is-210_grey iron casting

1s210:1993

Indian Standard

GREY IRON CASTINGS - SPECIFICATION

( Fourth Revision)

Second Reprint MARCH 1998

UDC 669.131.6-14

Q BIS 1993

BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG

i NEW DELHI 110002

December 1993 PriceGroop5 .

Pig Iron and Cast Iron Sectional Committee, MTD 6

FOREWORD

( Fourth Revision ) was adopted by the Bureau of Indian Standards, after the draft Iron and Cast Iron Sectional Committee had been approved by the Metallurgical

Rngincering DivirionCouncil.

This Indian Standard finalized by the Pig

This standard was first published in 1950 and subsequently revised in 1962, 1970 and 1978. While reviewing this standard in the light of the experience gained during these years, the committee decided to reviseit to align with the present practices followed by the Indian industries and to bring it in line with the other overseas standards.

The various diameters of test bar according to the section size of the castings have been replaced by a single size of test bar. Guidance on the effect of section size of the casting on the tensile strength is, however, given in Annex A. A comparison between grades is given in Annex B.

The production of castings in the higher gr@es of grey cast iron often involve3 special techniques. It is recommended, therefore, that for either large or intricate castings or ;1 casting involving both these conditions or where the castings have to withstand exception conditions, the grade of grey cast iron selected and any heat treatment involved should be agreed between the manufacturer and the purchaser. The hipher grades of grey cast iron ( that is, Grade FG300, FG350 and FG400 ) present special difficulties for section 10 mm ,and thinner.

For the benefit of the purchaser, typical properties of grey cast iron have been added in Annex C.

Information to be supplied by the purchaser while ordering grey iron castings according to this specification is given in Annex D.

In the formulation of thir standard assistance has been derived from IS0 185 ‘Grey Cast Iron - Specifi- cation’ issued by International Organization for Standardization.

For the purpose of deciding whether a particular requirement of this otindard is complied with, the final value, observed or calculated, expressing the result of a teat or analysis, shall be rounded of? in accordance with IS 2 : 1960 ‘Rules for rouading off numerical values ( rrvisod ) ‘. The number of significant places retained in the rounded off value should be the same as that of the apccified value in this standard.

IS 210:1993

Indian Standard

GREY IRON CASTINGS - SPECIFICATION

(Fourth Revision) 1 SCOPE

This standard covers the requirements for grey iron castings.

2 REFERENCES

The following Indian Standards are necessary adjuncts to this standard:

IS so. 1387 : 1993

1500 : 1983

2078 : 1979

4843 : 1968

5139 : 1969

5519 : 1979

13655: 1993

Title

General requirements for the supply of metallurrgical material ( second revision )

Method for Brine11 hardness test- for metallic materials ( second revision )

Method for tensile testing of grey cast iron ( jrst revision )

Code for designation of ferrous castings

Recommended procedure for repair of grey iron castings by oxyacetylene and manual metal arc welding

Deviations tor untoleranced dimensions of grey iron castings ( jirst revzsion )

Guidelines for heat treatment of cast iron

3 SUPPLY OF MATERIAL

General requirements relating to the supply of grey iron castings shall be as laid down in IS 1387 : 1993.

4 GRADES

There shall be seven grades of grey iron castings namely, Grades FG150, FG200, FG220, FG260, FG300, FG350 and FG 400.

5 MANUFACTURE

The castings shall be made by any process, as agreed between the supplier and purchaser, that will produce castings complying with the requirements of this Indian Standard and shall be in accordance with the pattern or working drawing as supplied by the purchaser.

6 CHEMICAL COMPOSITION

6.1 The composition of cast iron shall be left to the discretion of the manufacturer, but a m&xi- mum limit for phosphorus and/or sulphur may be specified by the purchaser, if he so desires.

6.2 In case of special castings, the detailed chemical composition shall be as agreed to Ere- tween the purchaser and the manufacturer.

7 WORKMANSHIP AND FINISH

7.1 The castings shall be accurately moulded in accordance with the pattern or working drawings supplled by the purchaser, with the addition of such letters, figures or marks as may be specrfied.

7.2 The purchaser shall specify tolerances, machining location and allowances with reference to all important dimensions On other dimensions tolerances specified in IS 5519 : 1979 shall apply.

