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IS 5699 (1970): Method for chill testing of cast iron [MTD3: Mechanical Testing of Metals]

IS :5699 - 1970

Indian Standard

METHODS FOR CHILL TESTING OF C&T IRON

f Second Reprint JU_NE 1990 >

\ : .

Gf2

UJX 669.13:620.192.422

@ Copyright 197 1

BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG

NEW DELHI 110002

3QWW 1971

IS : 5699 - 1970

Indian Standard METHODS FOR CHILL TESTING OF CAST IRON

kfethods of Physical Tests Sectional Committee, SMDC 3

Chairman Reprcsen tin<

SHRI S. N. MUKERJI l National Trst House, Calcutta

Members

DR. B. K. AGARWALA National Physical Laboratory ( CSIR ), New Delhi SHRI L. J. BALASUNDARA~I National Metallurgical Laboratory ( CSIR ),

Jamslredpui DR U. N. BHRANY Thr Indian Iron & Steel Co Ltd, Burnpur

SHRI K. H. SHARMA ( Alternate ) SHRI P. R. CHANDRAsEKilAIl Directorate Gcnrral of Civil Aviation ( Ministry 01

Tourism & Civil Aviation ) SHRI G. CHATTERJER Hindustan Steel Ltd, Ranchi

Snnr U. C. $IAI~M,\ ( &erna/e) CHEMIST AND METALLUZQIST Ministry of Railways

CHITTARAN.IAN LOCOMOTIVE WORKR

ASSWTANT DIRECTOR RESEARCI~ ( MET ) RESEARCH, DESIGNS AND

STANDARDS ORGANIZATION, CHIT’PARANJAN ( Alternate )

SHRI R. N. DATTA Ministry of Drfencr ( DGOF ) SHRI D. K. CBAKRAVORTY ( Alternate I ) SHRI D. SEN ( Alternate II )

SHRI N. T. GEORQE Ministry of Defencr ( R & D ) SI~RI D. K. JO~HI ( Alternate )

SHRI M. C. KU~~IARASWAM~ Tata Iron & Steel Co Lrcl: ~Jnmshrdput Snnr M. R. PATR:r. Inspection Wing, Dirrctorntc Gvnr-ml oC Supplies

& Disposals, Nrw Drlhi SHRI .J. P. SEN ( Altrrnate )

SIIRI N. A. I’RAnlIu M N. Dastur and Co ( 1’ ) Ltd, Ckdcultn SHRI N. v. RAWihVhN Mining and Allied Machinrry Corporation Ltil.

Durgapur DR P. R. K. SARMA ( Akcrrrate )

SIiltI V. RAMASWAMY Ministry of Drfcncc ( DGI ) SHRI M. B. SEIANKAR Hindustan Arronautics Ltd, Bang&xc

SIIRI P. K. KI’RIAN ( Alternate ) DR A. K. SINCU National Acronnuticnl Laboratory ( CSIR ).

Bangalore

( Continued on pq- 2 )

BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9 RAHADUR SHAH ZAFAR MARC

NEW DELHI 110002

IS:5699 - 1970

( Canti*urd~~rom page I )

Members

SHRI K. C. SRIVASTAVA

Representing

Itidian Sugar and General Engineering Corpora- tion, Yamunanagar

Strur A. UYAMAHERWARAN Dirrctorate of Technical Development & Produc- tion (Air ) ( Department of Defence Produc- tion )

SHRI R. P. VAR~HNEY ( Alternate ) SHRI R. K. SRIVASTAVA, Dirrctor General, ISI ( Ex-oj’icio Member )

Deputy Director ( Strut & Met )

Secfetaty .

SHRI P. K. J&IN

Assistant Director ( Met ), IS1

IS: 5699-1970

Indian Standard

METHODS FOR CHILL TESTING OF CAST IRON

0. FOREWORD

0.1 This Indian Standard was adopted by the Indian Standards Institt+ tion on 6 July 1970, after the draft finalized by the Methods of Physical Tests Sectional Committee had been approved by the Structural and Metals Divisoin Council.

0.2 It is often required in a cast iron foundry to measure the chilling tendencies of the metal in order to avoid any chilling or to have a speci- fied depth of chill where extreme hardness on the cast surface is required. This is evaluated by performing the chill test. This standard has been prepared to ensure more unified practice and help in attaining satisfactory results.

0.3 Out of the two methods covered in this standard, the wedge test is generally better adapted to the higher strength grey irons. The accelerat- ed cooling rate to induce the formation of a chill is brought about through the design of the test specimen.

