What can be made from cast iron

The use of cast iron of different grades in various industries

An alloy of iron containing carbon is called cast iron. In some cases, alloying additives are added to the composition, affecting its consumer qualities. Cast iron is a metal that is used primarily in ferrous metallurgy. It is not only used to produce steel, it is also in demand in the manufacture of forged artistic parts.

Gray cast iron

For mechanical engineering, gray cast iron containing graphite is mainly used. Parts made from such material do not react to stresses; they absorb vibrations that occur when mechanisms vibrate. Critical parts are made from it

1. Bushings;
2. Machine beds;
3. Heavy bases.

It began to be used as a structural material in almost all enterprises of the mechanical engineering industry. The following industries became the largest consumers of gray cast iron

1. Automotive industry;
2. Machine tool industry;
3. Metallurgy;
4. Sanitary.

Tractor parts made from gray cast iron reach 20% of the total number of parts. This use of this alloy is associated with high wear resistance. It does not lift up in case of high friction and lack of lubrication, in other words, it has damping ability . It is made from:

1. Blocks;
2. Bearing caps;
3. Brake discs;
4. Ferrado;

To manufacture the cylinder head of various engines, of low-alloy alloy :

The main requirements for the midrange during the production of liners were:

1. Pearlite structure;
2. Graphite;
3. High hardness.

For car engines of any design, cylinder liners made of a special alloy are used. In most cases, its phosphorous fraction is used.

Diesel engines during operation create a large load on the cylinder block , so alloy cast iron is used for them. Cylinder heads are made from high carbon alloy grades,

The same requirements are observed in the manufacture of liner castings, the material of which is a low-alloy alloy. The chemical composition of this material depends on several technological characteristics:

1. Melting method;
2. Casting dimensions;
3. Manufacturability of form.

Cars are equipped with cast iron camshafts, which are highly wear-resistant. This parameter is achieved thanks to surface hardening to which the metal is subjected.

When a part is operated at high speeds, when dry friction occurs, it is necessary to have increased wear resistance of the material and a high coefficient of friction. It is in such conditions that this alloy is simply irreplaceable.

Brake drums operating in such conditions are made from SCh20. When a part experiences high loads and thermal cracks may appear, a special heat-resistant alloy with a high carbon content and a high level of alloying is used.

For particularly severe conditions, parts made of pearlitic cast iron are installed. It contains vermicular graphite.

The rotation of the flywheel during operation reaches 7000 rpm. This speed causes tensile stresses to appear. The rotating surface of the flywheel constantly touches the working surface of another part. Such friction causes a strong release of heat, resulting in thermal cracks that negatively affect the strength of the part.

To increase strength , given the large weight of the flywheel and the size of its cross-section, it is made from various grades:

It must provide a workpiece strength above 250 N/mm2. Sometimes SCh 35 has strength that is not enough to ensure normal operation of the flywheel. In this case, cast iron is used, to which nodular graphite is added.

Passenger cars boast cast iron caps covering the main bearings . This design is found in most cases on cars with a carburetor engine. To ensure a pearlite structure, as well as high hardness exceeding 200 HB, SCh25 is used for the manufacture of bearing caps.

Manufacturing of collectors

In a car, the exhaust manifolds are exposed to exhaust gases, the temperature of which reaches 90 degrees. Collectors under the influence of an aggressive environment oxidize, deform and crack.

The use of gray cast iron ensures durability of such parts and high efficiency. Due to the fact that the thickness of the collector walls is very small, less than 7 mm, SCh15 is used for their manufacture. To increase its heat resistance, cast iron is alloyed with chromium or nickel additives.

For the manufacture of collectors experiencing high thermal loads, the following is used:

1. Ductile iron;
2. With additives of spherical graphite;

All of the above materials have high heat resistance and resistance to aggressive environments, alkalis and oxides.

Machine tool industry

In the machine tool industry, a large number of cast parts are made from gray cast iron, operating in various conditions, the weight of which can reach 100 tons , with a maximum wall thickness of 200 millimeters.

The classification of such cast parts in the machine tool industry, depending on the designs and the operating conditions created, corresponds to the current standard.

For each part, a special grade of cast iron is selected . It depends on the following parameters:

1. Class of the workpiece;
2. Wall thickness;
3. Hardness;
4. Microstructures.

Considering the specifics of many machine-tool parts, which work mainly on rigidity, for their manufacture they prefer to use cast iron, which has increased hardness and fairly low ductility.

The chemical composition of such cast irons is high in manganese and low in carbon. To obtain high hardness of cast iron, alloying and other technological processes are used.

SSP blanks are widely used in metallurgical equipment:

1. Sheet rolls;
2. Molds;
3. Slag bowls.

Plumbing

A lot of cast iron products are used in plumbing. Made from cast iron:

1. Heating radiators;
2. Pipes;
3. Fitting;
4. Sinks;
5. Kitchen sinks.

And today cast iron bathtubs remain in demand, which are distinguished by high strength , durability and reliability. Such products can be used for decades. They retain their original appearance and do not require replacement.

Craftsmen make artistic masterpieces from cast iron. For example, the embankments of St. Petersburg are decorated with cast iron parts. Walking along the streets of the city you can see openwork gates and original cast-iron fences. In the parks you can see cast iron monuments.

Application of Ductile Iron

This material has excellent damping properties and is capable of excellent performance at very low temperatures. This type of cast iron is used in the production of critical parts for tractors, as well as cars, which will have to perform their work in difficult climatic conditions.

Parts made of malleable cast iron have also found their application in the electrical industry . It is made from:

1. Terminals;
2. Insulator hooks;
3. Wire holders.

Such products cope well with force loads; they can bend under mechanical stress.

In textile engineering , ductile iron is used in the manufacture of:

1. Gears;
2. Forks
3. Spokes;
4. Parts for paper spinning machines.

In other words, for parts experiencing large static loads, subject to friction and rapid wear. For such products, anti-friction malleable cast iron is used, which is capable of creating minimal friction where there is maximum contact between the parts.

