FOUNDARY TECHNOLOGY

CASTING: Casting is a manufacturing process in which molten or liquid metal is poured into a mould
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containing a cavity of specific shape and then allowed to solidify the solid casting is then taken out and clean
to complete the process.
Advantages of casting process:
(1) complex geometry or hollow section can be casted (2) wide range of weight and size can be
possible by the process (3) it is economical (4) suitable for mass production
Limitations: it depends on the mechanical properties, casting methods, porosity, porous dimensional
accuracy, surface polishing/finishing.
# Casting process: 1. preparing a mould cavity of the desired shape with proper allowances and provided
with meansfor the escape of gas and air.
2. melting the metal with acceptable quality and temperature (temperature decrease liquid will notrun
smoothly)
3. pouring the metal into the cavity 4. solidification process designed and controlled to avoid the defects
5. finishing, cleaning, and inspection operation

# Type of foundry
Based on material
(1) ferrous foundry (2) grey iron foundry (3) steel foundry
Based on nature and organization formed
(1) jobbing foundry: the foundry that creates a wide cavity of casting
(2) production foundry:same type of casting is created
(3) captive foundry: did not sale outside

# Pattern: pattern is a replica of the casting except for the various allowances pattern exactly resembles
the casting to be made pattern maybe into two or three pieces where is casting are in asingle piece a
pattern is required even if one object has to be cast
# Function of a pattern: A pattern operator prepare a mould cavity for the purpose of making a cavity a
pattern main contain a projection known as core points if the casting requires a core pointand need to be
made hollows patterns property made and having a finished and smooth surface reduce the casting defects
property constructed pattern minimize overall cost of the casting
Q. Types of pattern materials

Wood, metal, plastic, plaster, wax

# Selection of pattern material
(1) number of castings to be produced (2) metal to be cast (3) dimensional accuracy and surface
finish (4) shape complexity and size of casting (5) type of moulding materials (6) change repeat
order (7) nature of moulding process (8) position of cost point

# Wood pattern: these are used where the number of castings to be produced in small and pattern size is
large.
Advantages: 1. inexpensive 2. easily available in large quantities 3. easy it fabricates 4. lights in weight
5. they can repair easily 6. easy to often good surface finish
Limitations of wood patterns: 1. suspectable to shrinkage and swelling 2.absorb moisture and
consequently get wrapped 3. can't with stand rough handling 4. life is very short
• commonly used materials tip fine dewater
 # Metal pattern: these are employed where large number of castings must be produced from samepattern
Advantages:
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1 don't absorb moisture 2 more stronger 3 poses much longer life and don't 4 wraps retain their shape 5
accurate and smooth surface finish
Limitations:
1 Expensive 2 require lot of machining for accuracy 3 not easily repaired 4 ferrous patternsget resulted
5 heavy weights thus difficult to handle
• commonly used for metal: cast iron, aluminum and its alloy, steel and brass
# Plastic pattern:
Advantages:
1 smooth surface 2 moisture resistance 3 does not involve any appreciable change in size orshape 4 light
weights 5 good strengths 6 good resistance and chemical atom
Limitations:
1.plastic pattern are fragile
2.these may not work well when subject to condition of severe shock as in machine moulding

# Plaster pattern:
Advantages: 1. it can be easily work by using wood working tools 2. integrate shape can be cast without
any difficulty 3. it has hi compressive strength 4. plaster maybe made of plaster of Paris example: jewelry.

# Wax pattern:
Advantages: 1. provides very good surface finish 2. impart high accuracy to casting.
3. after being moulded the wax pattern is not taken out of the mould by other patterns rather the mould is
inverted and heated the mould wax come out or is evaporated thus there is no chance ofthe mould cavity
getting damage while removing the pattern.

