Grey Iron Castings/

Spheroidal Graphite Cast Iron

Spheroidal graphite cast iron is a group of iron alloys specially formulated to create molded products with heightened elasticity, tensile strength and durability. Despite its wide use, grey iron tends to be brittle and is therefore discounted in many metallurgical applications. The creation of a spheroidal or nodular graphite microstructure, however, produces ductile cast iron that can be used more broadly.

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Capital Pattern and Model, Inc.
Glendale Heights, IL
630-469-8200
Capital Pattern and Model is a leading provider of quality custom prototype castings and short-run castings in numerous alloys including grey iron, cast iron, zinc, and more. A state of the art in-house pattern and machine shop offers green sand casting, air set and plaster molding. This along with engineering assistance provides clients with cost effective quality castings and quick turnaround.
 
Bearon Corp.
Manheim, PA
717-898-2210
Since 1980, Bearon has been a top provider of grey iron castings and other components. Bearon components are crafted from aluminum, brass, bronze, cast iron, ductile iron and malleable iron to suit a range of industrial applications. With manufacturing capabilities including casting, machining, fabrication, finishing, molding and more, Bearon can take care of your projects from start to finish.
 
Bernier Cast Metals Inc.
Saginaw, MI
800-252-3657
Bernier Cast Metals manufactures quality sand castings in prototype, small and semi-production quantities. With green sand molding, air-set and lost foam casting, Bernier offers castings in all grey iron and ductile iron alloys with additional value added services. On-time delivery, competitive pricing, quality products and friendly service make Bernier the number one source for cast components.
 
Benton Foundry, Inc.
Benton, PA
570-925-6711
For nearly a century, Benton Foundry has been supplying iron castings to a variety of industries, building a reputation for consistent, high-quality castings delivered on time. Working with all types of gray iron and ductile iron, Benton provides quality components and extraordinary service at a low net cost. Put Benton's near 100 year history to work for your most challenging casting application.
 
Bremen Castings Inc.
Bremen, IN
800-837-2411
As a foundry & machine shop, Bremen Castings continues to grow & diversify. BCI keeps making its ISO 9001:2008 system better & better; customers receive world class green sand casting & precision CNC machining under one roof! Founded in 1939 with an emphasis on using recycled ferrous material, this 4th generation family business produces complete assembled, precision gray & ductile iron castings.
 
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Industry Information

Spheroidal Graphite Cast Iron

Industries such as agriculture, irrigation, ventilation, automotive, water and sewage treatment, hydraulics, manufacturing, transportation, construction and building utilize spheroidal graphite cast iron products which also offer improved corrosion and wear resistance, machinability, and thermal tolerances as compared to comparable grey iron castings. Whereas most iron castings develop graphite flakes, or three dimensional rosettes, spheroidal graphite cast iron is processed at temperatures and cooling rates conducive to the formation of nodular or spheroid graphite. The lower aspect ratio of spheroids as compared to flakes reduces length and increases particulate separation. The rounded or blunt edges of the nodules also help to inhibit cracking and alleviate the internal stresses inherent to graphitic flakes. The elemental composition of spheroidal graphite iron alloys is also slightly different than the average gray iron as fractional amounts of magnesium or cerium must be included in order to effectively control the morphological structure of the graphite.

Grades of these alloys are standardized and can be used to determine the tensile strength and elongation of a particular product or material. A basic chemical constitution of these alloys is as follows. 95% of the total mass is iron with carbon amounts between 3.3 and 3.4% and silicon levels ranging from 2.2 to 2.8% of the weight. Manganese levels are between 0.1 and 0.5% with sulfur and phosphorous each comprising around 0.005% of the total mass. Spheroidal graphite cast iron necessitates the presence of between 0.03 and 0.05% magnesium, cerium or a combination. To achieve the production of nodules low sulphur, low silicon iron is liquefied and magnesium or cerium added. This is followed by the addition of silicon to prevent the formation of cementite and ensure that the carbon precipitates as graphite spheroids. The molten metal is poured into a pre-formed mold designed with the impression of the desired part. Cooling is performed at specific rates to solidify the material and facilitate the formation of a pearlite or ferrite matrix structure. In this way iron foundries can produce ductile castings of such varied products as gears, crankshafts, cylinder heads, support beams and pipes.