Malleable cast iron is also used in plumbing products . It is made from:

1. Water outlets;
2. Flange adapters;
3. Valves;
4. Heating radiators.

These products can work for a long time in an aquatic environment.

Gas systems use ductile iron to make the outlet fittings that connect pipes where all sorts of branches occur.

A variety of grades of malleable cast iron are widely used in landscape design when decorative parts are formed:

1. Original hedges;
2. Benches;
3. Gates;

This alloy is also used in the furniture industry, for elements that can be affected by precipitation:

1. Terrace furniture;
2. Gazebos.

Parts for household equipment are made from it

1. Vann;
2. Washing machines;
3. Gas stoves;
4. Frying pan;
5. Kotelkov.

A lot of car parts are made of ductile iron . These include:

1. Drives;
2. Wheel hubs
3. Gears;
4. Carters;
5. Engine brackets;
6. Skating rinks;
7. Brake pads;
8. Overlays;
9. Balancers
10. Cardan shafts;
11. Collectors.

Shipbuilding cannot do without malleable cast iron. In the manufacture of equipment for ships, CC is used for the production of:

1. Portholes;
2. Mast brackets;
3. Oarlock;
4. Breshtuk;
5. Water fittings.

Malleable cast iron has not been forgotten in the railway industry. During the construction of cars, the following are made from it:

1. Spare parts for air brakes;
2. Bearings;
3. Brackets
4. Traction and coupling systems;
5. Staples.

For many centuries, humanity has been using cast iron; today almost every person deals with such an alloy. It is highly durable and has a relatively low cost . The only drawback of cast iron parts is their fragility. But, with the correct technology for producing cast iron, this disadvantage is minimized, which is why cast iron parts are so widely used in the industries described above.

Source: https://stanok.guru/metalloprokat/truboprokat/v-kakih-otraslyah-promyshlennosti-neobhodimo-primenenie-chuguna.html

The use of cast iron and products made from it in construction and other areas

Cast iron is the main metal of ferrous metallurgy. It is an alloy of iron and carbon. Cast iron may contain special additives that make its properties special. This cast iron has the characteristics of wear resistance, corrosion resistance, heat resistance, non-magneticity and others. We will talk about the properties, composition and areas of application of gray, white, malleable cast iron, as well as high-strength and granular cast iron below.

Due to its valuable properties, low cost and good casting characteristics, cast iron is used for the manufacture of various parts and objects. Cast iron can be used to produce products of interesting and special shapes, since this material has excellent hardness and strength. Made cast iron objects can withstand quite serious loads. It is for this reason that machine bodies and machine tool bases are made of cast iron.

• Cast iron has always been used for the manufacture of parts and heavy industrial . It was used in metallurgy and machine tool building. Moreover, this material was taken in very large quantities. It was used as the main one for small items and for large items, the weight of which reached hundreds of tons.
• in mechanical engineering . This is the type that is always taken for the manufacture of critical parts. Cast iron machine products resist vibration and vibration well.
• In the automotive industry, cylinder blocks are made from cast iron. These are critical parts that must have high strength and wear resistance. Cast iron helps to meet these qualities. To make these indicators optimal, special additives in the form of graphite are added to cast iron. Graphite increases the strength properties of the alloy several times. Additives make it possible to perfect cast iron and use it in the manufacture of diesel crankshafts.
• Brake pads are made from cast iron . We know that these parts operate under high friction. Cast iron helps them withstand these harsh conditions. In addition, rollers for flour-grinding and paper-making machines are made from cast iron.
• Cast iron products work well at low temperatures . For this purpose, malleable cast iron is used. It is used to make parts of tractors and complex mechanisms that will subsequently operate under harsh conditions.
• Cast iron is widely used to make household items . This material is very popular among our population. Cast iron pots, frying pans, cauldrons can be found both in an ordinary kitchen and in a restaurant's arsenal of dishes. This is truly unique tableware.
• Any housewife knows about a cast iron frying pan, which has excellent quality. Cast iron cookware retains heat well. It is convenient to prepare dishes that require constant warmth. Cast iron cookware is used to prepare pilaf, porridge and stew. The products in it retain a lot of useful properties. Carcinogenic substances are not formed in such food. By the way, it has been proven that cast iron cookware can enrich foods with useful iron elements.
• For the oil industry , a complex and dangerous industry, pipes are made only from cast iron. The products are obtained with high performance qualities.
• Cast iron is distinguished by its durability . Therefore, in our homes to this day you can see sinks and bathtubs that were made more than 50 years ago and are still being successfully used today.
• Cast iron is very often used for artistic objects . Various works of art are made from it. Thus, the embankment of St. Petersburg is almost entirely decorated with cast iron items. Interesting and unusual fences, openwork branched gates and cast iron monuments are made from cast iron. All this became possible thanks to the good casting properties of this material. The items made practically do not wear out and look the same even after many years. It is not uncommon to find cast iron works of art within the walls of a museum.

It is especially pleasing that cast iron is well valued as a second-rate material. That is, if suddenly a cast iron item becomes unnecessary, you can turn it in for melting and get good money for it.

We will talk about the characteristics and areas of application of steels and cast irons (alloyed, antifriction, casting, etc.) below.

This video will tell you about the areas of application of cast iron:

This section will discuss the classification, marking (grades) and application of cast irons and their alloys.

Features of application

Gray cast iron is used in construction. White is too hard and brittle. It is smelted into malleable iron or steel.

Cast iron has been used in construction since ancient times. Products made from it were of excellent quality if the production technology was strictly followed. Cast iron has always been produced by casting. The manufactured material should not have air pockets, molding lines or cracks.