8 HEAT TREATMENT

Castings are generally supplied without having any heat treatment, However, if required by the purchaser, the heat treatment may be carried out in accordance with 2 of IS 13655 : 1993.

9 MICROSTRUCTURE

Where so required, the microstructure of grey iron castings and the location for taking the sample shall be as agreed to between the purchaser and the manufacturer.

IO FREEDOM FROM DEFECTS

10.1 The castings shall be sound, clean and free from porosity, blow holes, hard spots, cracks, hot tears, coldshuts, distortion, sand and slag inclu- sions and other harmful defects. They shall be well-dressed and fettled, and shall be readily machinable.

IO.2 No welding or repairs shall be carried out without the prior permission of the purchaser. Welding referred to here includes fusion welding in accordance with the common foundry practice. The method of repair by welding ( see IS 5139 : 1969 ) and subsequent stress-relieving shall be as agreed to between the purchaser and the manufacturer.

16 210 I 1993

11 PROVISION OF TEST BARS ‘13 SIZE OF TEST BARS

11.1 All test bars shall be cast separately in sand moulds and the number of test bars required shall be as specified in 11. They shall be cast at the same time and frc,m the same melt as the castings they represent.

A test bar from which the tensile test piece is machined shall be cast as a uniform cylindrical bar of 30 mm diameter. The tolerance on the diameter shall be + a mm. The minimum length

of the test bar shall be 230 mm.

11.2 The test bar material shall be identifiable with that of the castings represented.

14 TENSILE TEST

11.3 When castings are subjected to heat treatment, the test bars shall be heat-treated together with the castings they represent.

11.4 The test bars shall be cast in dried, baked or chemically bonded moulds made mainly of an aggregate of siliceous sand with appropriate binders. The average grain size of the sand shall be approximate to that of the sand in which the castings are poured. Moulds for the test bars shall be approximately at room temperature when poured. More than one test bar may be cast in a single mould, but each bar in the mould shall be surrounded by a thickness of sand which is not less than the diameter of the bar.

The tensile test shall be carried out in accordance with IS 2078 : 1979, using a test piece conforming to the dimensions in Fig. 1 and Table 2. The test piece shall be accurately machined, with a good surface finish. The transition between the ends and the parallel length shall be smooth, without undercutting or a sudden step down in diameter.

NOTE - Self-aligning grips are recommended to ensure axial loading.

15 TENSILE STRENGTH

12 FREQUENCY OF TESTING

12.1 The number of tests required for each melt or batch of castings shall be as laid down in Table 1, various classes of castings being divided into five representative groups according to mass.

When tested in accordance with the requirement of 13, the test piece shall comply with the minimum requirements specified in Table 3. The tensile strength specified is that obtained from test bars cast separately from the castings to which they refer. The test values. represent, therefore, only the quality of the metal from which the casting have been poured.

16 HARDNESS TEST

12.2 In the case of large tonnage of castings being produced continuously, the minimum number of test bars to be provided shall be one tensile test representing every two hours production from a melting furnace.

16.1 The Brine11 hardness test shall be carried out in accordance with the method given in IS 1500 : 1983. Brine11 hardness values for different grades or grey iron castings shall be as specified in Table 3.

Table 1 Number of Tests

( CluuSG 12.1 )

16.1.1 The hardness test shall be conducted at specific point on the castings. These specific points shall be such that they are amenable for hardness checking in routine procedure.

Test Reqriremeats

I’) Up to 12’5 kg One test for each 500 kg of castings or part thereof

16.1.2 The location of the specific point on a casting for hardness measurement shall be as agreed to between the purchaser and the manufacturer.

21) Over 12’5 kg and One test for every 1 tonne up to 50 kg of castings or part thereof

3i) Over 50 kg and up to One test for every 2 tonnes 500 kg of castings or part thereof

4i) Over 500 kg and up One test for every 3 tonnes to 1 tonne of castings or part thereof

5 Over 1 tonne One test for every 4 tonnes of rastiogs or part thereof or one test for every casting weighing 4 tonnes or more

17 TRANSVERSE TEST

If required, the transverse test may be carried out by the manufacturer in accordance with the method given in Annex E. The minimum test requirements shall be agreed upon at the time of enquiry and order.