#Different types of patterns: Types of patterns depend upon the following factors:
1.Shape and size of the casting 2. Number of castings required 3. methods of moulding employed
# Types

1. single piece pattern 2. split piece pattern 3.loose piece pattern 4. match plate patterns
5.sweep patterns 6. gated pattern 7. skeleton pattern 8. follow board pattern 9. cope and drag pattern
1. Single piece pattern: A. Made From one piece does not contain loose piece and joints 2. Inexpensive
c. used for large size simple casting d. pattern is accommodated either cope or in the drag
2. Split piece pattern: pattern of Intricate shape casting can't be made in one piece because of the inherent
difficulties associated with the moulding operation that is withdrawing the pattern from the mould and the
upper and lower part of the split piece patterns are accommodated in the cope and drag portion of the mould
respectively parting line of the pattern forms the parting line of the moulddouble pins are used for keeping the
alignments between the two parts of the pattern.
3. Loose piece pattern: certain patterns can't be withdrawn once they are embedded in the moulding sand
such patterns are usually made with one or more lose pieces facilitating from the moulding box and are
known as loose these pattern lose part or peace remain attached with the main body of the pattern with
the help of double pin the main body of the pattern is drawn first from the moulding boxand the area after
as soon as the lose part are removed the result is the mould cavity
4. Match plate pattern: it consists of a match plate on either side of which half of split pattern a number of
different size and shape patterns maybe a mounted on one match plate and the match plate with the help
of locator holes can be clamped with the drag after the cope and drag have been ramped with the
moulding sand the match plate pattern is removed from in between cope and drag match plate pattern
or normally used in machine moulding by using this we can eliminate mismatch of cope and drag cavity
 5. Sweep pattern: sweep pattern a sweep pattern is just a form made on a wooden board which sweep the
shape of the casting into the sand all around the circumference the sweep pattern rotates about the post
once the mould is ready sweep pattern and post can be removed the sweet pattern avoids the necessity
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of making function large circular and costly 3D patterns so making a Sweep pattern shapes a lot of time
and labour as compared to full pattern a sweep pattern is preferred for producing large casting of circular
section and symmetrical shape
6. Gated pattern: the section connecting different pattern serves as runner and gates this facilitates filling
of the mould with metal in a better manner and at the same time eliminates the time and labour otherwise
consumed in cutting runner and get. A get pattern can manufacture many casting at one time thus it is
used in mass production system. Gated patterns are employed for producing small casting.
7. Skeleton pattern: A skeleton pattern is the skeleton of a desire shape which may be (S) band pipe the
skeleton frame is mounted on a metal base and the skeleton is made from a wooden strip and skeleton
pattern is filled with a send and is ramped. skeleton patterns are employed for producing a few large
casting patterns is very economical because it involves material cost.
8. Follow board pattern: follow board is wooden board and is used for supporting a pattern which is very
thin and fragile and which have given way and collapse under pressure when the send above thepattern is
being ramped with the flow board support under the weak pattern the drag is Ramped and then the flow
board is withdrawn during this operation pattern remains over the inverted drag and get support from
the ramped sand of the drag under it and follow board are also used for casting master pattern for many
application
9. Cope and drag pattern: cope and drag pattern is another form of a
split pattern and each hub of the pattern is fixed to separated metal
or wood plate each hub of the pattern is moulded separately in the
separated moulding box and the two moulds of each hub of the
pattern are finally assembled and the mould is ready for poring
these are used for production big casting with as a whole cannot
be conveniently handled by one moulded alone.

# Pattern allowances: pattern is larger in size as compared to the final casting because it carries certain
allowances due to metallurgical and mechanical reason, for example- shrinkage allowance is the result of
metallurgical phenomenon whereas machining, distortion shake, and other allowances are provided on the
pattern because of mechanical reason.
# Type of pattern allowances: a. shrinkage or contraction allowances b. machining c. draft or tapper d.
distortion or chamber e. Shake or rapping f. heat treatment
A. shrinkage or contraction allowances: the metal shrinkage is of three types.
I. liquid shrinkage II. solid shrinkage III. solidification shrinkage

I. Liquid Shrinkage: Generally liquid shrinkage is 1.6% per C.

II. solidification shrinkage: it refers to the reduction in volume when the metal changes from liquid state to
solid state at the solidus temperature to account for this shrinkage riser which feed the liquid metal to the
casting area provided in the mould.