• In ancient times, supporting structures were made from cast iron, which were assembled piece by piece. First, the structural cast iron elements were cast, and then the bases were connected with fasteners. This method was especially often used in arched structures.
• Cast iron has always been used to make sewer pipes, racks and post bases. Various designer items were made from it for homes.
• Pipes in our houses, heating radiators, taps, water supply valves, fittings - all this is made using cast iron.
• Plumbing products can be partially or completely made from the described material.
• I would especially like to mention cast iron heating radiators. These devices are in high demand. Such heating radiators are durable, have high heat transfer and excellent heat-storing properties. They remain warm and give off heat to the room even an hour after being turned off. Compared to steel radiators, they lose heat twice as fast.
• Today and in the past, grates were made from cast iron. With this strong material it was possible to create various shapes and designs. Interesting patterns and lines made cast iron products truly skillful. Some embankment decorations and palace fences have survived to this day. These works of art were made according to the ideas of famous masters. And cast iron made it possible to bring these ideas to life and preserve them to this day.

There is one caveat. Modern building materials have replaced cast iron. In some products, cast iron has been replaced with plastic. Today, practically no water fittings, sewer pipes, or plumbing fittings are manufactured. However, lids, fences and large sewer pipes are still made from cast iron.

Cast iron fittings

Cast iron

This type of cast iron has become popular due to its low fusibility. It melts even at low melting temperatures and easily fills the mold. Cast iron castings are quite durable and free of bubbles.

If we are talking about high-quality cast iron, then when it changes its state (from liquid to solid) it does not change its volume. This effect is achieved by adding special impurities to cast iron in the form of phosphorus, sulfur, manganese and silicon.

• Due to its low fusibility, cast iron is used to make beautiful building parts in the form of various shapes. Subsequently, these parts are securely fastened with bolted connections.
• In architecture there is no place without cast iron. Decorative cast iron elements can decorate any building and architectural monument.

Forged products

Cast iron is highly valued by blacksmiths. This material lends itself well to forging. This is all connected with the atomic lattice of the material, which has gaps. Making any products from it is as easy as shelling pears for a blacksmith. The following forged products have become a part of our lives:

• Lanterns;
• Stairs;
• Decorative elements;
• Gates;
• Window grilles;
• Front gardens;
• Lantern poles.

Today, parks, offices and urban architecture are decorated with forged lattices, patterns, and applications.

Cast iron is resistant to corrosion. It is durable. And therefore, some cast iron elements have not lost their appearance to this day. It was noted that forged cast-iron stairs (both outside the house and inside), openwork drawings, sculptures, window grilles, gates and street lights look very impressive.

Cast iron staircase

In construction, cast iron has proven itself due to the following positive aspects:

• Cast iron decorative elements produce a good visual effect.
• Cast iron objects are not subject to corrosion processes.
• Complex cast iron shapes can be produced very quickly.
• Cast iron products have high strength.
• Simple production process.
• Making cast iron products is inexpensive.
• Long service period.

The price of forged products depends on the amount of material used, the complexity of production, speed of execution, and company prices. The price is available to everyone. Everyone can decorate their homes with fashionable elements and grilles.

This video will tell you how cast iron and steel can be used:

Source: http://stroyres.net/metallicheskie/vidyi/chyornyie/chugun/primenenie-v-stroitelstve-i-drugih-oblastyah.html

Replacing cast iron with steel

Cast iron is the main metal of ferrous metallurgy. It is an alloy of iron and carbon. Cast iron may contain special additives that make its properties special.

This cast iron has the characteristics of wear resistance, corrosion resistance, heat resistance, non-magneticity and others.

We will talk about the properties, composition and areas of application of gray, white, malleable cast iron, as well as high-strength and granular cast iron below.

Due to its valuable properties, low cost and good casting characteristics, cast iron is used for the manufacture of various parts and objects. Cast iron can be used to produce products of interesting and special shapes, since this material has excellent hardness and strength. Made cast iron objects can withstand quite serious loads. It is for this reason that machine bodies and machine tool bases are made of cast iron.

• Cast iron has always been used for the manufacture of parts and heavy industrial . It was used in metallurgy and machine tool building. Moreover, this material was taken in very large quantities. It was used as the main one for small items and for large items, the weight of which reached hundreds of tons.
• in mechanical engineering . This is the type that is always taken for the manufacture of critical parts. Cast iron machine products resist vibration and vibration well.
• In the automotive industry, cylinder blocks are made from cast iron. These are critical parts that must have high strength and wear resistance. Cast iron helps to meet these qualities. To make these indicators optimal, special additives in the form of graphite are added to cast iron. Graphite increases the strength properties of the alloy several times. Additives make it possible to perfect cast iron and use it in the manufacture of diesel crankshafts.
• Brake pads are made from cast iron . We know that these parts operate under high friction. Cast iron helps them withstand these harsh conditions. In addition, rollers for flour-grinding and paper-making machines are made from cast iron.
• Cast iron products work well at low temperatures . For this purpose, malleable cast iron is used. It is used to make parts of tractors and complex mechanisms that will subsequently operate under harsh conditions.
• Cast iron is widely used to make household items . This material is very popular among our population. Cast iron pots, frying pans, cauldrons can be found both in an ordinary kitchen and in a restaurant's arsenal of dishes. This is truly unique tableware.
• Any housewife knows about a cast iron frying pan, which has excellent quality. Cast iron cookware retains heat well. It is convenient to prepare dishes that require constant warmth. Cast iron cookware is used to prepare pilaf, porridge and stew. The products in it retain a lot of useful properties. Carcinogenic substances are not formed in such food. By the way, it has been proven that cast iron cookware can enrich foods with useful iron elements.
• For the oil industry , a complex and dangerous industry, pipes are made only from cast iron. The products are obtained with high performance qualities.
• Cast iron is distinguished by its durability . Therefore, in our homes to this day you can see sinks and bathtubs that were made more than 50 years ago and are still being successfully used today.
• Cast iron is very often used for artistic objects . Various works of art are made from it. Thus, the embankment of St. Petersburg is almost entirely decorated with cast iron items. Interesting and unusual fences, openwork branched gates and cast iron monuments are made from cast iron. All this became possible thanks to the good casting properties of this material. The items made practically do not wear out and look the same even after many years. It is not uncommon to find cast iron works of art within the walls of a museum.