0.3.1 The chili test is adapted to the softer grades of grey iron and should be used if the .casting is to have a specified depth of chill. The chill in this type of test is induced by casting one edge of the test specimen against a metal or graphite chilled plate or block.

0.4 In the preparation of this standard, assistance has been derived from ASTM Designation : A 367-1967 ‘ Methods of chill testing of cast iron’ published by American Society for Testing and Materials.

0.5 In reporting the result of a test or analysis made in accordance with this standard, if the final value, observed or calculated, is to be rounded off, it shall be done in accordance with IS : 2-1960*.

1. SCOPE

1.1 This standard prescribes the following two methods for chill testing of grey iron:

a) Wedge test, and b) Chill test.

‘Rules for rounding off numerical values ( revised ).

3

IS:5699- 1970

2. WEDGE TEST

2.0 Application - Selection of a test specimen of appropriate dimensions will allow measurement of chilling tendencies of all grey iron compositions, with the exception of those having silicon contents much over 2.5 percent together with carbon contents over 3.5 percent.

2.1 Test Specimen - The patterns for the test specimens shall be made of metal and shall be of dimensions given in Table 1. The length of the specimen shall not differ from the values indicated in Table 1 by more than f 3 mm, and the tolerance on other dimensions shall be f 1 mm. The radius on the apex of the wedge shall be formed by filing a 1 mm flat on the sharp edge of the metal pattern and then carefully rounding the edges formed by 1 mm flat and the sides of the wedge. If draft on the pattern is desired, it may be obtained by varying dimension H from one end of the specimen to the other. The pattern shall be mounted in a core box so that the final core may be poured with the wedge in such a posi- tion that its length is vertical. There shall be minimum of 25 mm sand at the bottom of the core.

TABLE 1 RECOMMENDED WEDGE DIMENSIONS

CROSS SECTION OF W

WEDGE No. ‘B H e LENGTH

mm mm mm

Wl 5 25 11’5” 100 w2 10 30 18” 100

w3 20 40 28 100

w4 25 45 32” 125

w5 30 50 34’5” 150

4

IS: 5699-1970

2.2 Cores - The test shall be made in a core. The cores shall be either single cores or gang cores. If a gang core is used, the minimum amount of sand between adjacent test specimens shall be not less than 2.5 X B. ‘The

sand cores shall be well-baked and may be either resin or oil bonded. The base sand shall be of such fineness that a smooth casting is obtained. A sand with a fineness of about 70 when determined in accordance with IS : 191%1966* will be satisfactory, although a sand with a fineness of 100 or finer may be used for the small test specimens.

2.3 Pouring Practice -The test specimens shall be poured at a fairly uniform temperature. Precautions shall be taken to obtain a representa- tive’sample of iron for the test specimen. Best results are obtained with a sample ladle lined with a refractory mixture which is free of graphite and chilled &on. The ladle shall hold at least 2’5 kg of iron in order to avoid excessive chilling of the iron before the test specimen may be poured. Filling the ladle once with iron just prior to obtaining the sample for test is recommended,

2.4 Cooling of Test Specimen - If time is an important factor in con- trol applications, the test specimen shall be quenched in water as soon as it is completely solid. The quenching shall be done carefully to avoid cracking of the chilled apex of the wedge. This may be accomplished by grasping the wedge with tongs at the apex of the wedge and immersing about 5 to 10 mm of t%e base of the wedge in water. The wedge shall then be gradually quenched but shall be removed while there is still sufficient heat in the wedge to dry off the water. If speed of testing is not important, the test specimen may be either cooled in the core <Jr in the air. If cooled to a very dull red before quenching in water, the demarca- tion between the chilled iron and the grey iron is somewhat clearer than if the test specimen is quenched as soon 5s it is solid.

2.5 Measurement of Chill - The test specimen shall be broken by strik- ing with a hammer in such a manner that the fracture is straight and midway of its length. The chilled iron at the apex of the wedge with a few exceptions consists of two zones. The portion nearest the apex enti- rely free ofiany grey spots shall be designated as clear chili. The portion starting with the end of the clear chill and continuing to the location where the last spot of cementite or white iron is visible shall be designated as the mottlid zone. The extent of the mottled zone may vary from virtu- ally nothing to an amount equal to and even greater than the amount of the clear chill. If the wedge is measured at the junction of the grey frac- ture with the first appearance of chilled iron, the measurement shall be designated as total chill. In all cases, the chill shall be expressed in millimetres as measured across the wedge. For structural control purposes it is generally satisfactory to measure the wedge where the structure is

*Methods of physical tests for foundry sands.

