Iron 101

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Learning Outcomes

  • Describe the critical factors and features of cast iron that make it the casting alloy of choice.
  • Understand how elements in cast iron are adjusted to produce different grades.
  • Explain the classification systems for each of the five cast iron families.
  • Discuss the mechanical and physical properties of each of the five families of cast irons.
  • State four important inspection/testing methods for determining cast iron quality.
  • Analyze how different elements impact the properties of cast iron.
  • Describe the basic melting practices and related technologies for cast iron.
  • Compare iron casting processes.
  • Explain the use of heat treatment of cast iron and how that affects mechanical properties and cost.
  • Apply safety procedures to the daily work environment in a metalcasting facility.

Course Introduction

This is an introductory course covering the major cast iron families. Topics include characteristics and properties as well as general applications for each iron type, common alloying elements and their uses, iron melting technology and considerations, compatible casting processes, and heat treatment options and applications.

 

Module 1: Introduction

Module 2: Overview of Cast Iron

  • Where are Iron Castings Used?
  • Why is Cast Iron Commonly Used?
  • Cast Iron Key Points

Module 3: Cast Iron Classification Systems and Properties

  • Cast Iron Families
  • General Cast Iron Properties Overview
  • Designation System Introduction
  • Gray Iron
  • Ductile Iron
  • Compacted Graphite, White, Malleable, and High Alloy Irons
  • Iron Family Group Activities

Module 4: Elements in Cast Iron

  • Main Elements in Cast Iron
  • Alloying and Trace Elements in Cast Iron

Module 5: Applications of Cast Iron

  • Alloy Selection

Module 6: Cast Iron Melting Technology

  • Cast Iron Safety
  • Furnace Types
  • Melting Practice Overview

Module 7: Iron Casting Processes

  • Sand Casting
  • Investment Casting
  • Lost Foam Casting
  • Casting Process Case Study

Module 8: Heat Treatment Overview

  • Reasons for Heat Treatment, Heat Treatment Options, and Results of Heat Treatment

Module 9: Conclusion

 

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