It is especially pleasing that cast iron is well valued as a second-rate material. That is, if suddenly a cast iron item becomes unnecessary, you can turn it in for melting and get good money for it.

We will talk about the characteristics and areas of application of steels and cast irons (alloyed, antifriction, casting, etc.) below.

This video will tell you about the areas of application of cast iron:

This section will discuss the classification, marking (grades) and application of cast irons and their alloys.

How to cast cast iron at home - Metals, equipment, instructions

Welding many types of steel at home is nothing supernatural.

If you have special equipment, even a person who is not particularly knowledgeable in this matter can cope with this work.

But, if you want to weld cast iron at home, you should be prepared for the fact that some difficulties may arise. What are they?

articles:

The main failure that will most likely befall you is the poor quality of the welded joint.

The complexity of welding is primarily determined by the composition of the metal.

Cast iron contains a large amount of carbon , which negatively affects its processing and further operation.

For this reason, ordinary people often have the following questions:

1. How to cook cast iron flawlessly using electric welding?
2. What are the known methods of working with cast iron?
3. What consumables are needed for this?
4. Useful tips for safe work.

Special Moments

• The material has a tendency to crack. This is due to its heterogeneous composition and the hardening and bleaching procedures that occur near the seam while the hot metal cools.
• is highly “buoyant” in its molten form, and this significantly complicates the formation of a high-quality weld scar.
• As a result of heat treatment, part of the carbon burns out, which contributes to the formation of pores.
• During the welding process, infusible acids appear , whose melting point is much higher than that of iron.

Do you know how to install a shower stall for a small bathroom? Read this useful article for interesting solutions for placing plumbing equipment in small apartments.

How to make a plasterboard countertop in the bathroom with your own hands is written on this page.

Surfacing technique

It is possible to cook cast iron with electrodes at home, but it is advisable to have certain practical skills and follow the recommendations of specialists.

Welding the cast iron from which the siphon for a double sink in the kitchen is made can be carried out using two methods:

Regardless of the chosen technique, the following factors should be considered.

The metal surface cannot be cooled quickly . If this rule is not followed, the welding quality cannot be good.

When welding cast iron with steel, in order to extend the cooling time of the part, it is covered with coal dust or fine dry sand (read about adapters for sewer pipes here).

When cast iron quickly heats up/cools , cracks form on its surface, and this will create additional difficulties in the process of subsequent processing of the product.

When the metal is in a liquid state , it is characterized by high fluidity, so it is necessary to use preforming.

This is the basis for the process of deformation and stress during welding.

Difficulties in argon arc (TIG) welding are usually associated with the need to make it possible to make a reliable connection of the weld.

In particular, it is difficult to connect two different types of elements (how to weld a squeegee to a heating pipe is written here). Sometimes, in the process of restoration work, it is necessary to restore a part made of an alloy of steel, aluminum and cast iron.

When carrying out work, it is necessary to take into account the characteristics of all materials.

A special property of welding cast iron and aluminum is the difference in the melting temperature of both metals.

For cast iron these are significantly lower figures. Therefore, it is worth knowing that during work you cannot do without a graphite plate - it will prevent leakage of cast iron.

Note! There are such expensive materials that are used only for processing cast iron. Others are used when two or more metals are combined.

If you want welding or surfacing of cast iron parts to be performed flawlessly, you need to strictly adhere to the technological process.

Do you know how to make a calculation for a heating expansion tank? The formula and calculation method are described in a useful article.

installation of a corner acrylic bathtub, see here.

On the page: http://ru-canalizator.com/santehnika/aksessuary/polotentsesushitel-vodyanoj.html it is written about the best heated towel rails for the bathroom.

As mentioned above, the welding process can be carried out using a cold or hot method. In this case, both ready-made electrodes and home-made electrodes are used.

By the way, components made by yourself are used not only for work at home, but also in production.

Composition of the electrode for cast iron:

• marble,
• aluminum,
• termite,
• liquid glass,
• ferrosilicon,
• fine titanium powder.

As a good alternative to such electrodes, a piece of filler wire with a graphite rod can be used.

Types of electrodes

A cast iron rod with a special coating , which contains a huge amount of carbon.

They can be cooked using any type of current.

At the same time, the welding arc operates more stably.

Metal rods coated with a layer of graphite . The products are not expensive, but the quality of the weld made with this electrode is “lame on both legs.”

The metal is deposited too unevenly, and the resulting welded joint is not easy to process.

Using such electrodes, microcracks are welded when installing cast iron heating radiators.

Rods with copper base.

The weld joint consists of the following alloy: iron, carbon and copper.

Small seams (no more than 5 - 6 cm long) are obtained of high quality.

This technique requires mandatory forging of the scar after the next pass.

This method is not used in places to which there is no easy access.

Rod with nickel frame . This model allows you to achieve an excellent, strong seam that is easy to process.

The resulting scar also needs to be forged, but it is carried out without any complications. Such electrodes have one drawback - the price is too high.

It is for this reason that they are sold in the form of an alloy of copper, nickel and iron.

To weld cast iron at home (read how to fix a leak in a cast iron sewer pipe here), professionals recommend using the following brands of electrodes:

1. OZCH 2,
2. OZCH 6,
3. OZZHN 1,
4. OZCH 3,
5. OZCH 4,
6. MNC 2.

There is a completely reasonable explanation for why electrodes that contain large amounts of copper and nickel are used.

Nickel is inert in relation to carbon and enters into a chemical reaction with it. What priorities does this give?

As a result, the weld is soft and elastic, and lends itself well to further processing.

