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Cast parts often require machining to achieve accurate tolerances and desired surface finishes. Carbon steel is the easiest type of steel to machine. High-carbon steel can be more time consuming to cut or grind, and will wear tools faster. Low-carbon steel can get gummy, making it difficult to work with.
However, too much alumina in the steel will clog the casting nozzles and cause the steel to 'choke off'. Computational fluid dynamics and other fluid flow techniques are being used extensively in the design of new continuous casting operations, especially in the tundish, to ensure that inclusions and turbulence are removed from the hot metal ...
Cast iron is made from pig iron, which is the product of melting iron ore in a blast furnace. Cast iron can be made directly from the molten pig iron or by re-melting pig iron, [4] often along with substantial quantities of iron, steel, limestone, carbon (coke) and taking various steps to remove undesirable contaminants.
Smooth cast surfaces (Ra 1–2.5 micrometres or 0.04–0.10 thou rms). Thinner walls can be cast as compared to sand and permanent mould casting (approximately 0.75 mm or 0.030 in). Inserts can be cast-in (such as threaded inserts, heating elements, and high strength bearing surfaces). Reduces or eliminates secondary machining operations.
Continuous casting is used due to the lower costs associated with continuous production of a standard product, and also increased quality of the final product. Metals such as steel, copper, aluminum and lead are continuously cast, with steel being the metal with the greatest tonnages cast using this method.
Steel is made from iron and carbon. Cast iron is a hard, brittle material that is difficult to work, whereas steel is malleable, relatively easily formed and versatile. On its own, iron is not strong, but a low concentration of carbon – less than 1 percent, depending on the kind of steel – gives steel strength and other important properties.
Gray iron, or grey cast iron, is a type of cast iron that has a graphitic microstructure. It is named after the gray color of the fracture it forms, which is due to the presence of graphite. [ 1 ] It is the most common cast iron and the most widely used cast material based on weight.
Cast iron is not malleable even when hot, but it can be formed by casting as it has a lower melting point than steel and good castability properties. [5] Certain compositions of cast iron, while retaining the economies of melting and casting, can be heat treated after casting to make malleable iron or ductile iron objects.
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