18 HYDROSTATIC TEST

t)In addition Groups 1, 2, 3, and 4 all castings represented by one test shall be poured from the same ladle or same heat as the bar or bars provided for the test.

If specified at the time of enquiry and order the castings may be tested for the hydrostatic test pressure. The requirements for the test pressure shall be mutually agreed to between the purchz:er

_ and the manufacturer.

2

IS 21u : 1993

Ls (SCREWED) -j----w

FIQ. 1 MACHINED TENSILE TEST PIECE

Table 2 Dimensions of Machined Tensile Test Piece

( Clause 14 )

Gauge Machining Minimum Minimum Phsii Ends JXameter Tolerance Parallel Radas T-__--h-_ _--_

D im the Length Minimum Minimum Gauge Diameter Length

Diameter Lc R d, r,

(1) (2) (3) (4) (5) (6)

mm mm ‘mm mm mm mm

20 +- 0’5 55 25 23 65

NOTE - With screwed-ends, any form of thread may be used provided that the thread is not less than that specified.

Screwed Em& -__--A_-_,

Minimum Minimum Dia at

Root Length

ds 4

(7) (8) mm mm 25 30

diameter at the root of the

Table 3 Mechanical Test Requirements

( Cf~~ses 15 and 16.1 )

Grade Tensile Brine11 (su~Is4S43:196S) Strength Hardness

Min MPa ( N/mm2 ) HB

(1) (2) (3)

FG 150 150 130 to 180

FG 200 280 160 to 220

FG 220 220 180 to 220

FG 260 260 180 to 230

FG 300 300 180 to 230

FG 350 350 207 to 241

FG 400 400 207 to 270

NOTE - Although mechanical properties are specified for Grade FG 150 the material shall be only tested if required by the purchaser.

19 RETESTS

19.1 If on being tested any test piece shows obvious signs of a casting defect, the results of the test may be discarded and a further test made.

19.2 If any sound test piece fails, two further tests shall be made, should either of these test pieces fail, the castings represented shall not comply with the requirements of this Indian Standard.

19.3 In the absence of further separately cast test bars, the manufacturer shall have the option of submitting test bars, sectioned from an agreed position in the castings. The requirements of the test shall be as agreed to between the purchaser and the manufacturer. However, the guidance mav be obtained from Annex A.

3

20 INSPECTION

By agreement with the manufacturer, the purchaser or his representative shall have across at all reasonable times to those parts of the manufacturer’s works engaged on his order, he shall be at liberty to inspect the manufacturer at any stage, to witness the required tests and to reject any material that does not comply with this standard. When the castings are to be inspected during manufacture and tested in the presence of the purchaser’s representative, this shall be stated on the enquiry and order.

21 TESTING FACILITIES

21.1 The manufacturer in supplying the test samples as required for testing shall prepare from them the necessary test pieces and supply the labour and appliances for making all tests on his premises in accordance with this standard.

21.1.1 Failing facilities for carrying ‘out the prescribed tests at his own works the manufacturer shall carry out the tests elsewhere.

22 MARKING

22.1 Each casting, if feasible, shall be legibly marked with a number of identification marks which it can be traced to the melt, and the batch of heat treatment, if done, from which it was made.

22.2 By agreement between the purchaser and the manufacturer, castings complying with the requirements of this standard shall be, after inspection, legibly marked with an acceptance mark

23 STANDARD MARK

The castings may also be marked with the Standard Mark.

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1s 210 : 1993

ANNEX A

( Foreword and Clause 19.3 )

APPROXIMATE VARIATION OF STRENGTH

A-l The Indian Standard grades of grey cast iron are based on the minimum tehsile strength obtained when metal is cast into test bars of 30 mm diameter. The strength developed by a given metal shall vary with the coolingrate in the mould higher strengths being obtained if the same metal is cast into smaller bars than 30 mm diameter and lower strengths if the metal is cast into bars larger than 30 mm diameter. Similarly, the cooling rate of a flat plate.is slower than that of a bar whose diameter is equal to the thickness of the plate so that the strength developed in the plate will be lower than that developed in the bar.

