Compacted graphite iron (GCI) is a cast iron grade that is engineered through graphite morphology modifications to achieve a combination of thermal and mechanical properties that are in between those of flake graphite iron and ductile iron. This chapter discusses the advantages of compacted graphite iron over gray iron and ductile iron. It presents examples of low- and high-frequency thermal cycling, both of which affect the thermal stresses that castings are exposed to during temperature fluctations. Information on optimum carbon and silicon ranges as well as mechanical property standards for CGI are provided. The chapter describes the critical factors that control CGI and discusses methods of CGI manufacturing.

Many companies conduct only metallurgical evaluations in the wake of failures, discovering nothing more than the physical mechanism by which the failure occurred. The origin of failures, however, is often complex, involving not only physical mechanisms, but also human behavior and latent factors. Failures may also involve multiple parts, entire machines, or processes of any size and shape. The chapter examines the unique aspects of many failures and explains how they can sometimes be traced to systemic issues. It also covers the reasons why products fail, including improper service or operation, improper maintenance, improper testing, assembly errors, fabrication or manufacturing errors, and design errors. The case of the Tacoma Narrows Bridge collapse is presented to illustrate the consequence of overlooked factors, in this case, wind dynamics, and the importance of identifying root causes to prevent repeat failures.

The wear caused by contact stress fatigue is the result of a wide variety of mechanical forces and environments. This chapter discusses the characteristics of four types of contact stress fatigue on mating metal surfaces: surface, subsurface, subcase, and cavitation. Features and corrective actions for these contact stress fatigue are discussed. The chapter also lists some possible ways to reduce the cavitation fatigue problem.

This chapter discusses the work of a famous stainless steel pioneer, Edward G. Budd. The discussion covers his early years, his automobile body business, the arrival of novel kind of stainless steel in America, Earl Ragsdale's shot weld patent, the world's first stainless steel airplane, the world's first stainless steel rubber-tired train, the Flying Yankee, the Mark Twain Zephyr, the development of the Budd Company in the war years and postwar years, and a review of the Budd Era.

This chapter discusses the crystal structures of steel and cast iron, the iron-iron carbide equilibrium diagram, microconstituents or phases in the iron-iron carbide phase diagram, the iron-carbon carbide-silicon equilibrium diagram of cast irons, and the influence on microstructure by base elements and alloying elements. Graphitization, cooling rates, and heat treatment effects are covered. There also is discussion on inoculation benefits, flake graphite types and typical applications, evolution of cast iron types, ASTM specification A247 for graphite shapes, and selection of the best molding process. A large table lists typical material choices for various applications.

This chapter covers mechanical properties, microstructures, chemical compositions, manufacturing processes, and engineering of gating practices for several applications of gray, white, and alloyed cast irons. It begins with a description of material standards, followed by a section providing information on the practice of stress relieving. Next, the chapter details various ways of eliminating slag entrainment while designing gating and venting systems. Several factors related to the establishment of the optimum pouring rate and time are then covered. Further, the chapter discusses the technology of unalloyed or low-alloyed gray iron castings and white iron and high-alloyed cast irons. Finally, it describes the casting defects that are associated with cast iron and the processes involved in solving these defects. The article includes a number of figures illustrating the topics discussed.

Distortion failures are readily identified by the inherent change in size and/or shape. They are serious because they can lead to other types of failure or may even cause complete collapse of structures, such as bridges, ladders, beams, and columns. Distortion failures may be classified in different ways. One way is to consider them either as dimensional distortion (growth or shrinkage) or as shape distortion (such as bending, twisting, or buckling). They may also be classified as being either temporary or permanent in nature. This chapter discusses the nature, causes, and effects of all of these types of failures as well as the methods to manage them.