III. solids shrinkage: it refers to the reduction in volume caused when metal losses temperature in solidstate to
account for this linkage allowances is provided on the pattern almost all cast metal shrink or contract
volumetrically after solidification and their for the pattern to obtain a particular size of casting is made over size
by an amount that equal to of shrinkage or contraction different metals shrink at different rates because
shrinkage is the property of the cast metal or alloy the metal shrinkage dependon the cost metal or alloys
a. pouring temperature of the metal/alloys b. moulding temperature of the metal c. casted dimension d.
casted design e. casted metal/alloys
contraction allowance for different metals (in mm/m):
grey cast iron = 7- 10.5, steel = 20, white cast iron = 21, malleable iron = 15 ,
copper and brass = 16, zinc = 24 , lead = 24 , Al = 16 , magnesium = 18
B. Machining allowances: will take care of the extra material that will be removed to obtain a finished
product. In this the rough surface in the cast product will be removed. The machining allowance depends on
the size of the casting, material properties, material distortion, finishing accuracy and machining method.
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C. Draft or trapper allowance: It’s given to all surface’s perpendicular to the parting line draft allowances is
given so that the pattern can be easily remove from the moulding material tightly packed around it without
damaging moulding material tightly packed around it without damaging mould cavity the amount of tapper or
trap depends on shape and size of pattern in the depth direction in contract with mould cavity.
-moulding method, -mould material, - draft allowances in imparted on internal as well as external
surface of course it is more on internal surface

D. Distortion or chamber allowances: casting will

distort if it is of regular shape for casting if it is of
regular shape all parts do not shrink uniformly some
parts shrink while other restricted from doing so( U or
V shape) The unprocessed , unequal parts causes
unequal thickness; one portion of the casting cools at
faster rate as compared to other.

E. Shaking allowances: A pattern is shaken or warp by striking the same with a wooden piece from side to
side and this is done so that the pattern a little is Loosen in the mould cavity and can be easily removed
therefore wrapping enlarges the mould cavity which results in a bigger size casting hence a negative
allowances is provided on the pattern and the pattern dimension are keep smaller in order to compensate the
in enlargement of mould cavity due to wrapping.
# Pattern colour
1. Pattern is imparted certain color and shades in order to identify quickly the main bodyof the pattern and
different part of pattern.
2. indicates the different type of metal to be cast
3. identify the core point piece etc. 4. visualize the surface to be missing
The colour code use is:
A) red or Orange on surface not to be finished and left as cast B)yellow on surfaces to be machined
C) black on core points for unmachined opening D) yellow strip on black or core points for machined opening
D) green for loose pieces or loose core point

Moulding sand
Moulding sands are most commonly used for making all type of moulds irrespective of whether they are used
for producing casting ferrous material or non-ferrous. Most sand-casting operation use silica sand.
A mixture of water and clay used as sand. A typical mixture by volume would be 89% sand + 4% water + 7%clay.
Characteristics. - (1) Refractory in nature can withstand temp of metal impart without fusing,
(2) Molding sand do not chemically react with molten metal.
(3) The sand has high degree of permeability and thus allow gases formed during the pouring to escape.
(4) This strain permeability of sand mixture can be changed be structure of sand.