A-l.1 The cooling rate of a casting in a mould ( hence the strength developed in any $rticular section thickness by the metal employed for its manufacture ) is influenced also by the presence of cores, changes in section thickness, the presence of bosses projections and intersections, such as the junctions of ribs and bosses. Thus, in castings of other than simple shape and uniform thickness the cooling rate of any part can be expected to differ from that of a flat plate of similar section thickness.

A-2 Figure 2 gives a guide to the likely variation in tensile strength in different sections when a given grade of grey iron is cast into a casting of simple shape and uniform thickness or containing cored holes where the cooling rate in the mould of a given section shall differ from that in a castmg of sample shape and uniform thickness, the dia- gram provides only an approximate guide to the likely tensile strength in different sections and design should be based on the measured tensile strength in critical parts of the casting.

A-2.1 Table 4 gives guidance to the likely variation in tensile strength for different casting section thicknesses when a given grade of grey cast iron is cast into a casting of simple shape and uniform thickness. For casting of non-uniform section or castings containing cored holes, the table provides only an approximate guide to the likely tensile strength in different sections, and casting design should be based on the measured tensile strength in critical parts of the casting.

CROSS-SECT!ONAL THICKNESS, mm

5 15 25 50-75 IQ0 125 159

0 15 30 50 75 100 125 150

BAR DIAMETER, mm

250

This dbam is for guidance and should not be used for acceptance purposes.

Fro. 2 VARIATION OF TENSILE STRENGTH WITH CROSS-SECTIONAL THICKNESS OF GREY IRON CASTIKGS

4

IS 210 : 1993

Table 4 Anticipated Tensile Properties for the Castings ( for Information Only )

( Clause A-2. I )

Grade

FG 150

FG 200

FG 260

FG 300

FG 350

Casting Section Thickness, mm

~-_---_h_-_-_-_-~

Over Up to and Including

2.5 10 10 20 20 30

30 50

2’5 10

10 20 20 30 30 50

4.0 10

10 20

20 30

30 50

10 20 20 30 30 50

10 20 20 30 30 50

Antidpated Tcndlc ShWgtk

MPa ( N/mms )

155

130

115

105

205

180 160

145

260

235

215

195

270 245

225

315

290 270

ANNEX B

( Foreword )

MPa

GRADE FG 600

(=N/mm2)

600 kgf/mm*

60

GRADE

LO

FG 350 350 35 35

FG 300 300 30 30

FG 260 25@----_25 25

FG 220

FG 200 200--20 20

FG 150 150 +,5 MPa

(=N/mm2)

15

CONVERSION FACTOR 1 N/mm2 = lMPa=O.1020 kgf/mmz .

FIT. 3 COMPARISCN BETWEEN GRADES IN THIS EDITION AND THE PREVIOUS EDITION

BASED ON MINIMUM TENSILE STRENGTH

5

IS 210 : 1993

ANNEX C

( Foreword )

TYPICAL PROPERTIES OF GREY CAST I RON

C-1 The following information is given for the guidance of engineers and designers. It does Iiot form part of the standard and shotild not be used for acceptance purposes:

Properties

Tensile strength

WOl percent proof stress

0’1 percent proof stress

Total strain at failure

Elastic strain at failure

Total minus elastic strain at failure

Notched tensile strength ( see Note 2 ) (Circumferential 45” V-notch, root radius 0’25 mm or Notch depth 2’5 mm, notch dia 20

notch gzh ‘3.3 mm, notch diameter 7.6 mm )

Circumferential notch, Radius 9’5 mm ( Notch depth 2’5 mm, notch diameter 20 mm )

Compressive strength

0.1 percent proof stress

0’1 percent proof stress

Shear strength

Torsional strength

Shear strain at failure

M;pntof elasticity

Compression

Modulus of rigidity

Poisson’s ratio

Fatigue limit ( M’oh- Jer )

Unnotched ( 8’4 mm dia )

V-notched ( Cir- cumferential 45” V-notch with 0’25 mm root radius, Diameter at notch %4 mm depth of notch 3’4 mm )

Hardness

unit Grade c---------- --~-_-_------_-_

FG 150 FG 200 FG 220 FG 260 FG 300

150 200 220 260 300

42 56 62 73 84

98 130 143 169 195

o’60-o’751) 0S48-O*671) O’39-O*631) 0.57 0.50

0.15 0’17 0’18 0’20 0’22

0.45~o’601) 0.3 l-0.501) 0.2 1-0’45~) 0.37 0.28

FG 350

350

98

228

0’50

0.25

0.25

FG 400 ’

