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IS : 5788 - 1986
Indian Standard
( Reaffirmed 2005 )
(First
Rev-ision
UDC
669.131.7-14
@ Copyright 1987
BUREAU
MANAK
OF
BHAVAN.
INDIAN
9
BAHADUR
STANDAR-DS
SHAH
ZAFAR
MARG
Gr-4
February
1987
IS :5788- 1986
Indian Standard
~P~FICATION
FOR
( First Revision)
Pig Iron and Cast h-on Sectional Committee, SMDC 9
Chairman
SHRI B. G.
Rsfiesrnling
Ductron Castings Ltd, Hyderabad
SASTIZY
Members
SHRI M. S. DALVI ( Alternate to
Shri B. G. Sastry )
SHRI P. K. AROUA
Mechanical
Engineering
Research Development
Organization ( CMERI ), Ludhiana
. Indian Iron &z Steel Co Ltd, Burnpur
Snn~ R. K. BANERJEW
SHRI R. DAYAL ( Alternafe )
Ministry of Defence ( DGOF j
SHRI T. K. BANERJEE
SHRI A. K. SARKA~~ ( Alfern& )
Bhagwati Spherocast Ltd, Hyderabad
DR P. N. BHA~WATI
SHRI M. R. SHAH ( Alternate )
Visvesvaraya Iron & Steel Ltd, Bhadravat
SHRI K. B. D. 5EERlAH
SERX B. S. UMAPATEY ( Alternale )
National Test House, Calcutta
SH~I A. M. BISWAS
SERI K. L. BARVI ( Alternafe )
Indian Institute of Technology, Kharagpur
PROBA. K. CHAK~ABOILTY
Indian Register of Shipping, Bombay
SHRI S. CBANDRA
SHRI H. K. TANEJA ( Allernalc )
CHIWIST & M x T A L L u R 0 I s T Ministry ofRailways
EASTERN RAILWAY, J AMALPUR
Hindustan Machine Tools Ltd, Bangalore
SHRI P. P. CHOPRA
SHRI H. S. RAWACEIANDRA ( Alternate 11
SERI P. RAYPRASAD
( Alternate IL )
SHRI V. N. VENKATESAN ( Allernate III )
SHRI A. SHANTARAIU ( Alternate IV )
( Continued on page 2
0
Copyright 1957
BUREAU
OF INDIAN
STANDARDS
This publication
is protected under the Indian Copyrighf Act ( XIV of 1957) and
reproduction m whole or in part by any means except with written permission of the
publisher shall be deemed to be an infringement of copyright under the said Act.
IS t 5188 - 1986
( Continued from pugs 1 )
Reprwnting
Members
Sash S. H. CO~XISSARIAT
SHRI B. K. DUTTA
Sxar S. S. SAH~ (
SHRI S. Y. GRORPADE
SH~I P. C. JAIN
SJXRIK. h. KINKAR
Alfernafs
Directorate
General
of Supplies
& Disposals
( Inspection Wing ), New Delhi
SHRI T. N. UBOVEJA ( Alfarnate \1
Electrosteel Castings Ltd, Calcutta
SIIRI B. v. LU
SHRI S. B. SEX?QUPTA( Altcrnats)
Heavy Engineering
Corporation
Ltd ( Foundry
SERI M. MOHAN
Forge Plant ), Ranchi
SERI I. ALI ( Alternate )
New Standard Engineering Co Ltd, Bombay
SHRI S. V. RAJWADE
SRRI R. R. SARIN ( Alternate )
SIIHK C. P. RAMAMURTI~Y
SIII~I D. VA:U~XVA RAO
Slllll
Srler S. Ctlouue~
REPXESENTATIVI
SHRI A. K. SAHA
SHRI B. P. SINoH
( Ahernate)
Sang P. J. SHENuY
SIII~I S. C. NAI(SARIA
SIHU I. S. P. SJJWTY
SIII:I T. SUL)IIXAI~ (
Steel
Development Commissioner
( Small Scale Industries ), New Delhi
Maruti Udyog Ltd, Gurgaon
Bokaro Steel Plant, Bokaro
( Alternate )
SlIIlI u. SEN
Steel Plant),
P. P. KAWOOI
RIXPRE~~:NTATIVE
Directorate
General of Technical
Nl w Delhi
Kesoram Spun Pipes & Foundries,
Atternnte )
Development,
Calcutta
IS: 5788.1986
Indian Standard
SPECIFICATION -FOR IRON CASTINGS WITH
SPHE-ROIDAL -OR NODULAR GRAPHITE FOR
PtiESSURE CONTAINING PARTS FOR USE
AT ELEVATED TEMPERATURES
( First Revision)
0.