Copper is needed for welding heat-resistant cast iron . It forms a stronger seam.

Welding of cast iron is carried out using any type of non-consumable electrodes, namely:

• graphite,
• tungsten,
• coal.

They also include filler rods consisting of different non-ferrous metals.

The welding zone is protected by flux (which contains borax).

Some craftsmen prefer inert argon.

Recently, AC TIG welding has been considered very popular.

In this case, a tungsten electrode with an alternating current supply is used.

The protective medium is argon and additives containing nickel.

Both manual arc welding and electric welding can be accompanied by such difficulties as the occurrence of cracks. To avoid unpleasant consequences, the main thing is to correctly select the optimal operating mode.

Technological measures that can be used to prevent the occurrence of small crevices:

• preventing excessive heating of cast iron during welding . This can be achieved by using electrodes of small diameter, or by carrying out welding work with low current “fly-in”;
• reduction of stress that occurs during the shrinkage of seams or welded areas that are obtained as a result of hot forging.

You can make electrodes with your own hands at home , the composition of which is similar to those listed above.

Considering the fact that MNC 2 is a rather rare and scarce product, making it yourself will be quite justified.

List of work that you will need to do:

1. Remove the coating from a conventional electrode.The coating that you remove must be crushed and a similar amount of iron powder added to the contents.

   You can only use fine chips.

2. Pour a small amount of liquid glass into a disposable bowlThen pour the mixture into a container in small portions. The composition should have the texture of thick sour cream. Not even all professional welders can afford to weld with copper electrodes (this is an expensive pleasure).

   You can reduce the cost of repair work by making homemade coating.

3. We take copper wire , markings M2, M3.
   Using sandpaper, we clean it well, then degrease it and cut it to the length we need.
4. We wet the finished workpieces in the coating and as a result we get an electrode with a copper wire about 1.5 mm thick.
   In order for the characteristics of the products you make to be almost identical, they need to be processed for the same amount of time.
5. For complete drying and hardening of the product , it is hung in a vertical position.

Worth knowing! Do not use a brass piece as a pin.

Since it contains a large amount of zinc, and this product is very poisonous.

When the electrode is burned, the toxic substance will evaporate, and this, most likely, will be the cause of serious poisoning.

  Aging metal at home

If you do not have the intention or time to make electrodes yourself, then at home you can weld cast iron with combined electrodes (copper-steel).

They are made by winding a spiral of copper or brass wire. In this case, the diameter should be no more than 1.5 mm.

It is necessary that the mass of the spiral be 5 times the weight of the iron core.

When using combined electrodes, the elements being welded cannot be overheated.

And also, it is imperative to take a break from work in order to allow the product being processed to cool.

When performing welding work, safety precautions must be observed.

1. At home, welding cast iron can only be done in a well-ventilated and lit area.
2. The equipment must be grounded according to all rules.
3. The metal does not need to be cooled quickly.
   Its surface must be protected from moisture penetration.
4. Availability of personal protective equipment, namely: overalls, glasses, gloves.

When working with cast iron using the electric welding method, you need to adhere to the basic requirements that apply to all manipulations associated with this complex production.

The master must follow safety rules when operating electric welding equipment.

Important information! This process is considered quite labor-intensive, so when welding cast iron parts it is better to use cold welding technology.

How to weld cast iron parts at home using a simple electrode and copper wire, watch the video below.

Source: https://spb-metalloobrabotka.com/kak-lit-chugun-v-domashnih-usloviyah/

Where is cast iron used?

Cast iron has been used for centuries, and now you can hardly find a person who has never heard of this alloy. Products made from it are used everywhere, as they are durable and relatively inexpensive.

Cast iron is an iron alloy that has a low carbon content. By adding special additives it is possible to significantly improve the quality of this material.

Advantages of cast iron

The key advantages of cast iron are immediately visible if you analyze the areas where this alloy is used and study the quality characteristics of the material. Among the main advantages are the following:

1. Wide range of applications.
2. Reasonable cost and relative simplicity of the production process.
3. Remarkable casting characteristics.
4. High strength.
5. Cast iron is easy to forge.
6. Features a long service life.

Areas of application

Cast iron has always been in demand in heavy industry, metallurgical and mechanical engineering industries, and machine tool building. Here it is used in large volumes, both very small parts and large-sized products weighing hundreds of tons are made from it.

Components for machine tools, shafts, and engines are made from cast iron. Pipes made from this alloy are in great demand, as they meet all the necessary requirements for durability and reliability.

The use of cast iron in everyday life has made this metal alloy popular among the population. In particular, taps, valves, fittings, heating radiators, and pipes are made from it. Many plumbing products are also made either entirely or partially from cast iron. Perhaps you have ever seen heavy but durable sinks and bathtubs made half a century ago. They can still be safely used; it is cast iron that ensures their durability.

What other advantages does this metal alloy have? Any blacksmith will tell you that forging cast iron is as easy as shelling pears. It is not without reason that various fences, bas-reliefs, and all kinds of beautiful decorative elements are often made from it. And in museums you can even see works of art forged from cast iron.

As for casting, this technology allows you to create many good, beautiful things. Cast iron products are practically not subject to wear and tear and will look great even after years. And if they suddenly turn out to be unnecessary, then they can be disposed of - sell scrap metal at a favorable price and make good money on it. As a recyclable material, cast iron is always valued.

Now a few words about the shortcomings. Cast iron has its flaws, the main one being fragility. Unfortunately, it can be split or deformed with a strong impact; however, this property of the material also largely depends on the processing technology of the alloy.

Source: https://planetaloma.ru/o-kompanii/stati/primenenie-chuguna

Iron casting

Cast iron is an alloy of iron with carbon and other elements. It is an inexpensive, durable, wear-resistant, but fragile structural material, widely used in industry and construction.