Types of moulding sand

1. Green sand: it is used in the wet condition for making the mold it is a mixture of silica andwith 15% to 25%
clay and 6 to 8% water the sand can be easily work with hand to give it any desired shape green sand molds
are not dried and metal is pored in them in wet condition this sand is used for producing small to medium size
mold which are not very complex.
2. Dry sand: it is the green sand that has been dried or baked after preparing the mold drying sand gives
strength to the mould so that it can be used for larger casting.
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3. Loam sand: it is the sand containing up to 15% clay which has been worked to the consistency of wildered
mortar this sand is used for moulds making for heavy casting usually with the help as Sweep and skeleton
patterns.
4. Parting sand: the sand is used during making of the mould to ensure that green sand does not stick to the
pattern and the cope and drag parts can be easily separated for removing the pattern without casting any
damage to the mould the partings sand consists of fine grain clay free dried silicas and or burnt sand with some
parting compound and the parting compound used include charcoal, limestone, talcum powder and calcium
phosphate.
4. Facing sand: it is the sand which covers the pattern all around it the remaining box is filled with ordinary
floor sand. facing sand forms, the face of the mould and comes in direct contact with the molten metal when it
is poured high, and refractoriness are required for the sand graphite molasses are added to the facing sand
thickness of the sand layer varingfrom 20 to 30 mm.
5. Baking sand: it is the bulk of the sand used to break up the facing sand and to fill up the volume of the flask
it consist mainly of old repeatedly used moulding sand which is generally black in colour due to the edition of
cold dust and burning on contact with hot metal because of the colour of baking sand it is also called black sand
sometimes the mainpurpose for the use of baking sand is to reduce the cost of moulding.
6. Core sand: it is sand used for making cores this is silica sand mixed with core oil that is alsocalled oiled sand
the core oil consists of linseed oil raisin like mineral oil with some binderfor larger sometime pitch or floor and
water may also be used for saving the cost.

# Properties of moulding sand

(i) green strength: adequate strength and toughness for making and handling the mould.
(ii) dry strength: dry sand must have strength to resist erosion and also the metallostatic pressure of
the molten metal.
(iii) hot strength: metalloid or metallostatic pressure of the liquid metal bearing against the mould
walls may cause mould enlargement or if the metal is still flowing erosion cracks or breakage may
occurs unless the send poses adequate hot strength.
(iv) permeability: the mould must be permeable that is porous to permit the gases to escape.
(v) thermal stability: heat from the casting causes rapid expansion of the sand surface at the mole
metal interface the mould surface may crack buckle or flake off (scabbing), unless the moulding
sand is relatively stable dimensionally under rapid heating.
(vi) refractoriness: the absence of melting softening or adherence of the sand is the casting makes
for better casting surface and easier cleaning of the casting (fusion type defect).
(vii) flowability: the sand should pack well or follow under load the sand of the low flowability may
result in non-uniform hardness soft mould enlargement of the casting or roughness of the casting
surfaces.
(viii) collapsibility: the moulding sand should also have collapsibility so that during the contraction of
the solidified casting it does not provides any resistance which materials incracks in the casting.
(ix) reusability: since large quantities of sand are used in a foundry it is very important that the sand
is reusable otherwise apart of cost it will create disposal problem.
(x) thermal conductivity: sand should have enough thermal conductivity to permit remove of heat
from the casting.
Ingredient of moulding sand
Moulding sand are actually mixture of three or more ingredients: green sand, clay and water.
Moulding sand contents 50-95% and the total material in a moulding sand. This sand particle may differ in the
following ways.
1.average green size. 2.grand size distribution. 3.grain shape 4. chemical composition.
5. refractoriness and thermal stability.
Generally, the purest silica sand i.e. 99.8% SiO2 to is considered most refractory and thermally stable.
Excessive amount of iron oxide alkali oxide and lime cause the loading of fusion point in some sand.
 Clay: with a suitable water content it's the principal source of strength and plasticity of the moulding sand
Bentonite are clay minerals. 6
Water: 1.5-8% It activate the clay to develop plasticity and strength water in moulding sand is often referred
as a tempered water. Water in access is called free water. The rigid clay coating of the sand grains may be
forced together to develop strength. Water free makes the sand more plastic and more moldable though the
strength maybe lower that's why control of water in sand is very important.
Special additives: Coal (by product of Coke breaking) pitch up to 2% to improve hot strength and casting
finish in ferrous casting.
Gilsonite: It is used about 0.4-0.8% to improve casting finish.
Sea cold: (2% generally used) used in grey and from malleable sand improve the surface finish and improve
easy of cleaning the casting.