FOREWORD
0.1 This Indian Standard ( First Revision ) was adopted by the Indian
Standards Institution on 16 June 1986, after the draft finalized by the Pig
Iron and Cast Iron Sectional Committee had been approved by the
Structural and Metals Division Council.
0.2 This standard was first published in 1970. While reviewing this standard in the light of the experience gained during these years, the Committee
has decided to revise this standard aligning it with other existing standards on the subject.
0.3 This standard keeps in view the manufacturing and trade practice
being followed in the country in this field. Assistance has also been
derived from ASTM A-395-1980 - Ferritic ductile iron pressure retaining
castings for use at elevated temperatures, issued by the American Society
of Testing and Materials.
0.4 This standard contains clauses which require the purchaser agreement and/o: to specify these requirements, if necessary, while placing the
order.
9.5 For the purpose of deciding whether a particular requirement of this
standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis shall be rounded off in accordance
with IS : 2-1960. The number of significant places retained in the rounded off value should be the same as that of the specified value in this
standard.
*Rules for roundingoff numerical values ( rsviscd) .
3
IS :5788-
1986
1. SCOPE
1.1 This standard covers the requirements for iron castings with spheroidal or nodular graphite for pressure containing parts for use at elevated
temperatures.
2. SUPPLY
OF MATERIAL
shall be
3. MANUFACTURE
3.1 The method of manufacture shall be left to the discretion of the manufacturer provided that the castings conform to this standard.
4. CHEMICAL
COMPOSITION
with IS : 228-1972t,
Constituent
+hall
Percent
3-O
2.50
0.08
NOTE1 - For each reduction of 001 percent below the maximum specified
phosphorus content, an,increase of 0?08 percent silicon above the specified maximum
will be permitted,up to a maximum of 275 percent.
NOTE2 - Silicon content above 275 percent, or phosphorus above 0.08 percent
have a tendency to lower the impact resistance of the material.
If the carbon content is below 3.00 percent, excessive cementite may form during cooling and if this
is not removed during the annealing cycle, the impact resistance of the material
may be lowered.
5. WORKMANSHIP
AND FINISH
or nodular
graphite
iron
6. HEAT
TREATMENT
6.1 All castings shall be~given a ferritizing heat treatment to ensure uniform mechanical properties throughout each section and to produce substantially a ferritic structure that contains no massive carbides.
6.2 When specified in the purchase order, castings with mechanical properties obtained as cast may have a stress relief heat treatment at a
minimum temperature of 550C.
7. FREEDOM
FROM
DEFECTS
7.1 The castings shall be free from surface defects, such as adhering sand
and shall be reasonably smooth. The runners, risers, fin.9and other extraneous metals shall be removed from the castings. They shall be well dressed
and fettled.
7.2 The castings shall not~berepaired by welding or brazing but may be
plugged in case they leak on hydrostatic test, provided that the diameter
of the plug does not exceed 50 mm. The details of the plugging of the
casting may be agreed to between the purchaser and the manufacturer.
Also any inherent defect revealed during subsequent machining, notwithstanding any previous certificate of satisfactory testing might make the
-castings liable to rejection.
8. TEST
SAMPLES
8.1 Test samples shall be cast separately in sand moulds. They shall be
poured from the same ladle of metal as that used to produce the castings
they iepresent and immediately after the castings are poured. Some additional recommendations
regarding casting the test samples are given in
Appendix A.
