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इंटरनेट मानक Disclosure to Promote the Right To Information Whereas the Parliament of India has set out to provide a practical regime of right to information for citizens to secure access to information under the control of public authorities, in order to promote transparency and accountability in the working of every public authority, and whereas the attached publication of the Bureau of Indian Standards is of particular interest to the public, particularly disadvantaged communities and those engaged in the pursuit of education and knowledge, the attached public safety standard is made available to promote the timely dissemination of this information in an accurate manner to the public. “जान1 का अ+धकार, जी1 का अ+धकार” “प0रा1 को छोड न’ 5 तरफ” Mazdoor Kisan Shakti Sangathan Jawaharlal Nehru “The Right to Information, The Right to Live” “Step Out From the Old to the New” IS 210 (2009): Grey Iron Castings [MTD 6: Pig iron and Cast Iron] “!ान $ एक न’ भारत का +नम-ण” Satyanarayan Gangaram Pitroda ““IInnvveenntt aa NNeeww IInnddiiaa UUssiinngg KKnnoowwlleeddggee”” “!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता हहहहै””ै” Bhartṛhari—Nītiśatakam “Knowledge is such a treasure which cannot be stolen” IS 210: 2009 (SupersedingIS6331:1987) ~ ~ ~ (t)crtl~lIl ~ - g;:r#erur ) ( Wi/eif Indian Standard GREY IRON CASTINGS - SPECIFICATION ( F((th Revision) res 7;.080!0 O BIS 2009 BUREAU OF INDIAN STANDARDS MANAK BHAVAN. 9 BAHADUR SHAH ZAFAR MARG NEWDELHI110002 July 2009 PriceGroup5 PigIronandCutIronSectionalConunittee,MTD6 FOREWORD ThisIndianStandard(Fifth Revision) wasadopted bytheBureauofIndian Standards,afterthe draft finalized by the Pig Iron and Cast Iron Sectional Committee had been approved by the Metallurgical Engineering DivisionCouncil. ThisstandardwasfirstpubIishedin1950andsubsequentlyrevisedin1962,1970, 1978and 1993. ThePigIron andCastIronSectionalCommitteedecidedtoreviseIS210bymergingitwithIS6331 :1987. Afterpublication ofthisstandard, IS6331 :1987willbewithdrawn. The various diameters oftest bars according to the section size ofthe castings have been replaced by a single size oftest bar. Guidelines on the effect of section size ofthe casting on the tensile strength are, however,given inAnnexA. Acomparisonbetween grades isgiven inAnnex B. The production ofcastings in the highergrades ofgrey cast iron often involves special techniques. It is recommended,therefore, thatforeither largeorintricate castingsoracastinginvolvingboththese conditions, orwherethecastingshave towithstand exceptional conditions,the grade ofgrey cast ironselectedandany heattreatment involved should beagreed betweenthemanufacturerandthe purchaser. The highergradesof greycastiron(that is,Grades FG300,FG350andFG400) presentspecial difficultiesforsection 10mmand thinner. Forthebenefit ofthe purchaser,typical properties ofgrey cast iron have been added inAnnex C. Informationtobesuppliedbythepurchaserwhileorderinggrey ironcastingsaccordingtothis specification isgiveninAnnexD. Inthe formulation ofthis standard assistance has been derived from ISO 185 : 2005 'Grey cast irons Classification', issued bythe InternationalOrganization forStandardization. Forthepurposeofdecidingwhetheraparticularrequirementofthisstandardiscompliedwith,thefinal value, observed or calculated, expressing the result ofa test or analysis, shall be rounded offin accordance with IS2: 1960'Rulesforrounding offnumerical values(revised)'. Thenumberofsignificantplacesretainedin the rounded offvalue should be the same asthat ofthe specified value in this standard. IS210:2009 Indian Standard GREYIRON CASTINGS - SPECIFICATION ( Fifth Revision) 1 SCOPE namely, grades FG 150, FG 200, FG 220, FG 260, FG300,FG350andFG400. Thedesignationsystem Thisstandard coversthe requirements for grey iron forgreycastiron isgiven inIS4843. castings. 