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Grey Iron Casting Terms

As–Cast Condition – Casting without later heat treatment.

Brinell Hardness Number (BHN) – A value given to a gray iron casting after undergoing a Brinell hardness test. Higher numbers indicate a harder material.

Brinell Hardness Test – A method used to measure how hard a material is. Typically for gray iron castings, a 3000kg metal ball is impressed on the surface of a flat gray iron piece; after removing the ball, the indentation in the metal is recorded and measured, determining a hardness value.

Chaplet – A small metal insert or spacer used in the molding process used to give support to the core.

Cope – The top half of a piece which has been forged or caste horizontally.

Deflection – The amount of bending or deformation that an iron casting endures due to an external load. Deflection is an important consideration for companies that plan on supporting a load with a gray iron casting.

Drag – The bottom half of a mold created horizontally.

Ductility – The ability of a gray iron casting to deform without being fractured. Iron castings have a considerable amount of ductility.

Ferrous – Any material that is made of or contains iron.

Foundry – A place where molten metal is poured into a mold, creating a metal casting.

Galling – A condition that results from excessive friction between metal surfaces. It creates surface deformation(s) and can result in temporary adhesion. Gray iron is renowned for its resistance to galling.

Hypereutectic Iron – Refers to an iron metal that is composed of more than 4.3 percent carbon.

Hypoeutectic Iron – Any iron alloy that is made up of 4.3 percent carbon or less.

Malleable – A property describing metals that can be pressed, hammered, formed, rolled, bent, etc.

Modulus of Elasticity – Measures the ration of stress to strain for an elastic material. Modulus of elasticity also describes stiffness of a material.

Permeability – The mold–metal property which allows passage of mold/core gasses during the pouring of molten metal.

Pilot Casting – Also known a sample casting in which a pattern produced by a production die is used to check the accuracy of the quality and dimensions of a potential order run casting.

Porosity – Holes formed in casting due to trapped gasses or chemical reactions between the molten metal and internal substances or objects such as chaplets.

Pounds per Square Inch (PSI) – The pressure a material applies on the walls of a closed enclosure. Atmospheric pressure at sea level is 14.7 psi.

Shrinkage – The decrease in the size of a material. Gray iron goes through little if any shrinkage when going through solidification.

Tensile Strength – The amount of stretching and bending that a material can undergo before breaking or tearing. The tensile strength for gray iron castings range from about 20,000 psi to 60,000 psi.