Material for May 7th 2010

Welding of Cast Irons

Lecturer Dr. Jippei Suzuki Graduate School of Engineering Mie University Department of Mechanical Engineering Faculty of Engineering, Mie University Kurima-Machiya-cho 1577, Tsu, Mie 514-8507 Tel. 059-231-9372 Fax. 059-231-9663 E-mail jsuzuki@mach.mie-u.ac.jp
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Fe-C dual equilibrium diagram (Fig.K1)

Fe-Fe3C system meta-stable system Fe-graphite system stable system

Peritectic point 0.18 1494 Primary austenite Primary graphite

Primary cementite

Temperature

(austenite)

C Eutectic point 4.32 (ledeburite)

Cast iron
(cementite)

Eutectoid point 0.77 (pearlite) (ferrite)

Carbon content

mass%

Temperature K

Stabilizing graphite (Fig.K2)

meta-stable
White cast iron Low C Low Si Rapid cooling Thin section

Mottled cast iron

pearlite

Gray cast iron

ferrite/pearlite
ferrite High C High Si Slow cooling Thick section
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stable

Effect of Si (Fig.K3)
C.E.=T.C.+
1 %Si 3 or = T.C.+ 1 (%Si+%P) 3 C.E.; carbon equivalent T.C.; total carbon content Degree of carbon saturation T.C. 4.30.3%Si

SC=

SC<1 ; hypo eutectic SC1 ; eutectic SC>1 ; hyper eutectic

Si
C content

Si content

eutectic point
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Maurer diagram (Fig.K2)

Relation of structure to carbon and silicon contents of cast iron b; pearlitic+ferritic cast iron ; pearlitic cast iron ; ferritic cast iron

; white cast iron a; mottled cast iron

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Greiner-Klingenstein diagram (Fig.K5)

7 % 6 5 4

III

C+Si

I
0 10

IIa II
20 30 40

IIb
50 60 70

thickness

mm

I; white cast iron, IIa; mottled cast iron, II; pearlitic cast iron IIb; pearlitic+ferritic cast iron, III; ferritic cast iron
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Classification of cast irons (Fig.K6)

Cast iron Fe-2.54.0%C-0.53.0%Si (Chemical compositions of cast irons are not stipulated.) low melting point(1147K), good castability, good absorbent of vibration, wear resistance, good machinability, good lubrication By luster of fracture surface Gray cast iron graphite flake White cast iron ledeburite+primary Fe3C or austenite Mottled cast iron By Morphology of graphite A. Flake graphite B. Lump graphite C. Spheroidal graphite By compositions Low carbon cast iron High carbon cast iron High silicon cast iron Alloy cast iron By the microstructure of matrix Ferrite cast iron Pearlite cast iron Austenite cast iron Bainite cast iron(acicular cast iron) By mechnical properties Normal cast iron(lower 300MPa) Tough cast iron(over 300MPa) Mottled cast iron
Hypo-eutectic W.C.I.
Hyper-eutectic W.C.I.

Gray cast iron

Eutectic W.C.I.

White cast iron

Morphology of flake graphite (Fig.K7)

A. Graphite flake B. Graphite rose C. Kish graphite(large graphite flake) +small flake(hyper-eutectic iron) D. Thin graphite between dendrites (eutectic graphite) E. Graphite fleke between dendrites

Spheroidal graphite (Fig.K8)

Degree of spheroidization

+Ce, Mg
(Mg alloy)

Gray cast iron Spheroidal graphite

Nodular graphite cast iron Spheroidal graphite cast iron (U.K.) Ductile cast iron (Japan, U.S.A.)
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Malleable cast iron (Fig.K9)

black heart malleable cast iron White cast iron black heart malleable cast iron
Structure of black heart malleable cast iron (lump graphite) 850950 680720

annealing

1st step time

2nd step

Example of annealing

First step decomposition of cementite in ledebrite Fe3C graphite Second step decomposition of cementite in pearlite Fe3C graphite

temperature

pearlitic malleable cast iron only 1st step

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white heart malleable cast iron

Oxidant or Oxide

White cast iron

Heating for decarburization 9001000 long period

white heart malleable cast iron

Ferrite near the surface Pearlite interior portion Temper graphite in core

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Weldability of cast iron (Table K1)

Generally it is difficult for cast iron to be welded because of its high carbon content and low ductility. Change to white cast iron by rapid cooling Oil remaining in a gap between graphite and matrix (repair welding) burning the cast before welding Cracking due to welding thermal stress peening pre-heating Type of cast iron Gray cast iron (graphite flake) Weldability normal

Spheroidal graphite cast iron (U.K.) Ductile cast iron (Japan, U.S.A.)
Malleable cast iron black heart malleable cast iron white heart malleable cast iron pearlitic malleable cast iron

good
difficult normal difficult

Alloy cast iron

Ni cast iron
Cr cast iron

normal
difficult
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Welding processes (Fig.K11)

Shielded metal arc welding Electrode Core wire pure Ni 60%Ni-Fe alloy Monel 20%Ni, 1.53.5%Cr, 18%Cu, Fe Bal. mild steel cast iron Flux graphite Welding without pre-heating bead length should be about 15mm peening Welding with low temperature pre-heating (370570K) small heat input straight short bead (2050mm) position of the crater Welding with high temperature pre-heating (about 870K) cast iron electrode weaving to slow cooling rate using furnace after welding to slow cooling
Welding portion

Gas welding Pre-heating over 870K Electrode(filler metal) cast iron rod high carbon-high silicon Flux sodium carbonate Na2CO310H2O sodium borate Na2B4O710H2O sodium bicarbonate NaHCO3 silica sand SiO2 orthoboric acid H3BO3

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