Nodular cast iron
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Ductile iron, also known as ductile cast iron, nodular cast iron, spheroidal graphite iron, spheroidal graphite cast iron and SG iron, is a type of
graphite Graphite () is a crystalline form of the element carbon. It consists of stacked layers of graphene. Graphite occurs naturally and is the most stable form of carbon under standard conditions. Synthetic and natural graphite are consumed on lar ...
-rich
cast iron Cast iron is a class of iron– carbon alloys with a carbon content more than 2%. Its usefulness derives from its relatively low melting temperature. The alloy constituents affect its color when fractured: white cast iron has carbide impur ...
discovered in 1943 by Keith Millis. While most varieties of cast iron are weak in tension and
brittle A material is brittle if, when subjected to stress, it fractures with little elastic deformation and without significant plastic deformation. Brittle materials absorb relatively little energy prior to fracture, even those of high strength. Br ...
, ductile iron has much more impact and fatigue resistance, due to its ''nodular graphite'' inclusions. On October 25, 1949, Keith Dwight Millis, Albert Paul Gagnebin and Norman Boden Pilling received US patent 2,485,760 on a cast ferrous alloy for ductile iron production via magnesium treatment. Augustus F. Meehan was awarded a patent in January 1931 for inoculating iron with calcium silicide to produce ductile iron subsequently licensed as Meehanite, still produced .


Metallurgy

Ductile iron is not a single material but part of a group of materials which can be produced with a wide range of properties through control of their microstructure. The common defining characteristic of this group of materials is the shape of the graphite. In ductile irons, graphite is in the form of ''nodules'' rather than flakes as in
grey iron Grey (more common in British English) or gray (more common in American English) is an intermediate color between black and white. It is a neutral or achromatic color, meaning literally that it is "without color", because it can be composed ...
. Whereas sharp graphite flakes create stress concentration points within the metal matrix, rounded nodules inhibit the creation of cracks, thus providing the enhanced ductility that gives the alloy its name. Nodule formation is achieved by adding ''nodulizing elements'', most commonly
magnesium Magnesium is a chemical element with the symbol Mg and atomic number 12. It is a shiny gray metal having a low density, low melting point and high chemical reactivity. Like the other alkaline earth metals (group 2 of the periodic ta ...
(magnesium boils at 1100 °C and iron melts at 1500 °C) and, less often now,
cerium Cerium is a chemical element with the symbol Ce and atomic number 58. Cerium is a soft, ductile, and silvery-white metal that tarnishes when exposed to air. Cerium is the second element in the lanthanide series, and while it often shows the +3 ...
(usually in the form of
mischmetal Mischmetal (from german: Mischmetall – "mixed metal") is an alloy of rare-earth elements. It is also called cerium mischmetal, or rare-earth mischmetal. A typical composition includes approximately 55% cerium, 25% lanthanum, and 15 ...
).
Tellurium Tellurium is a chemical element with the symbol Te and atomic number 52. It is a brittle, mildly toxic, rare, silver-white metalloid. Tellurium is chemically related to selenium and sulfur, all three of which are chalcogens. It is occasionall ...
has also been used.
Yttrium Yttrium is a chemical element with the symbol Y and atomic number 39. It is a silvery-metallic transition metal chemically similar to the lanthanides and has often been classified as a " rare-earth element". Yttrium is almost always found in co ...
, often a component of
mischmetal Mischmetal (from german: Mischmetall – "mixed metal") is an alloy of rare-earth elements. It is also called cerium mischmetal, or rare-earth mischmetal. A typical composition includes approximately 55% cerium, 25% lanthanum, and 15 ...
, has also been studied as a ''possible nodulizer''. '' Austempered ductile iron'' (ADI; i.e.,
austenite Austenite, also known as gamma-phase iron (γ-Fe), is a metallic, non-magnetic allotrope of iron or a solid solution of iron with an alloying element. In plain-carbon steel, austenite exists above the critical eutectoid temperature of 1000 K ...
tempered) was discovered in the 1950s but was commercialized and achieved success only some years later. In ADI, the metallurgical structure is manipulated through a sophisticated heat treating process.