8.1.1 The test pieces used for the test specified in 10.1 and 10.2 shall be
machined from one of the following type of test samples:
a) U-ty#e test samples - The test piece shall be machined from the keei
( that is, the cross-hatched section of Fig. 1 ),
b) 22yfie test samples - The test piece shall be machined from the keel
( that is, the cross-hatched section of Fig. 2 ), and
c)
Fig. 3.
IS : 5788
Types
1986
Type Ilb
L---I
RS
I-
R5
IIa
Ilb
i11
12
25
25
50
75
40
55
90
90
125
30
40
40
60
65
80
100
100
150
165
--
FIO. 1
8.1.3
In exceptional cases, and by prior agreement betw.een the partiesj
the test samples may be attached to the castings; in such cases, their location should be agreed to between the manufacturer and the purchaser.
8.1.4 The test samples shall be cast in sand moulds and stripped at a
temperature not exceeding 5OOW.
8.1.5 All test samples shall be heat-treated simultaneously
adjacent to the relevant casting or castings in the same furnace.
with and
9. SAMPLING
9.1 Sampling for Chemical Analysis - Two spoon samples shall be
taken during the pouring .of each cast or ladle when about one-third and
two-thirds of the metal has been discharged.
The spoon sainples so
obtained shall be cast separately in dry sand in the form ,of 30 mm
diameter bars about 75 mm long. Alternatively, the mould may be filled
directly from the metal stream; The test bars shall be suitably marked so
that the castings they represent could be identified.
6
II
111
IV
12
25
50
75
40
55
100
125
25
40
50
65
150
175
135
Y
I
NOTE - The
casting shall be
140
A function
thickness
of the
40 mm minimum
181) mm minimum
FIG.
sand
surrounding
length
I
I
during
9.1.1 After cleaning the surface, two flats shall be ground near the
bottom of each test bar and the test bar drilled with a 25 mm drill from
one clean surface to the other. The speed of the drill should not be more
than 9 to 10 rev/min. Drillings after being thoroughly mixed shall constitute the sample for chemical analysis.
9.1.2 For the determination
of total carbon the molten metal shall be
-poured into a special split mould ( see Fig. 4 ). This gives pins of iron
3 mm in diameter which have solidified white and which can be broken off
and used direct for total carbon determination.
Carbon determination
from drillings taken from grey samples shall not be done.
9.2 Sampling
for Mechanical
Tests
Z=ACCORDING
OF TEST
TO LENGTH
PIECE
AN AS-CAST
TEST SAMPLE
MOULD
All dimensions
FIG. 3
in millimetres.
IS : 578%- 1986
FRONT
AND
SIDE
ELEVATION
9.2.2 If successively treated ladles filled from one furnace are used to
produce castings, one tensile test shall be made from each O-5 tonne of
castings or part thereof. If more than one treated ladles are involved in the
production of this quantity of castings, the manufacturer shall take steps to
ascertain that the treatment of other ladles is done by such method as may
be agreed to between the purchaser and the manufacturer.
He may
examine the procedure adopted and satisfy himself that this is adequate.
9
IS : 5788 - 1986
9.2.3 In the case of large tonnage of castings being produced continuously the minimum II~UIII~~~of test bars to be provided shall be one
tensile test representing every two hours production froni a melting
furnace.
9.2.4 For castings weighing more than one tonne, one tensile test shall
be conducted on a test sample for each casting, the test sample being cast
as an integral part of the casting.
9.2.5 If more than one furnace is used to fill the ladles, then one tensile
test shall be made on a test sample poured from a treated ladle of each of
the furnaces.
9.2.6 Ml test samples and castings
fication.
10. MECHANICAL
shall be marked
TEST
10.1 Tensile Test - The tensile test shall be carried out in accordance
with IS : 1608-1972*, unlrss otherwise agreed to between the purchaser
and the manufacturer.
The test piece shall have a gauge diameter of
14 mm and a gauge length of 70 mm ( see Fig. 5 ). To determine compliance
with proof stress requirements, thk material tested shall be considered to
have passed the test if it dots not undergo an elongation exceeding the
specified percentage on being subjected to the specified minimum stress for
a period of 15 seconds.