MPa ( N/mm2 )

MPa ( N/mm% )

MPa ( N/mm’ )

Percent

Percent

MPa ( N/mm2 ) 120 160 176 208 240 280 320

MPa ( N/mm2 ) 150 200 220 2G0 300 350 40(:

MPa ( N/mm2 )

MPa ( N/mm2 )

MPa ( N/mm2 )

MPa ( N/mm’ )

MPa ( I%/mms )

Percent

GPa

GPa

GPa

-

MPa ( N/mm* )

MPa ( N/mm’ )

600 720

84 111

195 260

173 230

173 230

>4 >4

100 114

JO0 114

40 46

768

123

864 960

146 168

338 390

299 345

299 345

>4 Upto

1 080

196

1 200

224

286 455 520

253

253

>4

403 460

403 460

Upto Upto

120 128 135 140 145

120 128 135 140 145

48 51 54 56 58

4QO

112

260

0’50

0’28

0’28

c__--_-_-_--- 0’26 -----_-------__-j

68 90 99 117 135 149 152

68 87 94 108 122 129 127

Refer Table 3 for hardness values

Piopcrtics

Coefficient of thermal expression

- 100°C to 20°C

20% to 2oo”c

20°C to 4130°c

Thermal conductivity

100°C

200°C

300°C

400°C

500°C

Specific heat capacity

‘20°C to 200%

20°C to 300°C

20% to 400%

2OOC to 500%

20°C to 600°C

20°C to 700%

Relative density

,Magnetic and electrical prouerties

Maximum magnetic permeability

Remanent magne- tism

Coercive force

Hysteresis loss at 50 Hz

Electrical rcsistivity

NOTES

Unit Grade r---7---------m- A-,,----- -----

FG 150 FG 200 FG 220 FG 260 FG 300 FG350 FGMJtl

x IO-s/K +-_-__-____ -___ -_10’0 - -____ -+ 10’0 )

x IO-s/K +__-_ ____ ----_--_11’0 --_-- j 1lq)) (&a

x IO-*/K f--_---_-_-- -_--- 12.5--_-_-__+ 12’5 ) ,Note 3)

W/mK 52’5 50.8 50.1 48.8 41.4 45.7 44.0

W/mK 51.5 49.8 49’ 1 47’8 46’4 44’7 43.0

W/mK 50.5 48.8 48’ 1 46’8 45’4 43’7 42’0

W/mK 49.5 47’8 47’ 1 45’8 44.4 42.7 41’0

W/mK 48.5 46’8 46’1 44’8 43’4 41’7 40’0

J/kgIc J/k6 J/J@ J/k+ .J/kgK .J:k$

265 375 420 460 460 460 468

355 435 455 495 495 495 495

400 465 465 505 505 505 505

425 480 475 515 515 515 515

445 500 495 535 535 535 535

490 555 560 605 605 605 605

7-05 7.10 7.15 7’20 7.25 7.30 7.30

PW/ m

T

c_-_-__-___-_301 to 380-_-____.___-_--_-_+

A/m

J/m’

W/k &m

f_--_ _____- 0’4 to 0’5- ____--_ _ _--- --f

t_----__---_-560 to 720 ________ ---_~

+ -_-- --_------2 500 to 3 OOO- --_--_---_-_-_-_-_-_-j

.+__-----_--__-17’6 to 20-g---_--_---_-_-_-+

0.800 0.770 0’760 0.730 0’700 0’670 0.640

IS 210 : 1993

1 The typical properties given in this Annex are the proprrties in a 30 mm diameter separately cast test bar or in a casting section correctly represented by this size of test bar. Where the tensile strength does not correspond to that given, other properties may differ slightly from those given.

2 Notched tensile strengths increase slightly as notch severity ratio, above 0’47.

notch radius, notch diameter, increase

3 The values quoted for coefficient of thermal expansion. of Grade FG 400 are for material in pearlitic iron. Where accicular iron is used for this grade appropriate values are:

20°C to 200% 15’0 x 10*/K

20% to 400°C 16’5 x lo-s/K

I) Values depend on the composition of iron.

