Malleable iron has unique properties that justify its application in the metal working industry. This chapter discusses the advantages, limitations, and mechanical properties of malleable iron; provides a description of the malleabilization process; and presents manufacturing guidelines for malleable iron castings.

The commercial relevance of cast irons is best understood in the context of the iron-carbon phase diagram, where their composition places them near the eutectic point, which sheds light on why they melt at lower temperatures than steel and why they can be cast into more intricate shapes. This chapter examines these unique properties and how they are derived. It begins by describing the basic metallurgy of cast iron, focusing on the eutectic reaction. It explains how to control the reaction and thus properties of cast iron by overcooling and inoculation. The chapter also discusses composition, microstructure, heat treatments, and the classification and casting characteristics of white, gray, ductile, malleable, compacted graphite, and special cast irons.

This chapter discusses the effect of composition and cooling rate on the microstructure and properties of cast irons and explains how they differ from steel. It describes the conditions under which white, gray, mottled (chilled), and nodular (ductile) cast irons are produced, and examines the growth mechanisms and structural details that set them apart. It also discusses the formation of compacted (vermicular) graphite and malleable iron, and compares and contrasts the composition, properties, and heat treatment of whiteheart and blackheart malleable types.

This article discusses the production, properties, and uses of high-alloy white irons. It explains how the composition and melt are controlled to produce a large volume of eutectic carbides, making these irons particularly hard and resistant to wear, and how the metallic matrix supporting the carbide phase can be adjusted via alloy content and heat treatment to optimize the balance between abrasion resistance and impact toughness. It also describes the effect of alloying elements and inoculants on various properties and behaviors and provides information on commercial alloy grades and applications.

Microstructures can be altered intentionally or unintentionally. In some cases, metallographers must diagnose what may have happened to the steel or cast iron based on the microstructural details. This chapter discusses how microstructure in steels and cast irons can be intentionally altered during heat treatment, solidification, and deformation (hot and cold working). Some specific examples are then shown to illustrate what can go wrong through unintentional changes in microstructure, for example, the loss of carbon from the surface of the steel by the process known as decarburization or the buildup of brittle carbides on the grain boundaries of an austenitic stainless steel by the process known as sensitization.

Casting is one of the basic processes used for the shaping of steel. It is economical in both cost and time of production. Numerous components are produced from cast steel because of the advantages of the process. These advantages can best be described under the following headings: design flexibility, metallurgical versatility and quality, and economic benefits. This chapter looks at these advantages of steel castings. Of major interest is the comparison of cast steel with wrought steel and weldments in terms of properties, availability, cost, and quality. The chapter also includes information on cast steel compared to other cast metals and other methods of steel fabrication.

This chapter presents definitions of terms related to the metallurgy and metallographic study of irons and steels.

This chapter describes the general characteristics of major types of steel annealing, including the process of normalization, which is a process that refines or normalizes the microstructure of steel. The first part of the chapter begins with an overview of the three-stage process of recovery, recrystallization, and grain growth. This is followed by discussions on annealing processes, namely subcritical annealing, critical-range annealing, full annealing, isothermal annealing, annealing for microstructure, and solution or quench annealing. Next, the chapter describes two undesirable reactions that occur during annealing: decarburization and scaling. Information on the gases and gas mixtures used for controlled atmospheres is then provided. The second part of the chapter focuses on the processes involved in normalizing, along with information on furnace equipment for normalizing. In addition, the chapter includes information on processes involved in induction heating of steel.

This appendix is a compilation of terms and definitions related to light microscopy of carbon steels.

This appendix is a compilation of terms and definitions related to metallurgy.