Cast iron

Iron casting technology

The technology of cast iron casting was first mastered in China around the 10th century AD; in Europe it was first mentioned in the 14th century as a material for the production of cannons. In Russia, the first “iron casting suitable for making cannons” dates back to the era of Ivan IV Rurikovich.

The heyday of the cast iron era came in the 19th and 20th centuries. At this time, bridges and pipelines, lanterns and fences, elements of architectural decor and load-bearing structures of buildings were made from it. In addition, rails, parts of machine tools, and engines were cast from the same material.

Separately, it is worth mentioning cast iron cookware, irons and heating appliances.

Cast iron was also the starting component for the production of steel using the open-hearth method. The volume of its production was the most important indicator of the country's economic power and its military potential. With the invention of inexpensive technologies for the production and processing of aluminum and steel alloys, the importance of cast iron as a structural material has noticeably decreased. The widespread development of the production of high-strength plastics and composite materials has finally pushed cast iron from the forefront.

Iron casting process

Cast iron is produced in blast furnaces - huge structures as high as a ten-story building. After the ore is melted and impurities are removed, the cast iron is cast into steel molds - molds. The resulting ingots (pigs) contain cast iron of a certain grade and are ready for further processing. At foundries, various finished products are cast from them.

Iron casting process

The main stages of the iron casting process:

1. Preparing a finished product model
2. Making a mold for casting
3. Melting cast iron pigs
4. Melt casting into molds
5. Removing castings and finishing them

There are several methods for making models and preparing molds

Basic methods of iron casting

Modern industry uses many different methods to produce iron castings. They come down to several basic casting methods:

• into molds made from a clay-sand mixture (the so-called “in-ground” casting)

A model of the finished product is placed inside the mold, completely repeating its shape, but exceeding it in size by the amount of casting shrinkage. The clay-sand mixture is compacted and compacted, ensuring complete adherence to the model. Casting of cast iron into a mold is carried out through specially provided holes - sprues.

• into plaster molds (and from other hardening solutions);
• into shell forms;
• in chill molds (metal protected forms);
• by lost wax models;
• under pressure.
• In a gasified model

Experts distinguish several types of cast iron, depending on the content of certain impurities.

Types of cast iron

Gray cast iron contains from 2.9% to 3.7% graphite and silicon, has excellent casting properties:

• low melting point
• high melt fluidity
• small shrinkage.

It is a suitable material for machine bodies and mechanisms, pistons and engine cylinder blocks. High fragility precludes the use of the material in parts subject to bending and tension. Casting of gray cast iron is mainly carried out in sand molds and in chill molds.

High-strength cast iron, ductile iron, contains graphite in spherical form. This type of graphite is characterized by high viscosity and malleability, suitable for forging. Pipes, pipeline fittings, critical and highly loaded mechanical parts are cast from it.

Ductile iron

Products made from high-strength cast iron are also produced by casting into a gasified model. Cast iron is cast into a mold made from a sand mixture compacted around polystyrene model blocks.

To improve the mechanical properties, high-strength cast iron castings are subjected to heat treatment. Its main stages:

• heating up to 850 °C;
• exposure in a heated state for several hours;
• slow cooling in mineral oil at 350 °C.

Heat treatment increases the homogeneity of the material and relieves internal stresses in the casting, reducing the likelihood of cracks during operation

Iron production

From a number of the main indicators of the country's economic power, the production of cast iron was relegated to a number of secondary ones, but did not lose its importance for the economy.

The leader in pig iron production with an almost tenfold lead is China - 543.748 million tons per year, followed by Japan - 66.943 million tons, Russia - 43.945 million tons and India - 29.646 million tons. China produces more than 50% of the world's pig iron.

Cast iron is produced in blast furnaces, the prepared iron ore is smelted along with additives, and coking coal or natural gas is used as fuel.

The main consumption of pig iron today is as a component for steel smelting. The development of cast iron production is mainly in the direction of increasing its energy efficiency, environmental friendliness and cost reduction.

Iron production

The unique properties of cast iron - low cost, strength and corrosion resistance - allow the ferrous metal to look confidently into the future.

Cast iron castings

Cast iron castings come in different sizes - from small parts to multi-meter beds of large machine tools. Their configuration can also be very diverse - from simple bushings to sophisticated cast grilles and gates.

Cast iron castings

Iron castings are also divided into:

1. by purpose - general and special, such as anti-friction, heat-resistant, etc.
2. according to the structure of the material - ferritic, perritic and mixed
3. According to the type of graphite contained - into spherical, lamellar, flake and vermicular
4. According to carbon content - white, gray and bleached

In metallurgical science, there are other classifications of cast iron castings.

Casting methods

The most modern method is casting using gasified models. This method allows not only casting iron, but also producing steel castings. The method is economical, environmentally friendly and allows for the reuse of mold material.

The method consists of the following steps.

Model preparation

The models are made from pre-foamed and dried polystyrene with a grain size of 0.3-0.9 mm. (depending on the dimensions of the part). The material is blown into molds, baked and cooled.

Casting using gasified models

Models are glued or soldered into blocks. Next, the blocks are lowered into the bath to apply a non-stick coating and dried. If the product configuration is complex, then the coating is applied from a nozzle.

Molding

Model blocks are placed in a flask placed on a vibrating base, gradually filling them with a sand-clay mixture, their “earth”. Sometimes backfilling is done layer by layer, compacting each separately.

The filled and compacted molds are transported to the pouring shop. The vacuum pump completes the compaction of the sand and gives it sufficient strength.

Pouring metal

The metal is poured directly into the model material. The liquid melt evaporates the polystyrene models and fills all the relief details.

Cast iron forming

Polystyrene combustion products are removed by a vacuum pump directly through the walls of the mold.

Final operations

Iron castings cool in the mold. The rate of temperature decrease and its overall duration are determined by the weight of the part, the thickness of its walls and the requirements of the production process. Next, the molds are broken, the castings are cleaned of remnants of non-stick paint, and the sprues are removed.

