Posts Tagged ‘carbon’
Information about Cast Iron and Its Benefits
Information about Cast Iron and Its Benefits
Cast iron known as gray iron and it is one of the famous ferrous alloys for iron and metal industry. In cast iron carbon ( c) and silicon (s) are the main element with the amount of 2.1 to 4 wt% and 1 to 3 wt% respectively. Also you can mix Cr, Ni, Mo and Cu according to your requirement.
In India many Investment casting foundry used different ferrous metals such as carbon steel, alloy steel, stainless steel, cast iron for castings which formally known as ferrous castings. But they mostly prefer cast iron with its different compositions including white cast iron, gray cast iron, malleable cast iron, ductile iron etc. See below some basic description for above compositions.
White Cast Iron
White cast iron contains lower silicon and metastable phase cementite, Fe3C rather than graphite. It offers hardness with the rate of toughness. Generally white cast iron classified as cermet. Cast iron is used for structural components manufacturing for good hardness with low cost. Also it used for manufacturing or industrial parts such as slurry pumps, shell liners and lifter bars in ball mills and grinding mills, and the teeth of a backhoe’s digging bucket.
Grey Cast Iron
These types of cast iron characterize by its graphitic microstructure and its widely used cast iron based on weight. Cast iron having 2.5 to 4.0% carbon, 1 to 3% silicon so it’s pure iron also contain less tensile strength and shock resistance than ductile iron or malleable iron and its compressive strength is low then carbon steel. Many casting foundries used gray cast iron to manufacturing some general engineering components such as protective cover, cover, oil pan, hand wheels, frame, floor, hammer, small handle, machine base, frame, box, knife, bed, bearing seat, table, wheels, cover, pump, valve, pipe, flywheel, motor blocks.
Malleable Cast Iron
Its properties are same as mild steel property and it is heat treated iron with carbon alloy which solidifies with graphite free structures means carbon is present in the cemnetite form (Fe3C). This type of cast irons contains different chemical element composition such as carbon, silicon, manganese, sulfur, phosphorus etc. Also it possesses considerable ductility and toughness
All of the above cast iron compositions are widely used for making high quality and higher resistive part for industries. Also auto parts manufacturers in India widely used cast iron for making higher strength and corrosion free automotive parts with help of auto component castings
I am experienced Mechanical Engineer from India. I had been working in many big mechanical industries in India. Thorgh my experience I learned lots of new thing and also gain more and more knowledge. I would like to share various casting process and casting knowledge through the artitcles.
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ductile iron & gray iron castings foundry in the USA. Mabry Castings LTD, www.mabrycastings.com
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Welding cast iron can be easy
Welding cast iron can be easy
There are certain elements and materials that are difficult to weld. Cast iron is one such item. But with little effort and application of right strategies, it can also be welded. In most of the cases, welding on this item includes casting to repairs. In the foundry, the repair work is done. It is done where the casting operation is performed. The casting defects may be repaired after the portioned is machined. Mis-machined cast iron portion or part may require some repair welding, especially when holes are drilled or made in the wrong area. Welding technology is used for repairing broken cast iron parts. Broken cast iron parts are common. It is due to the brittle nature of the cast iron.
There is a wide variety of cast iron. Gray cast iron is one of the most popular types. There are some information regarding this variety of cast iron. It will definitely prove to be helpful for you to understand the welding challenges. Cast iron has 2%-4% carbon content. It is ten times much than the steel. Due to the high carbon content the carbon forms into flakes of graphite.
Molted iron is allowed to cool after it is poured into a mould. This is done during the preparation of casting. Castings that are free from any crack can be made when high carbon element is permitted to cool slowly. This is one of the most important information for you. It will be of great help while welding cast iron, especially during and after the completion of welding operation. You may allow the casting to be too slow or keep it cool so that the rate of cooling is not so crucial.
Most of the cast iron has a critical temperature of 1450 degrees F. this temperature condition can cause cracking. The arc will definitely heat the casting iron to temperatures above this point. So, it is very crucial on your part to check whether the casting is done for long periods at this temperature. It is one of the most important areas that you need to look at.
There are two common techniques of welding. One is welding through pre-heating procedure ad another is without pre-heating. In most of the cases, cast iron is welded through the pre-heating technique. In fact, it is the coon method used by most of the welding experts. Another method is to weld the cast iron by cooling it.
So now that you know the methods make sure that you find out what your requirements are and select the best method as per your needs.
The author of this article is a great welder. As a professional welder the author has great knowledge on the same. His articles are handy references for any welder out there.
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Introduction to Steel Castings
Introduction to Steel Castings
Steel casting is a kind of process which involves casting of various types of steel. Steel castings are mainly used when cast irons can’t provide enough strength and stun resistance. Hydroelectric turbine wheels, forging presses, gears, railroad truck frames, valve bodies, pump castings, mining machinery, marine equipment and engine castings are some of the example of high level steel castings.
