Phase Diagram

Iron-Carbon

Introduction
The iron-carbon phase diagram maps out all of
the possible temperature treatments and
carbon contents an iron-carbon alloy can
experience. If the temperature and carbon
content of an iron alloy are known, then the
iron-carbon phase diagram can be used to
predict in which phase states the iron-carbon
alloy now exists.
 Phases present
L
α ferrite
δ Bcc structure
Bcc structure Ferro
Paramagnetic magnetic
Fairly ductile

Peritectic L+δ = γ γ austenite Fe3C cementite

Fcc structure Orthorhombic
Eutectic L= γ+Fe3C
Nonmagnetic Hard
Eutectoid γ= α +Fe3C ductile brittle

Max. solubility of C in ferrite=0.022%

Max. solubility of C in austenite=2.11%

 Steel is an interstitial solid solution of carbon in iron.

Theoretically steel has a maximum of 2.11% carbon.

In practice, the amount of carbon rarely exceeds 0.8%

Classification/Nomenclature
Low carbon steels up to 0.2%C AISI 1020:
Last two numbers indicate
Medium carbon steels 0.20.4%C Amount of carbon :0.2%C
10 indicates plain carbon steel
High carbon steels >0.4% C AISI 4340: 0.4%C
43 indicates alloy steel
 IRON-CARBON (Fe-C) PHASE DIAGRAM
• 2 T(°C)
1600
important δ
points 1400 L
-Eutectic (A): γ+L
1200
γ A L+Fe3C
L ⇒ γ + Fe3C 1148°C

Fe3C (cementite)
(austenite)
R S
-Eutectoid (B): 1000 γ γ
γ γ γ+Fe3C
γ ⇒ α + Fe 3C
800
α B 727°C = T
eutectoid
R S
600 α+Fe3C
400
0 1 2 3 4 5 6 6.7
(Fe) 0.77 4.30 C , wt% C
120µm o
C eutectoid

Result: Pearlite = Fe 3C (cementite-hard)

alternating layers of
α and Fe3C phases. α (ferrite-soft)
(Adapted from Fig. 9.24, Callister 6e. Adapted from Fig. 9.21,Callister 6e. (Fig. 9.21
(Fig. 9.24 from Metals Handbook, 9th adapted from Binary Alloy Phase Diagrams, 2nd
ed., Vol. 9, Metallography and ed.,
Microstructures, American Society for Vol. 1, T.B. Massalski (Ed.-in-Chief), ASM
Metals, Materials Park, OH, 1985.)
IRON-CARBON (Fe-C) PHASE DIAGRAM

BCC crystal structure FCC crystal structure

Note: δphase is also called δferrite and is a BCC phase

 ALLOYING STEEL WITH MORE ELEMENTS

• Teutectoid changes: • Ceutectoid changes:

C eutectoid (wt%C)
0.8
T Eutectoid (°C)

1200 Ti Si
Mo W Ni
0.6
1000 Cr
Cr 0.4
Si
800 Mn
Mn 0.2 W
Ti Mo
600 Ni
0
0 4 8 12 0 4 8 12
wt. % of alloying elements wt. % of alloying elements
 Phase Diagrams

Why the FCC iron (/3 - iron) has highest packing density and, meanwhile has
larger interstitial room for carbon atoms than BCC iron (a - Iron)? How about
BCT structure (martensite iron)?

I
0.104nm
0.072 nm
BCC
FCC

Diameter of Carbon Atom = 0. 154 nm

BCT
 Overview of cast iron

• Iron with 1.7 to 4.5% carbon and 0.5 to 3%

silicon
• Lower melting point and more fluid than steel
(better castability)
• Low cost material usually produced by sand
casting
• A wide range of properties, depending on
composition & cooling rate
– Strength
– Hardness
– Ductility
 Production of cast iron

• Pig iron, scrap steel, limestone and

carbon (coke)
• Cupola
• Electric arc furnace
• Electric induction furnace
• Usually sand cast, but can be
gravity die cast in reusable
graphite moulds
 Types of cast iron

• Grey cast iron - carbon as graphite

• White cast iron - carbides, often
alloyed
• Ductile cast iron
– nodular, spheroidal graphite
• Malleable cast iron
 Effect of cooling rate

 • Slow cooling favours the formation of graphite

 & low hardness
•
 Rapid cooling promotes carbides with high hardness

• Thick sections cool slowly, while thin sections cool
quickly
 Sand moulds cool slowly, but metal chills can be used to
•increase cooling rate & promote white iron
 Effect of composition

• A CE over 4.3 (hypereutectic) leads to carbide

or graphite solidifying first & promotes grey
cast iron
• A CE less than 4.3 (hypoeutectic) leads to
austenite solidifying first & promotes white
 Grey cast iron

• Flake graphite in a matrix of

pearlite, ferrite or martensite
• Wide range of applications
• Low ductility - elongation 0.6%
• Grey cast iron forms when
– Cooling is slow, as in heavy sections
– High silicon or carbon
 Typical properties

