Ductile iron or SG iron is the commercial name for cast iron that possesses great strength, toughness and hardness. Nodular graphite structures are completely met by ductile iron, and those are the graphite structures that describe the ductile material. This makes it a versatile material that is used in various industries, such as automobile and heavy machinery industries, among others. But what is ductile iron, and why has this product recently been used more often? In this blog, let’s understand the composition of ductile iron, its grades, its properties, and its versatility across diverse industries.
What is Ductile Iron?
Ductile iron is a type of cast iron in which the carbon is dispersed in the form of round nodules as opposed to flaky carbides found in gray iron. This is made possible through the incorporation of other alloys, such as magnesium and cerium, during the casting process, which alters the shape of the graphite into a spherical form to offer the material flexibility, besides enhancing its mechanical properties. S.G. This ductile iron material was first produced and applied in 1943, and it has been widely used in a variety of sectors because of its ability to withstand high stress. It is highly ductile and does not break easily when met with impact.
Ductile iron does not break under pressure like normal cast iron, which is commonly used, which means that it has to be used where there is a need to use a material that will not crack. What is ductile iron used for? Its uses are numerous, and it can be found in pipelines, automotive components, and heavy industries.
Different Types of Ductile Iron Grades
Ductile iron is available in various grades, each of which can be used for specific applications depending on the mechanical characteristics and structure. These grades depend on the percentage of carbon and silicon together with other ingredients that change the nature of iron.
Every grade provides different properties most suitable for various use such as industrial equipment applications and automotive parts.
Ductile Cast Iron Composition
The main constituent metals that make ductile cast iron determine its mechanical features. Ductile iron is typically made up of::
- Carbon: 3.2% to 3.6%
- Silicon: 2.2% to 2.8%
- Manganese: 0.1% to 0.2%
- Magnesium: 0.03% to 0.04%
- Phosphorus: 0.005% to 0.04%
- Sulfur: 0.005% to 0.02%
- Iron: The remaining portion (approximately 94%)
Other material components such as chromium, nickel, and copper may be included in the steel to enhance certain properties such as corrosion protection and strength. This allows manufacturers to alter the material and use it for different high-strength applications due to the flexibility of this ductile cast iron composition.
Ductile Iron Applications
Owing to properties like high tensile strength, high ductility, good wear, and corrosion resistance, this material is used across various industries. Some of the most common applications of ductile iron include:
Piping and Pipe Fittings: More than 50% of ductile iron is utilized in producing pipes and fittings for carrying fluids.
Automotive Industry: Auto parts such as crankshafts, gears, connecting rods, etc., require strength and adequate tenacity of ductile iron.
Heavy Machinery: Since it is ductile iron with wear-resistant properties, it is suited to casting machine parts like housings, cylinders, and gearboxes.
Agricultural Equipment: Components like tractor tyres and yokes require high tensile ductile iron for its excellent tensile strength.
Military and Defense: Spheroidal graphite iron is used in high pressure valves and other casting parts that demand severe strength.
Infrastructure and Construction: Hydrostatic barrels, bridges, and heavy machine foundations need ductile iron as a constituent of their huge strength.
These applications show what ductile iron is all about, which is made of a very powerful and versatile material that has continued to remain in demand in today’s engineering.
Properties of Ductile Iron
Ductile iron exhibits a range of beneficial properties that make it a popular choice across industries:
- Tensile Strength: 414 MPa to 1380 MPa
- Yield Strength: 275 MPa to 620 MPa
- High Ductility: Ductile iron has an elongation of up to 35% or 18%.
- Impact Resistance: Ductile iron can withstand massive loads in terms of pressure without breaking.
- Wear Resistance: In the austempered grades, the versatility of ductile iron remains impressive in terms of durability.
- Good Castability: Applicable for complicated and large shapes.
- Corrosion Resistance: Certain components, such as chromium and nickel, can be incorporated into the alloy to improve corrosion resistance.
How Can AKP Ferrocast Add Value to You?
AKP Ferrocast is one of the leading companies in the cast iron industry that offers ductile cast iron and gray iron castings . Having serviced the market for many years, AKP Ferrocast offers solutions to satisfy the demands of particular industries. Some of these include the automotive, agriculture and construction industries across the world.
AKP Ferrocast’s vision is to be innovative and follow strict quality standards while embracing the use of manufacturing technology to produce superior products. Whether it is ductile iron castings for your machine tools or automotive parts, we can provide you with the perfect solutions for your organization.
Total Solution in Cast Iron for All Our Clients in Machined Casting Condition
AKP Ferrocast supplies SG Iron castings to meet the highest quality standards and fully machined casting. We provide high-precision cast iron parts, sparing our clients from the expense of having to go through other processes. Through our specialized services in machining, heat treatment and quality, AKP Ferrocast is here to fulfill your ductile and gray iron requirements.
Bottom Line
Ductile iron has emerged as one of the most important materials in many industries due to its characteristics of very high strength, flexibility and low cost; these are most evident. Since it is used in a wide variety of industry fields that include automobile manufacturing, large industrial machines and tools, it is a favored material by engineers and manufacturers. For getting high quality ductile iron castings, contact AKP Ferrocast and be assured of getting high quality castings as per your desired specifications.
Frequently Ask Questions
What are the advantages of using Ductile Cast Iron?
Ductile iron, besides having a high level of ductility, also displays high tensile strength as well as impact strength. Its ductile nature has led it to better wear resistance, making it more suitable than other forms of cast iron for various applications.
How is Ductile Cast Iron different from Gray Cast Iron?
The main difference is in the formation of graphite structure. In ductile iron, graphite is in the form of nodules, while in gray cast iron, graphite is present in the form of flakes. This provides ductile iron greater flexibility, as well as the ability to resist impact.
What are the key components in the manufacturing process of Ductile Iron?
Major Constituents: Carbon, Silicon, Manganese, Magnesium, Phosphorus, Sulphur, and Iron. Specific strength and corrosion resistance can be achieved by adding copper, nickel and chromium.
What are the types of Ductile Iron?
Ductile iron comes in a variety of forms, such as ferritic ductile iron, ferritic-pearlitic ductile iron, pearlitic ductile iron, martensitic ductile iron, and austempered ductile iron (ADI). Each grade is developed under specific properties that find special applications in end-use industries.