DEPARTMENT OF

MECHANICAL ENGINEERING

III-SEMESTER
ENGINEERING METALLURGY

CHAPTER NO. 5

CAST IRONS
&
NON FERROUS MATERIALS
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 CHAPTER 5:- SYLLABUS
Cast iron – Classification
1 .

gray cast iron, white cast iron

2

3 nodular cast iron, malleable cast iron,

Mottled cast iron, Ni – hard & Ni – Resist cast iron.
4
non- ferrous alloys – Brasses, its types, Cu-Zn
5 diagram

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 CHAPTER 5:- SYLLABUS

6 Bronzes, its types

.

7 Cu-Sn diagram

8 Al-Si diagram.

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 CHAPTER-5 SPECIFIC OBJECTIVE / COURSE OUTCOME

The student will be able to:

Understand the cast irons, classification, Applications.

1

2 Understand Non ferrous elements and their uses.

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LECTURE 1:- Cast iron

Cast iron - Ferrous alloys containing more than 2%

carbon so that the eutectic reaction occurs during
solidification.

Types of cast irons:

1. Gray cast iron
2. White cast iron
3. Malleable cast iron
4. Ductile or nodular, cast iron

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LECTURE 2:- White cast iron

 White cast iron: Shows Dendrite pattern of Pearlite

and cementite.

 White cast iron is extremely brittle hence can not be

used for any machinery part .

 Hardness about 350BHN can be obtained.

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LECTURE 2:- White cast iron

 Due to this high hardness it gives excellent wear

resistance at the surface.

 It can be utilized for rollers of the rolling mills,

wearing plates etc

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LECTURE 2:- Grey cast iron

• Grey cast iron: shows graphite flakes in the matrics of

ferrite/ pearlite.

• Graphite flakes act as discontinuity of matrics, hence

equally brittle like white cast iron.

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LECTURE 2:- Grey cast iron

• ASTM graphite flakes distribution chart clearly showing

that uniform distribution of graphite flakes can be
achieved by addition of inoculants.

• Prominent property of grey cast iron is its Damping

capacity.

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LECTURE 3:- Malleable Cast Iron

• Shows graphite rosettes on the back ground of ferrite/

pearlite.

• White cast iron can be converted to malleable cast iron

by Malleablizing treatment.

• Malleable cast iron shows better combination of tensile

strength and ductility

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LECTURE 3:- Nodular cast iron

• Also called as Ductile iron/ S.G.Iron

• Ductility of this cast iron is around 20%.

• It shows graphite nodules in the matrices of ferrite/

pearlite.

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LECTURE 3:- Nodular cast iron

• Due to its higher strength and ductility it shows

dimensional stability at higher temp.

• It can be used for furnace doors, crank shafts etc

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LECTURE 3:- Cast iron microstructures

Figure shows Schematic drawings of the five types of cast iron: (a) gray
iron, (b) white iron, (c) malleable iron, (d) ductile iron, and (e) compacted
graphite iron. 13

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LECTURE 3:- Cast iron microstructures

Figure (a) Sketch and (b) photomicrograph of the flake graphite in

gray cast iron (x 100).

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LECTURE 1:- Mottled Cast iron

• This cast iron is consisting of white cast iron at the

periphery and gray cast iron at the core.

• This combination will certainly give wider range of

properties and utilization.

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LECTURE 4:- Alloy Cast irons

Ni-hard Ni-Resist

1. To achieve shock and impact 1. To achieve corrosion

resistance combined with and heat resistance.
high wear resistance.

2. Addition of 3 to5% Ni and 1 2. Addition of 14 to 36%

to 3% Cr in White cast iron Ni and 1 to 5% Cr in
will produce Ni-hard C.I. Ni-hard cast iron will
produce Ni-Resist C.I.

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LECTURE 5:- Brass

Brass is an alloy of copper and zinc Single phase α-

brass is obtain up to 37.5% of Zn

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LECTURE 5:- Types of brasses

•Cartridge brass
–Consisting 70%Cu and 30% Zn
–Tensile strength 35kg/mm2 Ductility 60%

•Muntz metals
–Consisting 60%Cu and 40% Zn
–Tensile strength 38kg/mm2 Ductility 40%

•Gliding metals
–Consisting 95%Cu and 5% Zn
–Tensile strength 25kg/mm2 Ductility 42%
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LECTURE 5:- Defects in Brasses

• Season cracking of brasses

–due to internal stress
–Can b avoided by annealing at 300 oC

•Dezincification of brasses
–Due to reaction with sea water salt.
–can be avoided by addition of 1 to1.5% Sn

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LECTURE 5:- Defects in Brasses

• Orange peel defect

-Due to grain growth during cold working after annealing
above 600 oC.

• Can be avoided by controlling annealing temp. below

600 oC

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LECTURE 6:- Bronze

• Bronze is an alloy of Cu-Sn system

• Up to 5% of Sn in Cu we get single phase α-bronze.

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LECTURE 6:- Bronze

•Phosphor bronze consists of phosphorus up to 0.3%

•Bearing bronze can not be annealed because it losses

delta phase which is required for wear resistance

•Gun metal consist of 85% Cu 5% Sn 5% Pb and 5% Zn

•Bell Metals consisting 27% Sn (Tin) in Cu

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LECTURE 7:- Al-Si Alloy

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LECTURE 7:- Al-Si Alloy

•Aluminum -12% Silicon Alloy (Eutectic composition) is

widely use for pressure tight casting.

•This Alloy Need modification treatment.

• In which up to 0.1% metallic sodium (NaCl+NaF) is to

be added in the melt.

•Which will modified the structure and giving the desired

properties

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LECTURE 8:- Age hardening phenomenon of Al-Cu System

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LECTURE 8:- Age hardening phenomenon of Al-Cu System

• Al- 4% Cu when heated to a temp of 520oC the

structure become single phase α-solid solution.

• Alloy is then quenched in water from 520 oC , A

supper saturated solid solution is retained at room
temp.

• Reprecipitation of CuAl2 well obtained after certain

period of time which will increase the hardness and
strength of an alloy called as Age hardening
phenomenon

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 References Books:

1. Introduction to Engineering Metallurgy by Dr. B K

Agrawal, Tata McGraw-Hill

2. Introduction to Physical Metallurgy by Avner, Tata

McGraw-Hill

3. Engineering Materials & Metallurgy, Srinivasan, Tata

Mc-Graw Hill

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LECTURE 8:-

THANK YOU
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