Advantages of cast iron

Iron casting differs from castings from other materials in a number of advantages, such as:

• cheapness
• high strength and wear resistance
• high surface quality, minimizing subsequent machining

Characteristics and application of cast iron

It is important to note that when using modern casting methods, not only the casting itself is cheaper, but also the final product. Many industries, which at the end of the 20th century replaced the cast iron parts of their products with steel ones, have returned or are planning to return to the time-tested material at a new stage of its development.

Source: https://stankiexpert.ru/spravochnik/litejjnoe-proizvodstvo/chugunnoe-lite.html

Features of cast iron

An iron alloy containing more than 3% carbon is called cast iron. The metal has high fluidity and hardness, due to which it fills a mold with a configuration of any complexity. Cast iron can be exposed to the open air for a long time without being subject to corrosion or destruction.

The technology of cast iron production was mastered back in the 17th century. It was used to make bridge railings, sculptures, fireplace grates and stove grates. Simple forming and smelting technology allows cast iron to be cast on an industrial scale and at home.

Cast iron casting on an industrial scale

General properties of cast iron

Cast iron is produced in blast furnaces. The heating temperature from burning gas and coal dust increases. As a result, 2 types of high-carbon alloys are obtained:

Particle alloy, mostly white, very hard. It contains carbon in a bound form; the grain is white at the fracture. Very hard, cannot be processed with cutting tools. It is used as the main raw material for the production of steels of various grades.

Other types of cast iron: gray, malleable, high-strength. They have high fluidity and are used for the manufacture of parts by casting into molds followed by cutting. The hardness is significantly higher than that of non-hardened steels. High abrasion resistance. Disadvantages include fragility, low resistance to bending and torsion.

Cast iron is called malleable for its relatively high ductility and resistance to dynamic loads. It is stronger than gray due to the compact flake-like inclusions of graphite located between the grains. In a high-strength alloy, graphite has a spherical shape. Other types of cast iron contain free carbon in the form of graphite plates along the grain boundaries and break relatively easily. In fact, no type of cast iron can be forged.

When processing cast iron by cutting at low feed and speed, a surface with high cleanliness is obtained. Dimensions accurate to 0.02 mm.

Final operations

After pouring, the molds remain in the pit to cool evenly for 12–60 hours. The duration of the process depends on the largest cross-section of the casting.

The cooled mold is taken out, the part is freed from the molding sand and, together with the accumulators and profits, is placed in a thermal furnace for annealing. The metal is heated to 800⁰–900⁰, depending on the mass of the casting and the grade of cast iron. Then it is kept at a given temperature for several hours. The cast iron, together with the stove, slowly cools down to 300⁰. Then the casting is removed and cooling continues in air.

After annealing, the structure of cast iron is leveled and stress is relieved.
Now the technological extensions and other elements are cut off. The surface is cleaned from molding sand residues and scale. Casting using gasified models (LGM) ChugunSpetsStroy LLC

Home casting methods

Casting cast iron at home is possible.
In the mid-20th century in China, almost every garden had small stoves and everyone produced cast iron parts. Cast iron casting. DIY melting furnace from A to Z “Cupola furnace”. A bathtub or other container with a hole at the bottom must be lined with refractory bricks, filled with cast iron scrap, and coke and deoxidizer added. You can heat it with a gas burner. It is important to remember - the smaller the volume, the worse the quality of the metal.

Cast iron casting. Heavy metallurgists in Siberia. DIY melting furnace from A to Z “Cupola furnace”.

Source: https://metalloy.ru/obrabotka/lityo/chugunnoe

What is cast iron? Properties, composition, preparation and use:

Many people know about such a material as cast iron and its strength characteristics. Today we will deepen this knowledge and find out what cast iron is, what it consists of, what types it comes in and how it is produced.

Compound

What is cast iron? It is an alloy of iron, carbon and various impurities, thanks to which it acquires the necessary properties. The material must contain at least 2.14% carbon. Otherwise, it will be steel, not cast iron. It is thanks to carbon that cast iron has increased hardness. At the same time, this element reduces the ductility and malleability of the material, making it brittle.

In addition to carbon, cast iron necessarily includes: manganese, silicon, phosphorus and sulfur. Some brands also contain additional additives to give the material specific properties. Commonly used alloying elements include chromium, vanadium, nickel and aluminum.

Properties of cast iron

The material has a density of 7.2 g/cm3. For metals and their alloys this is a fairly high figure. Cast iron is well suited for the production of all kinds of products by casting. In this regard, it is superior to all iron alloys except some grades of steel.

The melting point of cast iron is 1200 degrees. For steel, this figure is 250-300 degrees higher. The reason for this lies in the increased carbon content in cast iron, which causes less close bonds between iron atoms.

During the smelting of cast iron and its subsequent crystallization, carbon does not have time to fully penetrate into the structure of the iron. Therefore, the material turns out to be brittle. The structure of cast iron does not allow it to be used for the production of products that are constantly subject to dynamic loads.

But what cast iron is ideal for is for parts that must have increased strength.

Receipt

Producing cast iron is a very costly and material-intensive process. To obtain one ton of alloy, 550 kg of coke and 900 liters of water are needed. As for ore, its quantity depends on the iron content in it. As a rule, ore with a mass fraction of iron of at least 70% is used. Processing less rich ores is not economically feasible.

Before being melted down, the material is enriched. Pig iron production in 98% of cases occurs in blast furnaces.

The technological process includes several stages. First, ore is loaded into the blast furnace, which includes magnetic iron ore (a compound of di- and trivalent iron oxide). Ores that contain hydrous oxide of iron or its salts can also be used. In addition to raw materials, coking coals are placed in the furnace, which are necessary to create and maintain high temperatures. Coal combustion products, as iron reducers, also participate in chemical reactions.

Additionally, flux is supplied to the furnace, which plays the role of a catalyst. It accelerates the process of melting rocks and releasing iron. It is important to note that before entering the furnace, the ore must undergo special processing.

