Castability of alloys is a measure of their ability to be cast to a given shape with a given process without the formation of cracks/tears, pores/shrinkage, and/or other significant casting defects. This article discusses the factors which affect the fluidity of an iron melt: alloy composition and initial melt condition. Besides the basic alloy properties, the effective castability of high-alloy irons can be significantly improved through casting and casting system design. The article describes the product design and processing factors of high-alloy graphitic irons and high-alloy white irons. It explains the heat treatment of high-silicon irons for high-temperature service and concludes with a discussion on machining and finishing of high-alloy iron castings.

The high-alloyed white irons are primarily used for abrasion-resistant applications and are readily cast into the parts needed in machinery for crushing, grinding, and handling of abrasive materials. This article discusses three major groups of the high-alloy white cast irons: nickel-chromium white irons, chromium-molybdenum irons, and high-chromium white irons. Mechanical properties for three white irons representing each of these three general groups are presented as bar graphs. The article also describes the various heat treatments of a martensitic microstructure, including austenitization, quenching, tempering, annealing, and stress relieving.

The high-alloy irons can be categorized into two main groups: the high-alloy graphitic irons (covering both gray and ductile grades) and the high-alloy white irons. High-alloy irons are used in applications with demanding requirements, such as high resistance to wear, heat, and corrosion, or for combined properties. This article discusses the specification and selection of high-alloy irons. The common alloying elements and their effect on the stable and metastable eutectic temperatures are listed in a table. The article provides information on the compositions, properties and applications of high-alloy graphitic irons and high-alloy white irons.

High-alloyed white cast irons are an important group of materials whose production must be considered separately from that of ordinary types of cast irons. The metallic matrix supporting the carbide phase in the high-alloy white cast irons can be adjusted by alloy content and heat treatment to develop proper balance between resistance to abrasion and toughness needed to withstand repeated impact. This article provides a brief discussion on the heat treatment, mechanical properties, and chemical compositions of high-alloy white cast irons such as nickel-chromium white irons and high-chromium white irons.

This article reviews the production stages of iron foundry casting, with particular emphasis on the melting practices, molten metal treatment, and feeding of molten metal into sand molds. It discusses the molten metal treatments for high-silicon gray, high-nickel ductile, and malleable irons. Foundry practices are also described for compacted graphite, high-silicon ductile, and high-alloy white irons.

This article presents a discussion on the melting, pouring, and shakeout practices; composition control; molds, patterns, and casting design; heat treatment; and applications of different classes of nickel-chromium white irons and high-chromium white irons.

Cast iron, which usually refers to an in situ composite of stable eutectic graphite in a steel matrix, includes the major classifications of gray iron, ductile iron, compacted graphite iron, malleable iron, and white iron. This article discusses melting, pouring, desulfurization, inoculation, alloying, and melt treatment of these major ferrous alloys as well as carbon and alloy steels. It explains the principles of solidification by describing the iron-carbon phase diagram, and provides a pictorial presentation of the basic microstructures and processing steps for cast irons.

This article discusses the classification schemes for cast irons and describes the characteristics of major categories, including gray iron, white iron, ductile iron, compacted graphite iron, mottled iron, malleable iron, and austempered ductile iron. It also discusses some of the basic principles of cast iron metallurgy. When discussing the metallurgy of cast iron, the main factors of influence on the structure include chemical composition, cooling rate, liquid treatment, and heat treatment. In terms of commercial status, cast irons can be classified as common cast irons and special cast irons. Special cast irons differ from the common cast irons mainly in the higher content of alloying elements. Alloying elements can be added in common cast iron to enhance some mechanical properties. They influence both the graphitization potential and the structure and properties of the matrix.