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Grey cast iron
# Grey cast iron is characterised by its graphitic microstructure, which causes fractures of the material to have a grey appearance
# It is the most commonly used cast iron and the most widely used cast material based on weight.
# Most cast irons have a chemical composition of 2.5–4.0% carbon, 1–3% silicon, and the remainder iron.
# Grey cast iron has less tensile strength and shock resistance than steel, but its compressive strength is comparable to low- and medium-carbon steel.
White cast iron
# White cast iron displays white fractured surfaces due to the presence of an iron carbide precipitate called cementite.
# With a lower silicon content (graphitizing agent) and faster cooling rate, the carbon in white cast iron precipitates out of the melt as the metastable phase cementite, Fe3C, rather than graphite.
# White iron is too brittle for use in many structural components, but with good hardness and abrasion resistance and relatively low cost
Malleable cast iron
# Malleable iron starts as a white iron casting that is then heat treated for a day or two at about 950 °C (1,740 °F) and then cooled over a day or two.
# As a result, the carbon in iron carbide transforms into graphite and ferrite plus carbon (austenite).
# The slow process allows the surface tension to form the graphite into spheroidal particles rather than flakes.
# Due to their lower aspect ratio, the spheroids are relatively short and far from one another, and have a lower cross section vis-a-vis a propagating crack or phonon.
# They also have blunt boundaries, as opposed to flakes, which alleviates the stress concentration problems found in grey cast iron.
Ductile cast iron
#  Has its graphite in the form of very tiny nodules with the graphite in the form of concentric layers forming the nodules.
# As a result, the properties of ductile cast iron are that of a spongy steel without the stress concentration effects that flakes of graphite would produce.
# Tiny amounts of 0.02 to 0.1% magnesium, and only 0.02 to 0.04% cerium added to these alloys slow the growth of graphite precipitates by bonding to the edges of the graphite planes.
# The properties are similar to malleable iron, but parts can be cast with larger sections.

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Ductile cast iron is not a single material but part of a group of materials which can be produced with a wide range of properties through control of their microstructure. The common defining characteristic of this group of materials is the shape of the graphite. In ductile irons, graphite is in the form of nodules rather than flakes as in grey iron. Whereas sharp graphite flakes create stress concentration points within the metal matrix, rounded nodules inhibit the creation of cracks, thus providing the enhanced ductility that gives the alloy its name.
1)known as
-nodular cast iron
-spheroidal graphite iron
-spheroidal graphite cast iron
-SG iron
2)Composition
-Carbon 3.2 to 3.60%
-Silicon 2.2 to 2.8%
-Manganese 0.1 to 0.2%
-Magnesium 0.03 to 0.04%
-Phosphorus 0.005 to 0.04%
-Sulfur 0.005 to 0.02%
-Copper <0.40%
-Iron balance
3)Application
-used for water and sewer lines.
-useful in many automotive components.
-In wind power industry nodular cast iron is used for hubs and structural parts like machine frames.
-SG iron is used in many grand piano.

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cast iron is classified as ferrous alloy and has carbon content of 2.14 wt%. Commonly, most cast iron has 3.0 and 4.5 wt % with addition of other alloying elements.
1) Compacted graphite iron
-Silicon content ranges between 1.7 and 3.0 wt% while its carbon has concentration normally 3.1 and 4.0 wt%.
-depending on heat treatment, the matrix phase will be pearlite and/or ferrite.
-   higher thermal conductivity
better resistance to thermal shock
lower oxidation at elevated temperatures
-   diesel engine blocks
exhaust manifolds, gearbox housings
brake discs for high speed trains
flywheels

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compacted graphite iron
* silicon ranges bet. 1.7% and 3.0wt%
carbon concentration between 3.1 and 4.0wt%.
* graphite forms wormlike or vermicular shape
* ductility intermidiate between values for gray and ductile irons
* E= 140 and 165 GPa
* high thermal conductivity
* better resistance to thermal shock
* low oxidation at level temperatures
* application - exhaust manifold, gearbox housing, brake discs for high speed train, flywheels

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malleable iron
* heating white iron at temp between 800 and 900 degree celsius for a prolonged time period in a neutral atmosphere causes decomposition of cementite forming graphite
* graphite exists as clusters or rosettes surrounded by a ferrite or pearlite matrix
* high strength and appreciable ductility or malleability
* application- connecting rods, transmission gears, flanges

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white cast iron
* low-silicon cast irons <1.0wt%Si + rapid cooling rates
* carbon exists as cementite
* white iron is extremely hard but very brittle
* application - rolles in rolling mills

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MALLEABLE IRON is a cast as white iron
-the structure is malleable form through an annealing treatment
-3 basic type of malleable iron is blackheart malleable iron, whiteheart malleable iron, and pearlite malleable iron
-good ductility
-better fracture toughness properties in low temperature environment.
-application
1.electrical fittings
2.hand tool
3.pipe fittings
4.