 Depend strongly on casting shape & thickness AS1830 &

ASTM A48 specifies properties
 Low strength, A48 Class 20, Rm 120 MPa
– High carbon, 3.6 to 3.8%
– Kish graphite (hypereutectic)
– High conductivity, high damping
 High strength, A48 Class 60, Rm 410 MPa
– Low carbon, (eutectic composition)
Graphite form

• Uniform
• Rosette
• Superimposed (Kish
and normal)
• Interdendritic random
• Interdendritic preferred
orientation
 Matrix structure

• Pearlite or ferrite
• Transformation is to ferrite when
– Cooling rate is slow
– High silicon content
– High carbon equivalence
– Presence of fine undercooled graphite
Properties of grey cast iron

• Machineability is excellent
• Ductility is low (0.6%), impact
resistance low
• Damping capacity high
• Thermal conductivity high
• Dry and normal wear properties
excellent
 Applications

• Engines
– Cylinder blocks, liners,
• Brake drums, clutch plates
• Pressure pipe fittings (AS2544)
• Machinery beds
• Furnace parts, ingot and glass
moulds
 Ductile iron

• Inoculation with Ce or Mg or both

causes graphite to form as
spherulites, rather than flakes
• Also known as spheroidal graphite
(SG), and nodular graphite iron
• Far better ductility than grey cast
iron
Microstructure

• Graphite spheres
surrounded by ferrite
• Usually some
pearlite
• May be some
cementite
• Can be hardened to
 Production

• Composition similar to grey cast

iron except for higher purity.
• Melt is added to inoculant in ladle.
• Magnesium as wire, ingots or
pellets is added to ladle before
adding hot iron.
• Mg vapour rises through melt,
removing sulphur.
 Properties

• Strength higher than grey cast iron

• Ductility up to 6% as cast or 20%
annealed
• Low cost
– Simple manufacturing process makes
complex shapes
• Machineability better than steel
 Applications

• Automotive industry 55% of ductile

iron in USA
– Crankshafts, front wheel spindle
supports, steering knuckles, disc
brake callipers
• Pipe and pipe fittings (joined by
welding)
 Malleable iron

• Graphite in nodular form

• Produced by heat treatment of
white cast iron
• Graphite nodules are irregular
clusters
• Similar properties to ductile iron
• See AS1832
 Microstructure

• Uniformly dispersed graphite

• Ferrite, pearlite or tempered martensite
matrix
• Ferritic castings require 2 stage anneal.
 Annealing treatments

• Ferritic malleable iron

– Depends on C and Si
– 1st stage 2 to 36 hours at 940˚C in a controlled
atmosphere
– Cool rapidly to 750˚C & hold for 1 to 6 hours
• For pearlitic malleable iron
– Similar 1st stage above (2 - 36 h at 940˚C)
– Cool to 870˚C slowly, then air cool & temper to
specification
• Harden and temper pearlitic iron for
martensitic castings
 Properties

• Similar to ductile iron

• Good shock resistance
• Good ductility
• Good machineability
 Applications

• Similar applications to ductile iron

• Malleable iron is better for thinner castings
• Ductile iron better for thicker castings >40mm
• Vehicle components
– Power trains, frames, suspensions and wheels
– Steering components, transmission and differential
parts, connecting rods
• Railway components
• Pipe fittings AS3673
Effects of alloy elements

• Promote graphite (Si, Ni)

• Promote carbides (Cr)
• Affect matrix microstructure
– Ferrite, pearlite, martensite or
austenite
• Corrosion resistance (Cr)
 Increasing carbon

• Increases depth of chill in chilled

iron
• Increases hardness
• Increases brittleness
• Promotes graphite during
solidification
 Increasing silicon

• Lowers carbon content of eutectic

• Promotes graphite on solidification
– Reduces depth of chill
• Negative effect on hardenability
– Promotes pearlite over martensite
• Raises Ms if martensite forms
• Can improve resistance to scaling
at high temperature
 Manganese and sulphur

• Each alone increases depth of chill

• Together reduces effect of other
(MnS)
• Mn in excess scavenges S and
stabilises austenite
• Solid solution strengthener of
ferrite / pearlite
• Sulphur lowers abrasion resistance
 Phosphorus

• Mild graphitiser
– Reduces chill depth
– Considered detrimental in alloy cast
irons
 Chromium

• Main uses:
– Forms carbides
– Gives corrosion resistance
– High temperature stability
• Up to 3% - no effect on
hardenability
• More than 10% - M7C3 carbides
stronger and tougher than M C
 Nickel

• Promotes graphite
• Increases strength of pearlite
• Increases hardenability
– 2.5 to 4.5% Ni-Hard irons
• Stabilises austenite
– Over 6.5%
 30<.8 rrm (12 n)
The austempered ductile iron crankshaft for the TVR sportscar.

TVR Tuscan Speed 6, high-performance sports car with an austempered

ductile iron crankshaft.

Austempered ductile iron suspension arm for a Ford Mustang Cobra

A truck trailer suspension arm made from austempered ductile iron,
Steele and Lincoln Foundry.
Thank you