Abstract: Disclosed herein is a gray cast iron having high strength and reduced casting defects. The high-strength gray cast iron may include: an amount of about 3.10 to 3.50 wt % of carbon (C), an amount of about 2.10 to 2.40 wt % of silicon (Si), an amount of about 0.50 to 0.80 wt % of manganese (Mn), an amount less than or equal to about 0.10 wt % (not including 0%) of phosphorus (P), an amount less than or equal to about 0.10 wt % (not including 0%) of sulfur (S), an amount of about 0.25 to 0.45 wt % of chromium (Cr), an amount of about 1.00 to 1.40 wt % of copper (Cu), an amount less than or equal to about 0.20 wt % (not including 0%) of nickel (Ni), and a balance of iron (Fe), all the wt % are based on the total weight of the gray cast iron. In particular, the gray cast iron may include a carbon equivalent (CEQ) of about 3.95 to 4.1% calculated by the Equation 1.

Abstract: An iron based alloy material for a thixocasting process and a method for casting the material which extends the service life of dies by inhibiting solidification contraction, and in which casting defects such as size variations and cracks can be inhibited. The material comprises 1.6 wt %?C?2.5 wt % and 3.0 wt %<Si?5.5 wt %, and a carbon equivalent (the value of CE) defined as “C(wt %)+?Si(wt %)” of 2.9 to 3.5. This material is made to be in a half-melted state with 35 to 50 wt % of a solid phase to be cast under a pressure load.

Abstract: An indefinite chill roll alloy composition is disclosed containing carbon ranging from 2.5 to 4.0% by weight of the alloy and the carbon is present as free graphite in an amount ranging from 2-7%, preferably 3-6%, of the total carbon. The composition further includes niobium which ranges from 0.3-6.0 % and is present essentially as discrete niobium carbide particles in the alloy. The present invention further includes a chill roll shell formed from the alloy and produced by a method including the steps of providing a molten indefinite chill roll composition, adjusting the composition by adding niobium in an amount sufficient to produce a molten batch containing 0.3 to 6.0% niobium based on the total weight of said molten batch, providing a stoichiometric amount of excess carbon to form niobium carbide and casting the molten batch to form the chill roll shell.

Abstract: An iron casting, such as a cylinder block for an internal combustion engine, includes a number of component zones, with each of the zones having selected surface to volume ratio and selected section thickness sufficient to cause in-mold cooling during the casting process at controllable, but varying rates sufficient to result in predetermined, different percentages of nodular and compacted graphite iron in at least two of the zones of the cylinder block or other iron casting.

Abstract: A cast iron component, eg a camshaft, has a wear-resistant layer formed on at least one surface portion thereof, said layer being rich in primary carbides. The cast iron surrounding the carbides and in the remainder of the component has a structure which is substantially ausferritic. A method of manufacturing a component is also claimed.

Abstract: A camshaft made of cast iron containing at least one element selected from the group consisting of Bi, Te, Se, As, Sb and Sn in a total amount of 0.0001 to 0.1 weight %, preferably, 0.001 to 0.1 weight %. The cast iron may further contain at least one element selected from the group consisting of Ni, Cu and Co, in an amount of 0.2 to 5.0 weight %. Furthermore, in the camshaft of the present invention, a carbide area ratio at the sliding surface of the cam lobe portion is not less than 40%, the chilled carbide has an average grain diameter of not more than 15 .mu.m, and the sliding surface of the cam lobe portion has a hardness of not less than HRC 53.

Abstract: A cast iron slide member is formed from cast iron comprising 3.0% to 3.6% by weight of carbon (C), 1.6% to 2.4% by weight of silicon (Si), 0.2% to 1.5% by weight of manganese (Mn), 0.5% to 1.5% by weight of chromium (Cr), 1.5% to 3.0% by weight of nickel (Ni), 0.5% to 1.0% by weight of molybdenum (Mo), 0.0003% to 0.1% by weight of at least one chilling promoting element E.sub.L selected from the group consisting of bismuth (Bi), tellurium (Te) and cerium (Ce), and the balance of iron (Fe) and unavoidable impurities. The slide member has a chilled slide portion. Thus, it is possible to improve the scuffing and pitting resistances of the slide portion.

Abstract: A method of producing a chilled iron camshaft is described, wherein the iron has a white iron structure adjacent chill inserts in a casting mould and a grey iron structure in substantially all other regions remote from the chills. The method comprises the steps of assembling a sand casting mould having a camshaft shaped cavity and also having chill inserts adjacent the cavity regions where while iron is desired, preparing a molten metal charge of cast iron having a carbon equivalent lying in the range from 3.3 to 3.85 wt % and adding sufficient nucleant prior to pouring to fill the mould cavity to ensure that undercooling of residual liquid remaining after solidification of the white iron structure adjacent the chills remains above the iron-cementite eutectic temperature prior to solidfication into grey iron.

Abstract: Spherical graphite cast iron utilized to prepare a lapping tool is manufactured by casting a molten composition into a mold cavity, and by chilling one side of the resulting casting thereby causing unidirectional solidification, the one side being used as the operating surface of the lapping tool. The molten composition consists of 3.0-3.8 wt. % of carbon, 2.0-2.9 wt. % of silicon, 0.3-0.9 wt. % of manganese, less than 0.05 wt. % of phosphorus, less than 0.03 wt. % of sulfur, 0.2-1.0 wt. % of nickel, 0-0.8 wt. % of copper, 0.05-0.5 wt. % of molybdenum, 0.03-0.09 wt. % of magnesium and the balance of iron. The lapping tool made of this casting has a percentage of sphericity of higher than 80%, graphite particle diameter of less than 100 microns, a density of graphite particles of larger than 70/mm.sup.2, and a Vickers hardness of larger than 200.

Abstract: Spherical graphite cast iron utilized to prepare a lapping tool is manufactured by casting a molten composition into a mold cavity, and by chilling one side of the resulting casting thereby causing unidirectional solidification, the one side being used as the operating surface of the lapping tool. The molten composition consists essentially of 3.0-3.8 wt. % of carbon, 2.0-2.9 wt. % of silicon, 0.3-0.9 wt. % of manganese, less than 0.05 wt. % of phosphorus, less than 0.03 wt. % of sulfur, 0.2-1.0 wt. % of nickel, 0-0.8 wt. % of copper, 0.05-0.5 wt. % of molybdenum, 0.03-0.09 wt. % of magnesium and the balance of iron. The lapping tool made of this casting has a percentage of sphericity of higher than 80%, graphite particle diameter of less than 100 microns, a density of graphite particles of larger than 70/mm.sup.2, and a Vickers hardness of larger than 200.

Abstract: This invention relates to a heavy wall monolithic iron pipe comprising nodular graphite in the outer portion of its wall and flake or quasi-flake graphite in the inner portion of its wall and a method for making said pipe. The central portion of the wall of the pipe may be a combination of nodular graphite and flake or quasi-flake graphite.