5 MANUFACTURE 2 REFERENCES The castingsshallbemade byany process,asagreed The following standards contain provisions which, between the supplier and the purchaser, that will through reference inthis text, constitute provisions produce castings complying with the requirements of this standard. At the time of publication, the ofthis standard and shall be inaccordance with the editions indicated were valid. All standards are pattern or working drawing as supplied by the subject to revision and parties to agreements based purchaser. on this standard are encouraged to investigate the possibility ofapplying the most recent editions of 6 CHEMICAL COMPOSITION the standards indicated below: 6,1 The composition ofcast iron shall be left tothe ISNo. Title discretionofthe manufacturer,but amaximum limit for phosphorus and/orsulphur may bespecified by 1387:1993 General requirements for the the purchaser, ifhe so desires. supply ofmetallurgical material (secondrevision) 6.2 Incaseofspecialcastings,thedetailedchemical composition shall be as agreed to between the 1500:2005/ Method for Brinell hardnesstest purchaserand the manufacturer. ISO6506-1:1999 for metallic materials (third revision) 7 WORKMANSHIP AND FINISH 1608:2005/ Metallic materiais - Tensile 7.1 The castings shall be accurately moulded in ISO6892:1998. testing at ambient temperature accordance with the pattern or working drawings (thirdrevision) supplied bythe purchaser,with the addition ofsuch 4843:1968 Code for.designation offerrous letters, figuresor marksas may bespecified. castings 7.2 The purchaser shall specify tolerances, 5139: 1969 Recommended procedure for machininglocationandallowanceswithreferenceto repair of grey iron castings by all important dimensions. On other dimensions oxyacetylene and manual metal tolerancesspecifiedinIS5519shall apply. arc welding 5519:1979 Deviations for untoleranced 8 HEATTREATMENT dimensionsofgrey iron castings Castings are generally supplied without havingany (firstrevision) heattreatment. However,ifrequiredbythepurchaser, 7754:1975 Method for designation of the heat treatment may becarriedout inaccordance microstructureofgraphite incast with20ftS 13655. iron 9 MICROSTRUCTURE 13655:1993 Guidelines for heat treatment of cast iron Where so required, the microstructure ofgrey iron castings and the location fortakingthe sampleshall 3 SUPPLY OF MATERIAL be as agreed to between the purchaser and the manufacturer. General requirements relating to the supply ofgrey iron castingsshall beas laid down in IS 1387. 9.1 Unless otherwise specified, the microstructure shall besubstantially free ofprimarycementiteand/ 4 GRADES ormassive steaditeandshall consist oftlakegraphite There shall be seven grades of grey iron castings inamatrix offerriteorpearlite ormixture thereof. IS210: 2009 are poured. Moulds for the test bars shall be 9.1.1 Unlessotherwise specified.thegraphite structure approximately at room temperature when poured. shall beprimarily DistributionAin accordance with More thanonetest barmaybe cast inasinglemould. IS7754. but each bar in the mould shall be surrounded by a 10 FREEDOM FROM DEFECTS thicknessofsandwhich isnotlessthan the diameter ofthe bar. 10.1 The castings shall be sound, clean and free from porosity. blow holes, hard spots. cracks. hot 12 FREQUENCY OF TESTING tears. coldshuts,distortion,sand and slag inclusions 12.1 The number oftests required for each melt or and other harmful defects. They shall be well batch ofcastings shall be as laid down in Table I, dressedand fettled, and shall be readilymachinable. various classes ofcastings being divided into five 10.2 No welding or repairs shall be carried out representative groups according to mass. without the prior permission of the purchaser. 12.2 In the case oflarge tonnage of castings being Weldingreferred to here includes fusion welding in producedcontinuously. the minimum numberoftest accordancewith the common foundry practice. The bars to be provided shall be one tensile test method of repair by welding (see IS 513Y) and representing every two hours of production from subsequent stress-relieving shall be as agreed to between the purchaserand the manufacturer. meltingfurnace. II PROVISION OF TEST BARS 13 SIZE OF TEST BARS A test bar from which the tensile test piece is 11.1 All test bars shall be cast separately in sand mouldsand the numberoftestbarsrequiredshall be machinedshall becastas auniformcylindrical barof as specified in 11.2.They shall be cast at the same 30 mm5diameter. Thetoleranceon the diametershall time and from the same melt as the castings they be + mm.Theminimum length ofthe test barshall represent. be230mm. 11.2 The test bar materialshall be identifiable with 14 TENSIL.E TEST that ofthe castings represented. The tensile test shall be carried out in accordance 11.3 When castingsare subjectedto heat treatment, with IS 1608. using a test piece conforming to the the test bars shall be heat-treated together with the dimensions inFig. 