Molding sand test

A. moisture content place 20-50 gram of prepared sand in the pan and heat it in a oven for 2-3 minute the
moisture in the moulding sand is thus evaporated moulding sand is takenout of the pen and weighted again.

B. clay content 50 gram of dry moulding sand transferred to the measuring flask. Add 475 cc of distilled
water and 25 cc of 3% NaOH, agitate this mixture for 10 minutes with the help of sand stirrer and fill the wash
bottle with water up to mark. After the sand has settled down, wash bottle from siphon water.

Methylene blue test (active clay test)

Methylene blue is an aromatic chemical compound C16H18N3SCl calibrate the methylene clay system number
of milliliters of methylene blue required for each percent of bentonite or clay. Take a 5 gram of sand in a
stainless steel container a 50 ml of 2% Tetra sodium pyrophosphate solution via pipet disperse the sand
particle using an ultrasonic vibrator slowly fill the vessel with methylamine blue from burette and stir the
system using a glass rod remove a single drop of the liquid and place it ona filter paper watch for the formation
of blue green. Hollow around the central spot increase the edition of methylene blue drop by drop till the blue
green hollow appears using the calibration factor to determine the clay content of the sand.
Grain fitness test
Place the sample of dry sand (clay remove) in the upper sieve and vibrate the sieve shaker for 15 minutes
and weight the amount of sand retained on each sieve and compute the percentage distribution of grains .
A sample of 50 gram of moulding sand was sieved through a sieve shaker. the quantity of sand collected in
different ship where deemed determine the AFS (American foundry society) grain fitness no of the sand. sand
retained on each ship.
Permeability test
the quantity of air that will pass through a standard specimen of sand at a particular pressure conditionis called
the permeability of the sand and inverted bell jar which floats in a water specimen tube for holding the sand
specimen and nanometer for measuring the air pressure show the air that is 2000cc volume held in the bell
jar specimen and take pressure reading in the time required for 2000 cc air topass the specimen
 Compatibility: the compatibility indicates the water tempering degree of the green sand molding
compatibility is the percentage decreased in height of a loose mass of sand under the influence of acontrolled
compaction.
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Green compression strength: it indicates the load bearing compacity of the mold in the pressure of
moisture.
Green sheer strength: it indicates the strength of the mold during the removal of pattern.
mould hardness: hardness indicates the resistance of the mold to plastic deformation.

BINDER
Ingredient which holds the sand each order by making bonds it should retain its property till the solidification
is complete when the solidification complete it lose its property.
Types of Binder:
inorganic binder – clay, Bentonite, sodium silicate
organic binder – resin bonded sand, oil bonded sand, neutral oil, synthetic relinSiO2, Na2O, H2O
ratio of = SiO2 / Na2O varies to 2-2.9 but in foundry 2-2.4 is needed and water content nearly 50%

Important facts about sodium silicate

- Higher the SiO2/ Na2O ratio for a given solid contact the greater is the viscosity.
- higher the viscosity lower the coating ability
- solution below 2.8 ratio are alkaline and above the solution is neutral
- silicate with ratio less than 2 do not hard and quickly to be of foundry use
Mechanism of hardening (CO2 process): In CO2 process the overall hardening is affected by 3 things:
(i) Chemical gelation
(ii) physical dehydration using gassing.
(iii) physical dehydration during storage due to loss of water molecules
Chemical gelation:
SiO2 + H2O + Na2O + CO2 → H2CO3 + Na2O + SiO2
SiO2 + H2O + Na2O + H2CO3 → H2CO3 + SiO2.2H2O
Physical dehydration: SiO2Na2O H2O bond is stronger than silica hydrogen bond this is because the drying up
of silica hydrogen andwill result information of micro cracks should be to get minimum of silica gel bond and
maximumof soda glass bond.
(a) Over gassing: this is the result of very low gas flow rates overall particular period of time producing high
quality of silica hydrogen gas this condition games sufficient time for Co2 to dissolve in water of sodium
silicate the week silica hydrogen bond will dry but due to prolonged guessing upon standing giving a friable
surface and sodium carbonate produce the
(b) Under gassing: high flow rate low time this condition occurs in the early stage of gassing afterthe first
silica hydrogen layer has been formed and before silicate glass has been formed any mould core strip in
this condition would develop very high strength on standing since only little amount of silica hydrogen has
been formed and there is much more sodium silicate left for conversion in strong silicate glass bond.
Ingredients: 1. Clay free dry sand 2. SiO2 / Na2O - 2.1 ratio 3. 3 to 5% of sand weight 4. 3 min mixing
5. 1 kg of sodium silicate will require 0.5 – 0.75 KG of CO2 gas.