Steel Castings are mainly categorized into two groups as Carbon Steels and Alloy Steels:
Carbon steel is one with main alloying constituent is Carbon. The American Iron and Steel Institute (AISI) defines carbon steel as: “Steel is considered to be carbon steel when no minimum content is specified or required for chromium, cobalt, columbium, molybdenum, nickel, titanium, tungsten, vanadium or zirconium, or any other element to be added to obtain a desired alloying effect; when the specified minimum for copper does not exceed 0.40 percent; or when the maximum content specified for any of the following elements does not exceed the percentages noted: manganese 1.65, silicon 0.60, copper 0.60.”
The term “carbon steel” may also be used in reference to steel which is not stainless steel; in this use carbon steel may include alloy steels. Steel with a low carbon content has properties similar to iron. As the carbon content rises, the metal becomes harder and stronger but less ductile and more difficult to weld. In general, higher carbon content lowers the melting point and its temperature resistance. Carbon content influences the yield strength of steel because carbon atoms fit into the interstitial crystalline lattice sites of the body-centered cubic (BCC) arrangement of the iron atoms. The interstitial carbon reduces the mobility of dislocations, which in turn has a hardening effect on the iron. To get dislocations to move, a high enough stress level must be applied in order for the dislocations to “break away”. This is because the interstitial carbon atoms cause some of the iron BCC lattice cells to distort.
Being a material scientist I research on different material patterns. In this article I’ve explained <a rel=”nofollow” onclick=”javascript:_gaq.push(['_trackPageview', '/outgoing/article_exit_link']);” href=” http://www.castechindia.com/steel-castings.html”>steel castings</a> and <a rel=”nofollow” onclick=”javascript:_gaq.push(['_trackPageview', '/outgoing/article_exit_link']);” href=”http://www.castechindia.com/”>metal castings</a>.
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1st of 5 in a video series featuring a simple evaluation comparing wheel impact absorption between an 8×2 polyurethane on cast iron core and Durastar’s 8×2 polyurethane on glass-filled nylon (fiberglass) core. This video features 26 of 87 hits to destroy this wheel. www.durastarcasters.com
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Metal Casting Technology: Solidification of a 500 lb. Carbon Steel Cover Casting
Alloy Casting Industries, metal casting technology, metal casting simulation, computer modelling, solidification, virtual reality, foundry, mold, molten metal, carbon steel, stainless steel, super duplex stainless steel, cast iron, ductile iron, gray iron, white iron, AFS, SFSA, engineering,…
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Iron Casting
Iron casting
Cast iron generally means grey cast iron, but is identifies a group of ferrous alloys which solidify with a eutectic.
Overview:
Iron accounts for more than 95% the alloy material, while the main alloying elements are carbon and silicon. The amount of carbon in cast iron is 2.1-4% while ferrous alloys with less carbon are called carbon steel by definition. Cast iron has appreciable amount of silicon normally 1.3%. Therefore, these alloys should be considered ternary Fe-C-Si alloys.
In spite of this, the principles of cast iron solidification are understood from the binary iron carbon phase diagram, where the eutectic point lies at 1154 °C and 4.3 wt% carbon. Because cast iron has this composition, its melting temperature of 1150 to 1200 °C is about 300 degrees less than the melting point of pure iron. Cast iron tends to be brittle, though the name of particular alloy may suggest opposite. The color of a fracture surface may be utilized to identify an alloy; carbide impurities allow cracks to pass straight through resulting in a smooth “white” surface, while graphic flakes deflect a passing crack and initiate countless new cracks as the material breaks, leading to a rough surface that looks grey with its low melting point, good fluidity, castability, excellent machinability and wear rising resistance, cast irons have become an engineering material with a wide range of uses like pipes, machine and auto parts.
Products:
Cast iron is produced by remelting pig iron, normally with large quantities of scrap iron and steel and initiating steps to remove unwanted contaminants like phosphorus and sulfur. Depending on use carbon and silicon content are lessened to the required levels which may be anywhere from 2% to 3.5% and 1% 3% respectively. Other elements are then added to the melt prior to the final form being made by casting.
Iron is generally melted in a small blast furnace called cupola. After melting is over the melted iron is ladled from the forehearth of blast furnace. This system was developed by the Chinese whose innovative ideas brought revolution in field of metallurgy. Before that iron was melted in an air furnace, which is a type of reverberatory furnace.
Some advantages of cast iron in engineering uses:
a) A family of metals having capacity of being used for engineering and production needs.
b) You can have it in a wide range of mechanical and physical properties.
c) Good strength to weight ratio.
d) Generally cheaper than other competing metals and lower financial cost per unit of strength compared to other metals.
e) Lesser density and higher thermal conductivity then steels at comparable tensile strength levels.
f) Easily mechniable, allows high speeds and feeds and less energy due to free graphite being presence.
g) Many iron castings may be utilized without heat treatment (as cast) but when required may be heat treated to increase overall properties or local property like surface hardness.
h) Very good damping capability especially in grey irons.
i) Chemical analysis may be changed to give improved special properties like corrosion resistance, oxidation and wear resistance.
j) Quickly changes from design to finished goods.
k) Capable of having highly complex sizes from ounces to 100 tons.
l) Of flexible pattern and capacity to improve appearance for sales appeal.
m) You can make intricate shapes as well as very thin to very thick sections.
n) Capable of redesigning and combining two or more parts from metals into a single casting thereby 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 tendency toward residual stress and warpage than other competing metals.
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