1read withTable2. Thetest piece castings they represent. shall be accurately machined, with a good surface 11.4 The test bars shall be cast in dried, baked or finish. The transition between the ends and the chemically bonded moulds made mainly of an parallel lengthshall be smooth,without undercutting aggregateofsiliceoussand with appropriatebinders. ora sudden step down in diameter. The average grain size of the sand shall be NOTE - Self-aligning grips are recommended to ensure approximateto thatofthe sand inwhich thecastings axial loading. Table I NumberorTests (Clause12.\) Group :\1:155 of Individ••1Castings Test Rftluinmtnts (II (2) (3) I" Up to 12.5 kg One test for eachof5 kg ofcastingsor part thereof Over 12.5 kg and up 1050 kg One test for every I tonne ofcastings or part thereof 3" Over 50 kg and up to 500 kg One lest for every 2 tonnes ofcastings orpart thereof -t', Over 500 kg and up to I tonne One test for every3 tonnes ofcastings orpart thereof 5 Over I tonne One test for every 4 tonnesofcastings or part thereof or one test forevery casting weighing4 tonnesormore t•InadditionGroups 1.2. 3and -tall castings represented byone test shall bepoured from the same ladle or same heat as the bar or bars provide lor the test. 15 210:2009 FIG. I MACHINEDTENSIl.E TEST PIECE Table2 DimensionsofMachinedTensileTest Piece (Clause 14) All dimensions in rnillimctres. Gauge Machining Minimum '\inimum Plain Ends Screwed Ends l>iameter -Tnlerance Parallel Radius A .A Minimun~ " D for the I.ength ' Milllmum 'Minimum Minimum Gauge Diameter I.ength Diaat Length l>iameter Root L R d, L d, L " (I) (2) (3) (4) (5) (6) (7) (8) 20 ± 0.5 55 25 23 65 25 30 NOTE - With screwed-ends. any form of thread may be used provided that the diameter at the rootofthe thread is not less than that specified. 15 TENSILE STRENGTH accordancewiththemethodgiven inIS 1500. Brineil hardness values for different grades ofgrey iron When tested in accordance with the requirements castingsshall be as specified in Table 3. of14 the test piece shall comply with the minimum requirements specified in Table 3. The tensile 16.1.1 The hardness test shall be conducted at strengthspecifiedisthatobtained from testbarscast specific point on the castings. This specific point separatelyfrom thecastingsto which theyrefer.The shall be such that they are amendable for hardness test values represent, therefore, only the quality of checkingto routine procedureandshall beasagreed the metalfrom whichthe castingshavebeenpoured. to between the purchaser and the manufacturer. 16 HARDNESS TEST 17 TRANSVERSE TEST 16.1 TheBrinell hardnesstestshall be carriedoutin Ifrequired,thetransversetest may be carriedoutby the manufacturer in accordance with the method Table3 MechanicalTestRequirements given inAnnex E. The minimum test requirements (Clauses15and16.1) shall beagreed uponat the timeofenquiry and order. Grade Tensile Strrngth Brinrll 18 HYDROSTATIC TEST (su IS 4843) Min Hardness Mra(N/OJ.') HBW If specified at the time of enquiry and order the (I) (2) (J) castings may be tested for the hydrostatic test FG 150 150 IJO to 180 pressure.Therequirementsfor the test pressureshall FG 200 200 160 to 220 be mutually agreed to between the purchaser and FG 220 220 180 to no the manufacturer. FG 260 260 180 to 230 19 RETESTS FG 300 300 180 to 230 FG 350 350 107 to 241 19.1 Ifonbeingtested any test pieceshows obvious FG 400 400 207 to 270 signs ofa casting defect. the results ofthe test may be discarded and a further test be made. NOTE - Although mechanical properties are specified tor Grade FG 150thematerialshallbeonlytestedifrequiredby 19.2 lfany sound test piece fails. two further tests the purchaser. shallbe made.should eitherofthese testpieces fail. 3 IS210:2009 the castings represented shall not comply with the 21 MARKING requirements ofthis standard. 