x 10 over 8 core manufacturing shell core dependable 200. Iron melting cupola furnaces for the small foundry. In the structure of gray cast iron, a large part or all of the carbon is in the form of flakes or nodules of graphite. High power, medium frequency coreless induction furnaces are commonly used in electric melting grey iron foundries. Pdf melting of grey cast iron based on steel scrap using. Safety data sheet sds gray and ductile iron castings.
The size of a cupola is expressed in diameters and can range from 1. Latent heat of melting for some common materials latent heat of fusion when changing between solid or liquid state for common materials like aluminum, ammonia, glycerin, water and more. The differences between ductile iron and gray iron. The overall shape is cylindrical and the equipment is arranged. Effect of manganese, silicon and chromium additions on. Gray iron consists of graphite flakes in a metallic matrix. Pdf melting of grey cast iron based on steel scrap using silicon. Cast iron is mainly manufactured by melting pig iron and then pouring it into the cast or mould of desired shapes and sizes. Our v2 class 40 continuous cast gray iron is a better alternative.
It has the second lowest strength compared to the other variants of grey cast iron. Pdf the paper presents the issue of synthetic cast iron production in the electric induction furnace exclusively on the steel scrap base. Properties of gray cast iron as affected by casting conditions. When fractured, it is grayish in colour hence the name specifically, a fracture will follow along the graphite flakes which are gray. Microstructural changes in the fusion region, deposited filler metal, fusion boundary region and heat. Jun 18, 2015 there are many grades of gray iron as per the astm a48 standard. Graphitic cast iron has a dark gray or almost black fracture xu et al. Also explore the seminar topics paper on spheroidal graphite s. Chromium improves the elevated temperature properties of grey iron. The following table of mechanical properties has been compiled to assist with the selection of the ideal grade of cast iron for your castings. Castings are classified on the basis of the tensile strength of the iron in separately. It is the most common cast iron and the most widely used cast material based on weight. A microstructural study of local melting of gray cast iron with a stationary plasma arc control of heat input and filler metal composition significantly influences the welding of gray cast iron with the plasma arc process by t. Modification of gray iron produced by induction melting.
Solidification study of gray cast iron in a resistance furnace. This is not a beginners furnace however and it requires a cutting torch, welder, and a small lathe for a couple of parts. Grey cast iron rusts much faster than white at low temperatures, while at high temperatures. Astm a48 a48m03 2016, standard specification for gray iron castings. Large furnaces melt the iron and stay at temperatures ranging 2,600 to 2,800 degrees fahrenheit.
Comparison of mechanical properties of gray and ductile iron. Control of chilling tendency in grey cast iron reuse 1. Gray iron, or grey cast iron, is a type of cast iron that has a graphitic microstructure. Beyond this range, it is necessary to add a graphitised to avoid the formation of carbides and hard edges. This has resulted in low sulphur 1,500 c, contributing to unfavourable. Innovative refractory technology for coreless induction. Grade 25 cast iron is grey cast iron in the asfabricated no temper or treatment condition. Experimental investigation of melting gray cast iron by laser. Resistance to oxidation grey cast iron is highly resistant to rust, which is formed by the reaction of oxygen and iron.
Preconditioning of gray iron melts using ferrosilicon or. Radzikowska, the foundry research institute, krako. In the product as sold, nickel is in the elemental form. This specification covers gray iron castings intended for general engineering use where tensile strength is a major consideration. Pdf experimental investigation of melting gray cast iron by. Oxidization is the process by which oxygen combines with the metal molecules to form rust. Melting iron at waupaca foundry the iron melting process begins at waupaca foundry by selecting from a variety of material solutions to meet each gray iron and ductile iron castings unique specification. Design of gray iron castings download design of gray iron castings ebook pdf or read online books in pdf. The gray iron research institute iron casting research institute.
This chemical analysis is obtained from samples prepared by melting a sufficient scrap of brake rotors that made from a gray cast iron alone, mixed in furnace to simulate the actual practice conditions and then pouring into a sand mold. Class 40 gray iron s hardness ranges from 187 to 269 bhn. Chastains book iron melting cupola furnaces for the small foundry is not a rewrite of information from the past but steve has designed, built and has in use a cupola furnaces suitable for casting those obsolete iron parts you can no longer find or making proto types allin your back yard but only if you have vary good neighbors. An industrial grade hypoeutectic gray iron melt was produced with a chemical composition as shown in table 1. Upon small degrees of supercooling, graphite is formed when the cast iron solidifies from its liquid state. Foundry b is a large automotive foundry melting traditional gray and ductile iron in medium frequency coreless furnaces. Steel scraps were used as the main raw materials including 70% steel scraps and 30% pig iron to prepare the gray cast iron ht250 in a mediumfrequency induction melting furnace. Pdf cercetarea a fost elaborata pentru a investiga efectul elementelor.
Gray iron contains more silicon and is less hard and more machinable than is white iron. There are many grades of gray iron as per the astm a48 standard. Four heats, all melted in a highfrequency induction furnace, were made for each type of iron with maximum heating temperatures. Dec 06, 2011 low melting point grey cast iron has low melting point 1140. In this work, a modified cast iron is developed with the composition 3. V2 class 40 gray iron features a tensile strength of 40,000 psi with a compression strength of 150,000 psi. It is named after the gray color of the fracture it forms, which is due to the presence of graphite. It is a metal that belongs to the first transition series and group 8 of the periodic table. Grade 25 is the astm designation for this material. Sulfur is also reported to be one of the more difficult elements for a spectrometer to read.
It is used for housings where the stiffness of the component is more important than its tensile strength, such as. For ex ample, just to illustrate the order, in gray iron the oxygen. The differences between ductile iron and gray iron castings. This is a nice book on how to build a realatively small cupola for melting iron. This has resulted in low sulphur iron, with a potential. Grey cast iron is one of the most widely used types of cast iron. This causes an expansion that counteracts the shrinkage of the metal during solidi. Synthetic cast iron, grey cast iron, silicon carbide, ferrous alloys carburization, cast iron microstructure 1. Grey iron distributor body inoculated in the ladle with 0. A microstructural study of local melting of gray cast iron. Gray iron is the most widely cast metal and is easier to cast and less costly to produce than other types of cast iron because it neither requires special alloy additions necessary to produce ductile iron or compactedgraphite iron nor does it require annealing. The all data in this documents is referred to chinese standard of gbt.
The average chemical composition of the gray cast iron samples is given in the following table 3. The article provides analysis of results of gray iron experimental melts in induction furnace and the following melt modification with bariumstrontium carbonate. Pdf preconditioning of electrically melted grey cast irons. Safety data sheet sds gray and ductile iron castings in. G iron with abstract or synopsis, documentation on advantages and disadvantages, base paper presentation slides for ieee final year mechanical engineering me or production automobile students for the year 2019 2020. Specifically, what makes grey iron grey is the graphite flake structure from the carbon created during cooling the casting. Iron melting points of binary eutectic alloys fe iron binary eutectic alloys and melting points latent heat of melting for some common materials latent heat of fusion when changing between solid or liquid state for common materials like aluminum, ammonia, glycerin, water and more. Properties of gray cast iron as affected by casting. Seventeen gray cast irons from cupola and induction melting, four ductile irons, including a quench and temper grade. Grey cast iron composition and property grey cast iron gray iron is so called because of the colour of the fracture face.
Oxygen activity in ductile cast iron melts with ferritic. Study of the effect of solidification on graphite flakes. Gray iron specifications frequently limit sulfur contents to. The furnace is lined with acid refractory and the coils are water cooled the pressure of circulating cooling water is maintained at a pressure of 0.
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