ANNEX D

( Foreword )

INFORMATION TO BE SUPPLIED BY THE PURCHASER

D-l BASIS FOR ORDER

D-l.1 FVhile placing an order for the purchase of grey iron casting covered by this standard, the purchaser should specify the following:

a) Material specification;

11) Any required limits on the sulphur and phosphorus content

c) Drawing or reference number of the pattern ( if supplied by the purchaser !, along with a copy of the drawing;

7

IS 210 : 1993

d) Tests required;

e) Whether the castings are to be inspected and tested in the presence of the purchaser’s representative;

f) Condition of delivery;

g)

h)

Any special requirement of the purchaser, for example, hardness tests and locations of non-destructive testing, quality assu- rance, etc; and

Test reports, if required.

ANNEX E ( Clause 17 >

TRANSVERSE TEST FOR GREY CAST IRON

E-l OBJECT OF THE TEST E-3 PROCEDURE

The object of this test is to determine the transverse bending strength of grey cast iron by applying constantly increasing single load at the centre of a test bar arranged as a beam between two supports until fracture occurs.

~-3.1 Place the two ends qf the test bar on hori- zontal supports. The support and the point of application. of the load shall be rounded to a radius of 5 to 20 mm. Apply a single load verti- cally at the centre of the bar ( see Fig. 4 ).

E-2 TEST BARS

E-2.1 The cast test bars shall have the dimensions given in Table 5.

Table 5 Dimensions of Transverse Test Bars

E-3.2 Increase the load uniformly without shock until the bar fracture. The load should be applied in such a way that the increase of stress does not exceed 3 MPa per second Find out the load at the fracture of the test bar with the accuracy indicated in Table 6.

( Clauses E-2.1 and E-2.2 )

Diameter Permissible Variation Length (L) of the Cast from Nominal Min

Test Bar Diameter ---- - *--_-7 Unmachined Machined

(1) (2) (3) (4) mm mm mm mm

30 + 1’2 + 0’2 500

E-2.2 Test bar is normally tested unmachined. The surface of the test bar shall be free from un- evenness and seams which may be removed by careful grinding. The diameter shall be measured at the centre ot the test bar in two directionsper- pendicular to one-anbther. The difference between two measurements shall not exceed 5 percent of the normal diameter. The mean value of the two diameters shall be the diameter do ( see E-4 ) of the test bar. For its permissible variations from the nominal diameter and the accuracy of measurement of the diameter, the values indicated in Tables 5 and 6 shall apply.

E-3.3 Determine the deflection of the test bar from the motion of the thrust relative to the fixed supports or to the supper ting table of the machine. In order to eliminate any errors in m-asuring the deflection, the measurement should be started after applying a small preload as given in Table 6.

Table 6 Testing Conditions and Accuracy of Readings

( Clauses E-2.2, E-3.2, E-3.3 and Fig. 4 )

Nominal Distance Accuracy of Readings Pre- Diameter Between ,-- -----.h_--,=~ Load

d Ccntre of Diame- LoadP, Deflec- Appror Supports, ter of Ml%% tion at

1s Bar Frac- d ture

(1) (2) (3) (4) (5) (6) mm mm mm mm mm mm

30 450 0.1 100 0’2 200 to 400

LOAD POSITION

I

Fra. 4 TRANSVERSE TEST BAR OF GREY CAST IROX

IS 210:1993

E-4 TEST RESULT

The test report shall include:

a) load at fracture in N;

where

P = maximum load at fracture in N,

b) bending strength fb, to an accuracy of O-5 Ls = distance between centres of supports

MPa calculated from the formula: in mm, and

8 PL, do - mean diameter in mm, and

fb = xd” 0 c) deflection at fracture in mm.

9

:., .,.’ .

,1, , ‘- AMENI)MENT NO. 1 AUGUST 1998-,!!

TO!.,,,., IS 210:1993 GREY.lRON CAf’INGS —.“..,

;,‘: .,,, ... ‘ SPECIFICATION

(Fourfh Revision),!.

‘ (Page8,Tuble6,CO14 and6 ) — Substitute, ‘N’ ~or ‘mm’ as unit of load.

Mm 6 )

Reprography Unit, BIS, New Delhi, India i>

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is-210_grey iron casting

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