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Ferrous Casting Alloys Ferrous Casting Alloys Introduction Iron-Carbon Phase Diagram Basic Cast Iron Metallurgy Cast Irons Microstructural Formation Solidification Specifications, properties and applications Cast Steels Ferrous Casting Alloys Literally iron-based casting alloys Cast Iron – iron alloy with significant C and Si Gray Ductile Compacted Graphite Austempered Ductile Malleable Specialty Cast Steel – iron alloy with low C and Si Ferrous Casting Alloys Iron – Carbon Phase Diagram Iron – Carbon Phase Diagram Points of note Phase changes of pure iron (? ? ? ? ?) Eutectic, eutectoid peritectic reactions Graphite is stable, but metastable Fe3C (aka cementite or iron carbide) occurs frequently Desired for cast irons: graphite eutectic product, cementite eutectoid product Iron – Carbon Phase Diagram What microconstituents are possible on cooling from austenite? Depends on cooling rate Pearlite Bainite – upper and lower Martensite Iron – Carbon Phase Diagram Pearlite Lowest relative cooling rates At eutectoid composition (0.78% C) The eutectoid product – ferrite + cementite – grow in lamellar form Nucleates at prior austenite grain boundaries Pearlite Pearlite Slowest relative cooling rates At eutectoid composition (0.78% C) The eutectoid product – ferrite + cementite – grow in lamellar form Nucleates at prior austenite grain boundaries Cooling rate determines interlamellar spacing Lower rates – coarse spacing More massive cementite platelets mean lower strength better machinability 20 – 23 HRC Higher rates – fine spacing Higher strength poorer machinability 30 – 35 HRC Pearlite Pearlite Off eutectoid composition Hypoeutectoid Ferrite nucleates at grain boundaries Pearlite grows at eutectoid temperature Hypereutectoid Cementite nucleates at grain boundaries Pearlite grows at eutectoid temperature Cast irons are (extremely) hypereutectoid We’ll discuss this further with steels Bainite Martensite Bainite Intermediate cooling rates Ferrite “lath” with Fe3C Two ty