Advantages: (a) much more rigid and stronger and core can be formed.
(b) high flowability show gives a better come mould casting produced have betterdimensional accuracy.
(c)less friable and hence lesser sand inequation. (d) for faster production less skilled required.

Disadvantage: 1. core breakdown property and core collapsibility.

2. higher cost off sand reclamation 3. shorter bench life

Organic Binder: Cold box process

1. Resin (Phenolic resin) Dissolved in organic solvent to give low viscosity solution to facilitate coating of sand
and building with the second component.
2. Hardness Polymeric isocyanate landed with
organic solvent to form a low viscosity solution
weight.
3. catalyst- Dimethyl ethyl amine sand of weight
1.5-2%.
CO2, N2, air is used as a carrier gas of dimethyl
ethyl amine.

Mechanism:
Phenolic resin + Poly isocyanate → (catalyst: vapor of amine) UR ethene(polymeric bond)

No water or other byproduct is not formed. or any during the reaction. Only 3-4%. N2 comes from Second
component.
Clean silica sand minimum clay content should be used. zircon chromite / Polyvinyl chromite can be used.
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These systems contain high carbon which contribute the formation of reducing atmosphere during the pouring.
This system strip time is 10-30 sec.
Additives generally 1-2% sugar blend or 1-3% iron oxide. Iron oxide / black or red iron oxide is recommended
for stopping veining in steel casting. Veining is more in high temperature.

Advantages of cold box process:- "(1) High dimensional accuracy and surface finish.
(2) Low gas evolution. (3) Excellent collapsibility (4) sand metal ratio can be reduced 1:1 due to sand strength.

Limitation: (1) Amine vapor is highly inflammable and poisonous. Binder component in inflammable therefore
storage temperature 20-30°. At low pouring temp metals and alloys may not show Hot box proces:

Hot box process:

Urea formaldehyde: N₂ can be tolerable.
Phenol formaldehyde: N2 can be less, good f or steel.
Urea-Phenol formaldehyde: N2 less, suitable for grey iron casting
Typically resin contest: 1.5-2.1%, and catalyst is acid salt ammonium nitrate or ammonium chromite
Chlorite type of catalyst is more reactive. Therefore, can be used in winter. and nitrate in summer.
Addition of catalyst: 0.5-25% of resin weight

Advantages of hot box process: (1) Less resin. (2) Binder cost is less
(3) Lower resin addition lower gas problem. (4) generally temp 220-245°c
Limitations: Production of hollow books require costly products.

Centrifugal casting

The casting process in which molten metal is poured into a permanent water-cooled mould which rotates about
its axis. The centrifugal force works in two ways to give a good casting:
Distribution of metal towards the periphery of mould and it helps in directional solidification.
Production technique 1. Type of machine 2. Type of mould 3. Pouring methods

Types of centrifugal casting: 1. Centrifuging 2. Semi-centrifuging 3. True centrifuging

Centrifuging casting: In this process, circular molding box is taken. Smaller casting can be made by this process.
For each casting separate equal distance gates are attached with a central screw so that centrifugal force exerted on
each cavity is uniform. The mold is rotated as a pre-determined speed about its axis before pouring the metal. The
metal is poured under gravitational force whereas filling up the mould cavity take place under presser due to
centrifugal force.
Semi-centrifugal casting - Costing is due to centrifuge! force and somewhere due to static force. Big gear can
be cast by this process. 9
True-centrifugal
casting: It is generally
used for making pipes
(spun pines)