R20
d=@\L+0.09
R20
with their
Lo is theoriginal
gauge length; here & = 5d;
d is the original diameter of the test piece;
LC is the parallel length; LC >~~I% by agreement
between the manufacturer and the purchaser
( in principle LC - LO > d ); and
Lr is the total length of the test piece, which depends on LO and It.
All dimensions
FIQ. 5
in millimetres.
10
IS : 5788 - 1996
19.1.1 In case of samples of type I, the test piece having a reduced
diameter shall comply with the following formula:
L, -
5+35$?.
5d
where
original
cross-sectional
area, and
The mechanical
TABLE 1, MECHANICAL
1.
PROPERTIES
REQUIREXENT
CEARACTEI~ISTIC
Tensile strength, MPa, Min
Proof Stress ( 02 percent ), Min
Elongation
percent, Min
410
270
16
10.1.3 In the case of tests carried out on test bars cut from the finished
castings, the mechanical properties shall be as agreed to between the purchaser and the manufacturer.
when
10.2 Hardness Test - The Brine11 hardness of the meterial,
tested in accordance
with IS : 1500-1983*,
shall be between 142 and
187 HB.
10.2.1 The hardness test shall be carried out on either
on a test coupon representing the material of the casting.
11. VALIDITY
the casting or
OF TESTS
11.1 A test may be disregarded if proof results are obtained which are not
due to the quality of the cast iron itself, but to any of the following
reasons:
a) Faulty mounting of the test piece or
test machine;
defective
operation
of the
11
16 : 5298 - 1986
12. RE-TEST
12.1 Should any ofthe tests fail to meet the specified property requirements, two re-tests per failed test shall be carried out.
12.1.1 The batch is regarded as conforming to the specified requirements when the results of the two re-tests conform to the values specified
in the standard. However, the batch may be rejected if one of the re-tests
fails.
12.2 Should the samples of castings supplied in the heat-treated condition
fail%0 pass the test, the manufacturer shall have the,right to reheat-treat
the castings together with the representative test bars and resubmit &em
for inspection and testing.
13. ADDITIONAL
~TESTS
requirements, such as
this standard, he shall
for the material. The
the purchaser and the
14. MARKING
14.1 Unless the purchaser desires otherwise, each casting, wherever practicable, shall be legibly marked with a number or identification mark by
which it can be traced to-the melt from which it was made.
14.1.1 Wherever practicable, the castings may also bear the ISI
fication Mark.
Certi-
NOTE - The use of the IS1 Certification Mark is governed by the provisions of
the Indian Standards Institution ( Certification
Marks ) Act and the Rules and
Regulations made thereunder.
The IS1 Mark on products covered by an Indian
Standard conveys the assurance that they have been produced to comply with the
requirements of that standard under a well-defined system of inspection, testing and
quality control which is devised and supervised by IS1 and operated by the producer.
IS1 marked products are also continuously checked by IS1 for conformity to that
Details of conditions under whicha licence for the
standard as a further safeguard.
use. of the IS1 Certification Mark may be granted to manufacturers
or processors,
may be obtained from the Indian Standards Institution.
12
1s : 5188 - 1986
APPENDIX
( Clause 8.1 )
RECOMMENDATIONS
FOR CASTING
OF TEST SAMPLES
A-l. The test sample may be cast in sand to any convenient size and
shape, .provided the sample is sound and free from any casting -defect.
A-l.1 Suitable samples for providing a proportional sound tensile test
piece are represented in Fig. 1, 2 and 3. These keel or U-blocks have
been found satisfactory in service.
A-I.2 A convenient form of test sample cut from one of the castings, as
agreed to between the purchaser and the manufacturer, may be used for
the purpose of testing strength of the casting.
A-I.3 In case of sand moulds for test samples of Type III and IV ( see
Fig. 1 and 2 ), a rigid COB sand mould is recommended.