21.1 Eachcasting,iffeasible,shall belegiblymarked 19.3 In the absence offurther separately cast test withanumberofidentificationmarks which itcanbe bars, the manufacturer shall have the option of traced tothemelt,and the batch ofheattreatment,if submitting test bars, sectioned from an agreed done,from which itwasmade. positioninthe castings.The requirementsofthetest 21.2 By agreement between the purchaser and the shall be as agreed to between the purchaserand the manufacturer, castings complying with the manufacturer. However, the guidance may be requirements of this standard shall be, after obtainedfromAnnexA. inspection,legiblymarked with an acceptancemark. 20 .INSPECTION 21.3 BIS Certification Marking Byagreement with the manufacturer, the purchaser The castings mayalso be marked with the Standard or his representative shall have access at all Mark. reasonabletimes tothosepartsofthemanufacturer's works engagedon hisorder, heshall beat libertyto 21.3.1 The use ofthe Standard Mark is governed inspect the manufacturer at any stage, to witness bytheprovisionsofthe Bureaua/IndianStandards therequiredtests and torejectanymaterial thatdoes Act, 1986 and the Rules and Regulations made not comply with this standard. When the castings threrunder. The details of conditions under which are to be inspected during manufacture and tested the licence for the use of Standard Mark may be in the presence ofthe purchaser's representative, granted to manufacturers or producers may be this shall be stated in the enquiry and order. obtained from the BureauofIndian Standards. ANNEXA (Foreword,and Clause 19.3) APPROXIMATEVARIATIONOFSTRENGTH A-I The Indian Standard grades ofgrey cast iron flat plate ofsimilarsectionthickness. are basedon the minimumtensile strengthobtained A-2 Figure 2givesaguideto the likely variation in when metal iscast into test barsof30 mmdiameter. tensile strength in different sections when a given The strength developed by a given metal shall vary grade ofgrey iron is cast into a casting ofsimple with the cooling rate in the mould higher strengths shape and uniform thickness or containing cored being obtained ifthesame metal iscast intosmaller holed where the coolingrate inthe mouldofagiven barsthan 30mmdiameterand lowerstrengths ifthe section shall differ from that ina castingofsample metal iscast into bars larger than 30 mmdiameter. shape and uniform thickness, the diagram provides Similarly, the cooling rate ofa flat plate is slower only an approximate guide to the likely tensile than that ofa bar whose diameter is equal to the strength in different sections and design should be thicknessofthe platesothat the strengthdeveloped based on the measured tensile strength in critical inthe plate will be lower than that developed inthe parts ofthe casting. bar. A-2.1 Table4givesguidance tothe likely variation A-1.1 Thecoolingrateofacastinginamould(hence in tensile strength for different casting section the strength developed in any particular section thicknesses when a given grade ofgrey cast iron is thicknessbythemetal employedfor itsmanufacture) cast into a casting of simple shape and uniform isinfluencedalso bythe presenceofcores, changes thickness. For casting of non-uniform section or in section thickness, the pressure of bosses castings containing cored holes, the table provi~es projectionand intersection, such asthejunctionsof only an approximate guide to the likely ten~"e ribs and bosses. Thus, in castings of other than strength in different sections, and casting desl~n simpleshapeand uniformthicknessthecoolingrate should be based on the measured tensilestrength In ofany part can be expected to differ from that ofa critical parts ofthe casting. 4 IS210:2009 CROSS SECTIONAL THICKNESS,m m 5 15 25 50-75 100 125 150 350 350 l-\l E E z 300 300 II ro o, ~.. 250 250 :::x: I- (!) z -- -- w 200 200 a:: I- lI) -- -- W.J 150 150 Vi z W I- 100 100 0 15 30 50 75 100 125 150 BAR DIAMETER~ mm FI<1.2 VARIATIONOFTENSILESTRENGTHWITHCROSS-SECTIONALTHICKNESSOFGREYIRONCASTINGS Table4 AnticipatedTensilePropertiesfortheCastings (ForInfonnationOnly) (ClauseA-2.l) Gradc CastingSectionThidmrss Antieipaltd mm Tensile Strengtb r ~ Mr. (N/mm1) Includin~ Over Uptoand (I) (2) (3) (4) FG150 2.5 10 155 10 20 130 20 30 115 30 50 105 FG200 2.5 10 205 10 20 180 20 30 160 30 50 145 FG260 4.0 10 260 10 20 235 20 30 215 30 50 195 FG300 10 20 270 20 30 245 30 50 225 FG350 10 20 315 20 30 290 30 50 270 5