Horizontal axis casting:

L/D>4
Inclined axis casting:
1<L/D>4
Vertical axis casting:
L<D

The pouring material is a mixture of alumina, silica and graphite. The pure silicon is not used because chance of
fusion. Fe-Si powder is used. If the mold is rotated about its longitudinal or vertical axis and inner surface of
casting is formed under the influence of centrifugal force. Then the process is called true-centrifugal casting.
The process is utilized on essentially cylindrical shape where only the outside diameter and the length are
fixed by the mold candy. The inner dia. of the pipe is controlled by the volume of metal to be poured.
In case of alloy, there is chance of segregation of elements. If Copper tin alloy is used, outer layer copper &
inner layer tin.

Activated clay: active clay is a naturally occurring porous mineral which has been dried toproduce an
adsorbent material. The clay has a good adsorption capacity within normal temperature and relative
humidity ranges. Activated clay retains its structure as it becomessaturated and can be easily reactivated for
re-use by heat.
Briefly discuss different type of cast iron.
Ans- There are primarily 4 different types of cast iron. Different processing techniques can be used to produce
the desired type, which include:
(i)
(ii)
(iii)
(iv)
Grey Cast Iron (carbon 2.5 – 4.0, silicon 1.0 – 3.0)
White Cast Iron (carbon 1.8 – 3.6, silicon 0.5 – 1.9)
Ductile Cast Iron (carbon 3 - 4 , silicon 1.8 - 2.8 )
Malleable Cast Iron (carbon 2 – 2.9, silicon 0.9 – 1.9 )
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Cast Iron is an iron-carbon alloy that typically contains greater than 2% carbon. The iron and carbon are mixed
in the desired quantities and smelted together before being cast into a mould.

(i)Grey Cast Iron: Grey Cast iron refers to a type of cast iron that has been processed to produce free graphite
(carbon) molecules in the metal. The size and structure of the graphite can be controlled by moderating the
cooling rate of the iron and by adding silicon to stabilize the graphite. When Grey Cast Iron fractures, it
fractures along the graphite flakes and has a grey appearance at the fracture site.
(i)Grey Cast Iron is not as ductile as other cast irons, however it has an excellent thermal conductivity and
the best damping capacity of all cast irons. It is also hard wearing making it a popular material to work with.
(II) The high wear resistance, high thermal conductivity, and the excellent damping capacity of Grey Cast Iron
makes it ideal for engine blocks, fly wheels, manifolds, and cookware.

(II)White Cast Iron: White Cast Iron is named based on the appearance of fractures. By tightly controlling the
carbon content, reducing the silicon content, and controlling the cooling rate of iron, it is possible to consume
all carbon in the iron in the generation of iron carbide. This ensures there are no free graphite molecules and
creates an iron that is hard, brittle, extremely wear resistant and has a high compressive strength. As there are
no free graphite molecules, any fracture site appears white, giving White Cast Iron its name.
White Cast Iron is used primarily for its wear resistant properties in pump housings, mill linings and rods,
crushers and brake shoes.

(III)Ductile Cast Iron: Ductile Cast Iron is produced by adding a small amount of magnesium, approximately
0.2%, which makes the graphite form spherical inclusions that give a more ductile cast iron. It can also
withstand thermal cycling better than other cast iron products.
Ductile Cast Iron is predominantly used for its relative ductility and can be found extensively in water and
sewerage infrastructure. The thermal cycling resistance also makes it a popular choice for crankshafts, gears,
heavy duty suspensions and brakes.

(IV)Malleable Cast Iron: Malleable Cast Iron is a type of cast iron that is manufactured by heat treating White
Cast Iron to break down the iron carbide back into free graphite. This produces a malleable and ductile product
that has good fracture toughness at low temperatures. Malleable Cast Iron is used for electrical fittings, mining
equipment and machine parts.