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-Theory > 2.14wt% carbon
-Usually 3-4.5wt. C
-Brittle
-1-3wt% silicon
-Become liquid easily between 1150°C n 1300
-Cnt easily cast
-inexpensive
-Machinable
-wear resistant

A. Gray iron
-diesel engine casting
-cylinders
-pistons

B. Nodular
-valves
-pump bodies
-crankshafts
-gears automotive components

C. White iron
-gears
-dies
-automobile crankshafts
-many other machine parts.
- rolles in rolling mills

D. Malleable iron
-electrical fittings
-hand tool
-pipe fittings

E. Compacted graphite iron
-diesel engine
-turbo housings
-exhaust manifolds.

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-cast iron is formed with carbon content exceeding 2%
- resistant to wear and good machinability
-has low melting point which makes it easier to be melted and mold
-widely used in application ex. cookware, gearbox case

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cast irons are ferrous alloys with carbon contents above 2.14 wt%

gray iron

* contains carbon between 2.5 and 4.0wt% silicon between 1.0 and 3.0wt%

* graphite exists as flakes which surrounded by a-ferrite or pearlite matrix.
* weak and brittle in tension

* strong and ductile under compressive load.
* application - diesel engine casting, cylinders and pistons

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ductile (nodular) iron
* gray iron + small amount of magnesium and/ or cerium before casting
* graphite forms as nodules or spherelike particles
* casting stronger and much more ductile than gray iron
* application - valves, pump bodies, crankshafts, gears automotive components

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Cast iron:-
-Gray iron
-White iron
-Malleable iron
-Ductile iron
-Graphite iron

Malleable iron:-
-Produce by heat treatment of white iron
-Consist of ferrite & particle of free graphite
-Godd ductility & machinability
-Bearing caps,  steering gear housing, railroad equipment

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Group of iron-carbon alloy

Properties:
- brittle
- hard
-more fusible than steel
-weak in tension

Composition:
2.5%-4% carbon
1%-3% silicon
Other is Iron

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white iron.

gray iron.

ductile iron.

malleable iron.

wrought iron

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-group of iron-carbon alloys
-contain more than 2% carbon
-low melting point

Type of cast iron:
A) white cast iron
- C 3.4, Si 0.7, Mn 0.6
- Bearing surfaces

B) grey cast iron
- C 3.4, Si 1.8, Mn 0.5
- Engine cylinder blocks, flywheels, gearbox cases, machine-tool bases

C) ductile cast iron
- C 3.4, P 0.1, Mn 0.4, Ni 1.0, Mg 0.06

D) malleable cast iron
- C 2.5, Si 1.0, Mn 0.55

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WHITE CAST IRON

* WHITE CAST IRON FORM EUTECTIC CEMENTITE DURING SOLIDIFICATION

* WHITE IRON MICROSTRUCTURE IS DUE TO FAST SOLIDIFICATION RATES AND ALLOWING THAT PROMOTES EUTECTIC CARBIDE FORMATION

* WHITE IRON TYPICALLY HAVE LOW DUCTILITY, HIGH HARDNESS AND GREAT WEAR RESISTANCE

*WHITE IRON GOT ITS NAME FROM SHININESS OF THEIR CRYTALLINE FRACTURES IN COMPARISON TO DULL GRAY FRACTURE OF GRAPHITE IRON

APPLICATIONS
* GEARS
* DIES
* AUTOMOBILE PARTS
* MACHINE PARTS

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- carbon content more than 2%
-types of cast iron

Gray iron.

White iron.

The alloy constituents affect its colour when fractured: white cast iron has carbide impurities which allow cracks to pass straight through; grey cast iron has graphite flakes which deflect a passing crack and initiate countless new cracks as the material breaks; ductile cast iron which stops the crack from further

Ductile iron

A typical chemical analysis of this material:

Carbon 3.2 to 3.60%

Silicon 2.2 to 2.8%

Manganese 0.1 to 0.2%

Magnesium 0.03 to 0.04%

Phosphorus 0.005 to 0.04%

Sulfur 0.005 to 0.02%

Copper <0.40%

Iron balance

Malleable iron.

Malleable iron is cast as white iron, the structure being a metastable carbide in a pearlitic matrix. Through an annealingheat treatment, the brittle structure as first cast is transformed into the malleable form. Carbon agglomerates into small roughly spherical aggregates of graphite leaving a matrix of ferrite or pearlite according to the exact heat treatment used. Three basic types of malleable iron are recognized within the casting industry: blackheart malleable iron, whiteheart malleable iron and pearlitic malleable iron.

Wrought iron.

a tough malleable form of iron suitable for forging or rolling rather than casting, obtained by puddling pig iron while molten. It is nearly pure but contains some slag in the form of filaments.

-properties
•hard
•weak in tension
•brittle

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-carbon content greater than 2 percent
-low melting temperature
-white cast iron allow cracks to pass straight through because of the carbide impurities
-grey cast iron deflecr a passing crack because of the graphite flakes
-ductile cast iron can stop the crack from further progressing because of their spherical graphite

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It is an iron that contain 2-4 percent of carbon. Used to make pots, pans and all type of utensils. This is because it can distribute heat evenly. It has a relatively poor tensile strength but good compressive strength. It has a crystalline structure

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5 types of cast iron;
1)grey cast iron - carbon as graphite
2)white cast iron - carbides often alloyed
3)ductile cast iron - modular, spheroidal graphite
4) malleable cast iron - graphite modules are irregular cluster/tempered graphite
5)compacted graphite iron - CG or vermicular iron

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-Class of ferrous alloy with carbon contents above 2.14 wt%
-both microstructure and mechanical behaviour depend on the composition and heat treatment
-Most common iron types :
1) Gray Iron
The carbon and silicon contents vary between 2.5 and 4.0 wt% and 1.0 and 3.0 wt%, respectively.
Normally surrounded by an alpha-ferrite or pearlite matrix
Comparatively weak and brittle in tension
Strength and ductility much higher under compressive lods
Very effective in damping vibrational energy
Are among the least expensive of all metallic materials
Exhibit a high resistance to wear

Application
1.Small cylinder block
2.Cylinder heads
3.Clutch plates
4.Diesel engine castings