Since small parts melt better, it is pre-crushed in a crushing plant. The ore is then washed to remove non-metal impurities. Then the raw materials are dried and fired in ovens.

Thanks to firing, sulfur and other foreign elements are removed from it.

After the furnace is fully loaded, the second stage of production begins. When the burners are started, the coke gradually heats the raw material. This releases carbon, which reacts with oxygen to form an oxide. The latter takes an active part in the reduction of iron from compounds in the ore. The more gas accumulates in the furnace, the slower the reaction proceeds.

When the required proportion is reached, the reaction stops altogether. The excess gases subsequently serve as fuel to maintain the required temperature in the furnace. This method has several strengths. Firstly, it allows you to reduce fuel costs, which reduces the cost of the production process.

And, secondly, combustion products do not enter the atmosphere, polluting it, but continue to participate in production.

Excess carbon is mixed with the melt and absorbed by iron. This is how cast iron is made. Impurities that have not melted float to the surface of the mixture and are removed. They are called slag. Slag is used in the production of certain materials. When all excess particles are removed from the melt, special additives are added to it.

Varieties

We have already found out what cast iron is and how it is obtained, now we will understand the classification of this material. Pipe and foundry cast iron is produced using the method described above.

Pig iron is used in steel production via the oxygen converter route. This type is characterized by a low content of silicon and manganese in the alloy. Foundry cast iron is used in the production of all kinds of products. It is divided into five types, each of which will be considered separately.

White

This alloy is characterized by the content of excess carbon in the form of carbide or cementite. The name of this species was given for the white color at the fracture site. carbon in such cast iron usually exceeds 3%. White cast iron is highly brittle and brittle, so its use is limited. This type is used for the production of parts of a simple configuration that perform static functions and do not bear heavy loads.

By adding alloying additives to white cast iron, it is possible to increase the technical parameters of the material. For this purpose, chromium or nickel is most often used, less often vanadium or aluminum. A brand with this kind of additives is called “sormite”.

It is used in various devices as a heating element. “Sormite” has a high resistivity and works well at temperatures no higher than 900 degrees. The most common use of white cast iron is in the production of household bathtubs.

Grey

This is the most common type of cast iron. It has found application in various areas of the national economy. In gray cast iron, carbon is present in the form of pearlite, graphite or ferrite-perlite.

In such an alloy the carbon content is about 2.5%. Like cast iron, this material has high strength, so it is used in the production of parts that receive cyclic loads.

Gray cast iron is used to make bushings, brackets, gears and housings for industrial equipment.

Thanks to graphite, gray cast iron reduces friction and improves the effect of lubricants. Therefore, parts made of gray cast iron are highly resistant to this type of wear. When operating in particularly aggressive environments, additional additives are introduced into the material to neutralize the negative impact.

These include: molybdenum, nickel, chromium, boron, copper and antimony. These elements protect gray cast iron from corrosion. In addition, some of them increase the graphitization of free carbon in the alloy.

Thanks to this, a protective barrier is created that prevents destructive elements from reaching the surface of the cast iron.

Half-hearted

An intermediate material between the first two varieties is half-cast iron. The carbon it contains is presented in the form of graphite and carbide in approximately equal proportions. In addition, such an alloy may contain small amounts of lideburite (no more than 3%) and cementite (no more than 1%).

The total carbon content of half cast iron ranges from 3.5 to 4.2%. This variety is used for the production of parts that are operated under conditions of constant friction. These include automobile brake pads, as well as rolls for grinding machines.

To further increase wear resistance, all sorts of additives are added to the alloy.

Malleable

This alloy is a type of white cast iron, which is subjected to special firing in order to graphitize free carbon. Compared to steel, such cast iron has improved damping properties. In addition, it is not as sensitive to cuts and performs well in low temperature conditions.

In such cast iron, the mass fraction of carbon is no more than 3.5%. In the alloy it is presented in the form of ferrite, granular pearlite containing inclusions of graphite or ferrite-pearlite. Malleable cast iron, like half-cast iron, is used mainly in the production of parts operating under conditions of continuous friction.

To improve the performance characteristics of the material, magnesium, tellurium and boron are added to the alloy.

High strength

This type of cast iron is obtained due to the formation of spherical graphite inclusions in the metal lattice. Because of this, the metal base of the crystal lattice weakens, and the alloy acquires improved mechanical properties.

The formation of spherical graphite occurs due to the introduction of magnesium, yttrium, calcium and cerium into the material. High-strength cast iron is close in its parameters to high-carbon steel. It lends itself well to casting and can completely replace steel parts of mechanisms.

Due to its high thermal conductivity, this material can be used for the manufacture of pipelines and heating devices.

Industry challenges

Today, cast iron casting has dubious prospects. The fact is that due to high costs and large amounts of waste, industrialists are increasingly abandoning cast iron in favor of cheap substitutes. Thanks to the rapid development of science, it has long been possible to obtain higher quality materials at lower costs. Environmental protection plays a major role in this issue and does not accept the use of blast furnaces.

It will take years, if not decades, to completely convert iron smelting to electric furnaces. Why so long? Because it is very expensive, and not every state can afford it. Therefore, all that remains is to wait until mass production of new alloys is established. Of course, it will not be possible to completely stop the industrial use of cast iron in the near future. But it is obvious that the scale of its production will fall every year.

This trend began 5-7 years ago.

Conclusion

Having dealt with the question: “What is cast iron?”, we can draw several conclusions. First, cast iron is an alloy of iron, carbon and additives. Secondly, it has six types. Thirdly, cast iron is a very useful and versatile material, so for a long time its expensive production was feasible. Fourthly, today cast iron is already considered a relic of the past, and is systematically losing its position to more reliable and cheaper materials.

Source: https://www.syl.ru/article/304510/chto-takoe-chugun-svoystva-sostav-poluchenie-i-primenenie