IS : 5699 - 1970

approximately 50 percent white iron and 50 percent grey iron. In report- ing the chill measurement, the size of the test specimen shall be indicat- ed. A chill reported as W3-12 would indicate that wedge W3 was used and the width at the junction of the chilled and grey portions of the frac- ture was 12 mm.

3. CHILL TEST

3.0 Application - This method is better adapted than wedge test to irons having silicon contents of 2.5 percent and over and carbon contents of 3.5 percent and over. It is also useful for control purposes in high pro- duction foundries making iron somewhat lower in carbon and silicon than indicated above. This method is also preferable for applications in which the casting is to have a specified depth of chill.

3.1 Test-Specimen - The patterns for the test specimens shall be made of metal and shall be of dimensions given in Table 2. The length of the specimen shall not differ from the values indicated in Table 2 by more than f 3 mm, and the tolerance on other dimensions shall be f 1 mm. ‘The specimen shall be cast with the chilled face in a horizontal position. For high production work a gang core box and pattern may be used in which case a test specimen with the chilled face in a vertical position may be found more convenient.

3.2 Cores - The test shall be made in a core. For general application a single core may be more satisfactory than a gang core. If a gang core is used, the amount of sand between test specimens shall be 25 mm minimum or 2.5 x A ( see Table 2 ), whichever is greater.

3.3 Chill Plates - Chill plates may be cast iron, steel, copper, or gra- phite. The surface of the chill plate shall be machined. When single test specimens are cast, the chill plate shall extend at least 25 mm beyond the test specimens in all directions and shal! be at least 25 mm thick. For high production work, a sufficient number of chill plates should be available to keep the temperature of the plate below 250°C. A water-cooled steel plate may be found more satisfactory for high production work. The chill plate shall be kept free of fire cracks and all foreign matter as the depth of chill is markedly affected by the presence of films of burned oil or other accumulations. The- best practice is to clean off the plate with a wire blush as soon as the core and test specimen is removed.

3.4 Pouring Practice - The specimen shall be poured in accordance with 2.3.

3.4.1 Iron shall not be poured directly on the chill plate as the depth of chill may be affected or the test specimen may burn on chill plate. It

6

IS : 5699 - 1970

may be desirable to place a I\-eight on the core when pouring it as there may be a tendency for the core to lift as it is being poured. The opening in the core shall be free of sand fins and shall set flat on the chill plate. In the event the core does not ,fit the chill plate, it shall be rubbed until it does.

3.5 Cooling of Test Specimen-- This shall be done in accordance with 2.4.

TABLE 2 RECOMMENDED DIMENSIONS FOR CHILL TEST SPECIMEN

( Clause 3.1 )

All dimensions in millimetres.

I Gl

rw

CHILL &sT T A B H L D d G SO.

IC 5 6.5 3 30 65 20 12.5 0.8 2c 6’5 8 5 40 75 22.5 12.5 0.8

3c 9.5 11 8 45 90 22.5 12’5 1.6

4c 12’5 14.5 11 50 100 25 16 1%

5c 19 21 17.5 65 125 25 16 2’4

OF

RECOMMENDED S CHILL DEPTH

R.%NGE

5 2.5 to 10

5 3 3, 12

5 5 ,, 20 5 6 ,, 24

5 10 ,, 40

3.5.1 If rapid testing is desired, the specimen may be quenched in water, starting with the edge farthest from the chilled edge.

7

IS : 5699 - 1970

3.6 Measurement of Chill - The test specimen shall be broken in such a manner that the fracture is straight and follows the notch in the test specimen. The chill from the chilled face to the first appearance of a grey spot shall be designated as cfe~r chill. The distance from chilled face to the last appearance of a spot of white iron shall be designated as total chill. The portion of the chill affected zone between the clear chill and the total chill shall bi designated as the mottled tone. For general structure and quality control purpose the chill shall be measured from the chilled face to a location where the structure is approximately 50 percent white iron which is roughly half-way through the mottled zont?. If the chill test is used for the control of iron for castings having a chilled surface for wear resistant purposes, it would be desirable to measure and record clear chill. If the casting with a chilled surface is to have some machining ope- ration in the proximity of the chilled surface, it may also be necessary to specify maximum depth of total chill as well as depth of clear chill. In all cases, the depth of chill shall be expressed in millimetres and the size of the test specimen used shall be indicated.

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