Composition

Other ductile iron compositions often have a small amount of sulfur as well. *
Carbon Carbon () is a chemical element with the symbol C and atomic number 6. It is nonmetallic and tetravalent—its atom making four electrons available to form covalent chemical bonds. It belongs to group 14 of the periodic table. Carbon mak ...
, 3.3–3.60% *
Silicon Silicon is a chemical element with the symbol Si and atomic number 14. It is a hard, brittle crystalline solid with a blue-grey metallic luster, and is a tetravalent metalloid and semiconductor. It is a member of group 14 in the periodic ta ...
, 2.2–2.8% *
Manganese Manganese is a chemical element with the symbol Mn and atomic number 25. It is a hard, brittle, silvery metal, often found in minerals in combination with iron. Manganese is a transition metal with a multifaceted array of industrial alloy use ...
, 0.1–0.2% *
Magnesium Magnesium is a chemical element with the symbol Mg and atomic number 12. It is a shiny gray metal having a low density, low melting point and high chemical reactivity. Like the other alkaline earth metals (group 2 of the periodic ta ...
, 0.03–0.04% *
Phosphorus Phosphorus is a chemical element with the symbol P and atomic number 15. Elemental phosphorus exists in two major forms, white phosphorus and red phosphorus, but because it is highly reactive, phosphorus is never found as a free element on Ear ...
, 0.005–0.04% * Sulfur, 0.005–0.02% *
Copper Copper is a chemical element with the symbol Cu (from la, cuprum) and atomic number 29. It is a soft, malleable, and ductile metal with very high thermal and electrical conductivity. A freshly exposed surface of pure copper has a pinkis ...
, <0.40% *
Iron Iron () is a chemical element with Symbol (chemistry), symbol Fe (from la, Wikt:ferrum, ferrum) and atomic number 26. It is a metal that belongs to the first transition series and group 8 element, group 8 of the periodic table. It is, Abundanc ...
, balance Elements such as copper or
tin Tin is a chemical element with the symbol Sn (from la, stannum) and atomic number 50. Tin is a silvery-coloured metal. Tin is soft enough to be cut with little force and a bar of tin can be bent by hand with little effort. When bent, t ...
may be added to increase tensile and yield strength while simultaneously reducing ductility. Improved corrosion resistance can be achieved by replacing 15–30% of the
iron Iron () is a chemical element with Symbol (chemistry), symbol Fe (from la, Wikt:ferrum, ferrum) and atomic number 26. It is a metal that belongs to the first transition series and group 8 element, group 8 of the periodic table. It is, Abundanc ...
in the alloy with varying amounts of
nickel Nickel is a chemical element with symbol Ni and atomic number 28. It is a silvery-white lustrous metal with a slight golden tinge. Nickel is a hard and ductile transition metal. Pure nickel is chemically reactive but large pieces are slow ...
, copper, or chromium. Silicon as a graphite formation element can be partially replaced by aluminum to provide better oxidation protection.Aluminum ADI
/ref>


Applications

Much of the annual production of ductile iron is in the form of
ductile iron pipe Ductile iron pipe is pipe made of ductile cast iron commonly used for potable water transmission and distribution.Moser, A. P. and Folkman, Steven L. (2008) ''Buried Pipe Design'' (3rd edition) McGraw-Hill, New Yorkp. 336-337 This type of pipe ...
, used for water and sewer lines. It competes with
polymer A polymer (; Greek '' poly-'', "many" + ''-mer'', "part") is a substance or material consisting of very large molecules called macromolecules, composed of many repeating subunits. Due to their broad spectrum of properties, both synthetic a ...
ic materials such as PVC,
HDPE High-density polyethylene (HDPE) or polyethylene high-density (PEHD) is a thermoplastic polymer produced from the monomer ethylene. It is sometimes called "alkathene" or "polythene" when used for HDPE pipes. With a high strength-to-density ratio, ...
,
LDPE Low-density polyethylene (LDPE) is a thermoplastic made from the monomer ethylene. It was the first grade of polyethylene, produced in 1933 by Imperial Chemical Industries (ICI) using a high pressure process via free radical polymerization. Its ...
and
polypropylene Polypropylene (PP), also known as polypropene, is a thermoplastic polymer used in a wide variety of applications. It is produced via chain-growth polymerization from the monomer propylene. Polypropylene belongs to the group of polyolefins a ...
, which are all much lighter than steel or ductile iron; being softer and weaker, these require protection from physical damage. Ductile iron is specifically useful in many automotive components, where strength must surpass that of aluminum but steel is not necessarily required. Other major industrial applications include off-highway diesel trucks,
class 8 trucks Class or The Class may refer to: Common uses not otherwise categorized * Class (biology), a taxonomic rank * Class (knowledge representation), a collection of individuals or objects * Class (philosophy), an analytical concept used differently ...
, agricultural tractors, and oil well pumps. In the wind power industry ductile iron is used for hubs and structural parts like machine frames. Ductile iron is suitable for large and complex shapes and high (fatigue) loads. Ductile iron is used in many grand piano harps (the iron plates to which high-tension piano strings are attached). Ductile iron is used for vices. Previously, steel was commonly used.


See also

* Malleable iron


References


Bibliography

* *


External links

{{Commons category
Ductile Iron Society

Ductile Iron Pipe Research Association
Cast iron Ferrous alloys