13
fS:5788-1986
MCfl,bCtS
Re~wcscnting
DR G. VENICATARAMAN
Snur A. K. MIWAI>
( Alternafe)
Director
SARI K. RAoaAv1sN1maN,
Director
Bharat Heavy
Electricals
General,
Ltd
Secrelary
SJiRI S. S. SRTHI
Joint Director
Spheroidal
Graphite
( Metals ), IS1
Iron Castings
Subcommittee,
SMDC
9 : 2
Comerrcr
DR P. N. I~J~AOWATI
Uhagwati
Spherocast
Ltd, Ahmadabad
Members
SHILI M. 11. SllhJr ( flbmnle
Dr 1. N. Bhagwati )
SHRI S. K. AIIU.I,\
Snsr 1). 13. Vyas ( Allcrrrale )
DEPUTY DIRECTOR ( MET )-I
to
Indian Smelting
Research,
Designs
Lucknow
Sr Standards
Organisation,
A~SISTAN~I, RI.:SI~A~L~X0a~:lcx.I~
( MW-III
) ( illfemale )
Mysorc Kirloskar Ltd, Harihar
SIII:I D. K. DI\I~
il!I~I u. S. (:OVlNI, ( /,llrrtftife )
EIindustan Machiue Tools Ltd, Bangalore
SHl<I 1~. A. GANJ)III
Hindustan Motors Ltd, Trivellore
SllltI v. S. UiX.\NAl 11
S~tax Ii. SI~INIV.~SAN ( nllertrale )
Escorts Ltd, Faridabad
SERI Sarv I). K~[ANNA
SHRI NAXINIMR SINC~I ( Allernale )
Business Combine Ltd, Nasik
SHRI s. B. PATlIAR
Snnr P. R. Txxavult ( dllernale )
Tata
Engineering
&
Locomotive
Co
DR P. S. PATTIIIAL
Jamshedpur
DR P. 6. DASUTI<AI~ ( dllemnfe )
AShok Leyland Ltd, Madras
REPRESENTAJIVE
.
SHRI
R. C.
PItASAD
HMlW,
Ranchi
SHRI D.K.
DAM ( A&male )
Premier Automobiles Ltd, Bombay
SHRI K. S. SHAII
SEW M. S. SAIIANI ( Aller&e )
Ductron Castings Ltd, Hydcrabad
SHRI B. G. SAsTRY
SIIHI M. S. DALVI ( rlhunfe
)
Tractors & Farm Equipment Ltd, Madras
SERI N. S. SWAMLNAPHAN
SHRI S. NATESAN ( Allerfrale )
Fouthcrn Alloy Foundries Pvt Ltd, Madras
SHRI S. THIAWXARAJAN
SHRI A. TEENGAVELU ( Allertrale )
14
Ltd,
BUREAU
INDIAN
OF
STANDARDS
Headquarters:
Manak
Bhavan,
Telephones:
Regional
Central
9 Bahadur
331
01 31,
13 75
NEW DELHI
Telegrams:
( Common
110002
Manaksanstha
to all Offices)
Telephone
Offices:
: Manak
: C. I. T. Campus,
TWestern
: Manakalaya,
BOMBAY
Branch
MADRAS
E9 MIDC,
400093
600113
Marol,
Andheri
331 01 31
331 1375
36 24 99
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3
41
41
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92 95
Offices:
Pushpak. Nurmohamed
Shaikh
AHMADABAD
380001
SPeenya Industrial Area
BANGALORE
560058
Marg, Khanpur,
2-63
I
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Tumkur Road
Marg, C Scheme,
B Sarvodaya
Nagar,
JAIPUR
KANPUR
208005
( With
16
5 36 27
3 31 77
23 1083
667
6
6
21
I 21
6
16
16
302005
T.C.
/nspaction
48
2 63 49
38 49 55
38 49 56
34
98
68
82
23
21
21
71
32
76
92
05
04
17
Sale Point ):
2 51 71
5 24 35
AHENDMENT
NO.
NOVEMBER 1987
TO
IS:5788-1986 SPECIFICATION FOR IRON CASTINGS WITH
SPHEROIDILL.
OR NODULAR GRAPHITE -FOR PRESSURE
CONTAINING PARTS FOR USE AT
ELEVATED TEMPERATURES
(First Revision)
4.1) - Substitute
(Page 4, clause
following for the existing clause:
the
Percent
3.0
2.50
0.08
*
.
(SMDC 9)