Astm A159-83-2001
Astm A159-83-2001
Astm A159-83-2001
This standard has been approved for use by agencies of the Department of Defense. This specification replaces Federal specification
AA-I-653A.
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TABLE 2 Brake Drums and Clutch Plates for Special Service
B
G2500a 3.40 HB 170-229 Type VII, size 2–4 lamellar pearlite
4.6–4.0 BID or as agreed A distribution ferrite if present not to exceed 15%
C
G3500b 3.40 HB 207-255 Type VII, size 3–5B lamellar pearlite
4.2–3.8 BID or as agreed A distribution ferrite or carbide if present not to exceed 5%
G3500c 3.50C HB 207-255 Type VII, size 3–5B lamellar pearlite
4.2–3.8 BID or as agreed A distribution ferrite or carbide, if present not to exceed 5%
A
The chemical analysis for total carbon shall be made on chilled pencil-type specimens or from thin wafers approximately 1/32 in. (0.8 mm) thick cut from test coupons.
Drillings are not reliable because of the probable loss of graphite.
B
See Method A 247.
C
Grades G 3500b and G 3500c normally require alloying to obtain the specified hardness at the high carbon levels specified.
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APPENDIX
(Nonmandatory Information)
X1.1 Definition TABLE X1.2 Usual Composition of Brake Drums and Clutch
Plates for Special Service
X1.1.1 gray iron—a cast iron in which the graphite is
present as flakes instead of temper carbon nodules as in Chemical Compo- Grade Grade Grade
malleable iron or small spherulites as in ductile iron. sition, % G2500a G3500b G3500c
X1.2 Chemical Composition Carbon, total (mandatory) 3.40 min 3.40 min 3.50 min
Silicon (as required) 1.60–2.10 1.30–1.80 1.30–1.80
X1.2.1 The ranges in composition generally employed in Manganese (as required) 0.60–0.90 0.60–0.90 0.60–0.90
producing the various grades of most automotive gray iron Sulfur, max 0.12 0.12 0.12
Phosphorus, max 0.15 0.15 0.15
castings are shown in Table X1.1. The composition ranges for Alloys as required as required as required
such special applications as heavy duty brake drums and clutch
plates and camshafts are shown in Table X1.2 and Table X1.3,
respectively. The contents of certain elements for these appli- TABLE X1.3 Usual Chemical Composition of Alloy Gray Iron
cations are critical in terms of service requirements and the Automotive Camshafts
ranges are specified in the standard.
X1.2.2 The specific composition range for a given grade Grade G4000d, %
may vary according to the prevailing or governing section of Total carbon 3.10–3.60
the castings being produced. Silicon 1.95–2.40
X1.2.3 Alloying elements such as chromium, copper, Manganese 0.60–0.90
Phosphorus 0.10 max
nickel, tin, molybdenum, or other elements may be employed Sulfur 0.15 max
to meet the specified hardness or microstructural requirements Chromium 0.85–1.25
or to provide the properties needed for particular service Molybdenum 0.40–0.60
Nickel 0.20–0.45 optional
conditions. Copper residual
X1.3 Microstructure
X1.3.1 The microstructure of the various grades of gray iron after solidification, the design and nature of the mold and the
are generally a mixture of flake graphite in a matrix of ferrite, casting, and by other factors such as inoculation practice in
pearlite, or tempered pearlite. The relative amounts of each of addition to the composition of the iron.
these constituents depends on the analysis of the iron, casting X1.3.4 Alloying with nickel, chromium, molybdenum, tin,
design, and foundry techniques as they affect solidification and copper or other alloys usually promotes a more stable pearlitic
subsequent cooling rate and heat treatments if any. structure and is often done to obtain increased hardness,
X1.3.2 The distribution and size of graphite flakes like the strength, and wear resistance especially in heavy sections
matrix structure of gray iron depends greatly on the solidifi- subjected to severe service.
cation rate and cooling rate of the casting. If a section solidifies X1.3.5 Alloying is sometimes used to obtain structures
very rapidly an appreciable amount of carbide causing a containing a controlled percentage of carbides as in camshaft
mottled fracture or chilled corners can be present. If a section or valve lifter castings.
cools slowly, as in a massive heavy-section casting, an appre- X1.3.6 Primary carbides or pearlite or both, can be decom-
ciable amount of ferrite may be present. In like manner, light posed by appropriate heat treatment. Gray irons of suitable
sections will contain small graphite flakes while graphite will composition and structure can be hardened by liquid quenching
form in much larger flakes if the same iron is poured into a or by flame or induction selective hardening.
heavy casting.
X1.3.3 For these reasons the strength and hardness of gray X1.4 Mechanical Properties
iron are greatly influenced by the rate of cooling during and X1.4.1 The mechanical properties listed in Table X1.4 can
Grade Carbon Silicon Manganese Sulfur, max Phosphorus, max Approximate Carbon
Equivalent
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TABLE X1.4 Mechanical Properties for Design Purposes
Grade Hardness RangeA Tensile Strength, min, psi Transverse Strength, Deflection, min, in.
(kgf/mm2) min, lb (kg)B (mm)B
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of the casting and details of melting practice. In making a given quirements for Grade G4000d alloy cast iron camshafts.
casting, it is recognized that the foundry will find it necessary
to adjust the chemistry to narrower limits within the range of X1.8 Additional Information
analysis in Table X1.3. X1.8.1 Additional information concerning gray iron cast-
X1.7.3 As the performance of an automotive camshaft is ings, their properties and uses can be obtained from the
determined by the microstructure and hardness, producers do following sources:
not normally use tensile or transverse tests for quality control (1) Metals Handbook, 8th Edition, Vols 1, 2, and 5, published
purposes. Camshaft iron with chemistry as given in Table X1.3 by the American Society for Metals, Metals Park, Ohio.
would be expected to have the following minimum mechanical (2) Cast Metals Handbook published by the American Found-
properties. rymen’s Society, Des Plaines, Ill.
Tensile strength, min: (3) Gray & Ductile Iron Castings Handbook (1971) published
psi 40 000 by Gray and Ductile Iron Founders Society, Cleveland,
kgf/mm2 28 Ohio.
Transverse strength, min:
lb 2600 (4) Physical and Engineering Properties of Cast Iron, Angus,
kg 1180 British Cast Iron Research Association (1960), Alve-
Deflection, min: church, Birmingham, England.
in. 0.27
mm 6.9 (5) Engineering Data on Gray Cast Irons, G. N. J. Gilbert
Hardness, HB 241–321 British Cast Iron Research Association (1968), Alve-
BID 3.9–3.4 church, Birmingham, England.
(6) Gray, Ductile and Malleable, Iron Castings Current Ca-
X1.7.4 Microstructure——See 9.5 for microstructure re- pabilities. ASTM STP 455, (1969).
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