International Journal of Civil & Environmental Engineering IJCEE-IJENS Vol: 10 No: 03

Effect of Graphite Nodularity on Mechanical

Properties of Ductile Iron for Waterworks
Fittings and Accessories
A. I. Al-Ghonamy1, M. Ramadan1,2*, N. Fathy3 , K. M. Hafez1,2 and A. A. El-Wakil1,4

Abstract— Waterworks fittings and accessories are important productivity. Although there are currently aplenty of new and
applications for ductile irons. Although, in the design of these advanced materials, cast irons still the most used casting alloy
components the graphite nodularity is a critical attribute for for its considerable reduction in their production. Their
material selection, the International Standard ISO 2531 does not
popularity stems from an ability to cast complex shapes at
include the minimum required value of graphite nodularity and
its definite effect on mechanical properties. In this research the
relatively low cost and the wide range of properties that can
effect of graphite nodularity on tensile strength, elongation, be achieved by careful control over composition and cooling
impact strength and wear rate was studies. Different samples rate.
from four heats of cast iron containing several of graphite
nodularities were cast. Different degrees of graphite nodularities In Ductile Iron (DI) the graphite is in the form of
from low graphite nodularity of about 21% up to high graphite spherical nodules rather than flakes, thus inhibiting the
nodularity of 94% were produced by treatment cast iron by creation of cracks and providing the enhanced ductility that
different amount of spheroidizing (Mg) and antispheroidizing gives the alloy its name. In order to improve the properties of
(Ti) elements. It is concluded that all properties relating to
cast iron a method was developed to give the graphite a
strength and ductility decrease as the graphite nodularity
increase, and those properties relating to failure, such as tensile spherical shape by adding cerium to the melt. Later on, the
strength and impact strength are more affected by changing of method was improved by using magnesium instead of cerium,
graphite nodularity. The minimum graphite nodularity of 60% cast iron with spherical shaped is today well known as ductile
can be considered for design as satisfactory values of ductile iron cast [1]. DI is not a single material, but a family of materials
fittings and accessories for all DN values. offering a wide range of properties obtained through
microstructure control. The common feature that all ductile
Index Terms— graphite nodularity, mechanical properties, ductile irons share is the roughly spherical shape of the graphite
iron, fittings nodules. These nodules act as crack-arresters and make DI
ductile. This feature is essential to the quality and consistency
of DI, and is measured and controlled with a high degree of
I. INTRODUCTION assurance by competent DI foundries. By changing the
graphite nodularity from spheroid to compacted one until
Materials serve as an enabling technology contributing to about 20 % graphite nodularity, a relatively new type of cast
solutions in problems of concern to society. The civil and iron can be found called Compacted Graphite Iron (CGI).
environmental profession can contribute to improvements in
the quality of life by seeking solutions to infrastructure Graphite morphologies in CGI are randomly
deterioration, hazard mitigation, structural safety, oriented, elongated and interconnected within eutectic cells as
sustainability, environmental protection, and construction in gray iron, but stubby, blunt-edged and have rounded ends
and rough interfaces with matrix, and generally considered as
Manuscript received April 30, 2010
a transitional form between flake and nodular. Therefore, CGI
A. I. Al-Ghonamy1 (e-mail: abdulaz@uoh.edu.sa),
M. Ramadan1,2* Corresponding author
provides higher strength and ductility than gray iron and better
(e-mail m.ramadan@uoh.edu.sa), thermal conductivity and damping properties than nodular
N. Fathy3 (e-mail n.ismail@uoh.edu.sa), iron, which represents an optimal combination of strength,
K. M. Hafez1,2 (e-mail k.hafez@uoh.edu.sa), ductility and thermal properties for certain engineering
A. A. El-Wakil1,4 (e-mail abdelaziz_elwakil@yahoo.com) applications and has received considerable attention especially
1
College of Engineering, University of Hail, P.O. Box 2440 Hail, during recent years [2]. Although the tensile strengths of
Saudi Arabia compacted graphite iron (CGI) are lower than those of
2
Central Metallurgical R& D Institute, P.O. Box 87 Helwan, Egypt spheroidal, or ductile, graphite irons (DI), CGI has several
3
Physic Dept. College of Science, University of Hail, P.O. Box 2440
superior characteristics such as improved castability, damping
Hail, Saudi Arabia
4
National Institute of Standards, Tersa Street, El-Harm, P.O. Box capacity and machinability [3]. This means that decreasing
136, Giza 12211, Egypt graphite nodularity in DI can lead to CGI, which can be used
in many applications.
International Journal of Civil & Environmental Engineering IJCEE-IJENS Vol: 10 No: 03

This research work is concerning with the effect of graphite C. Mechanical Properties
nodularity on mechanical properties of ductile iron Unnoutched charpy specimens (55x10x10mm) and tensile
waterworks fittings and accessories. Also, indentifying the specimens conforming to ASTM A439-71 dimensions were
value of graphite nodularity that leads to the minimum values machined from as cast samples. Unnotched charpy specimen
of mechanical properties required standard to DI for were tested at room temperature using" Shimadzu 30 kgf.m
waterworks fitting and accessories. capacity charpy test machine. Tensile testing was performed
on a 50 KN SHEMADZU universal testing machine with
II. EXPERIMENTAL constant speed. The ultimate tensile strength, 0.2% proof
stress and elongation to failure were recorded. Hardness
A. Casting procedure measurements were made using a standard hardness tester
with a 10-kg load. Each measurement represents the average
The alloy was melted in a 350 kg capacity medium of seven indentations. Wear tests were conducted on
frequency induction furnace with a silica lining and treated tribometer testing machine with 70 mm outer diameter. All
with Fe–Si–Mg alloy and Fe–Si–Mg–Ti alloys using a texts were carried out under pure sliding and dry condition
sandwich method. Four heats of cast iron containing several of between the specimens and the used adhesive disc. The
graphite nodularities were cast into 25mmY-blocks made revolving speed of adhesive disc was 265 rpm and 1.5 normal
from green sand moulds. A treatment alloy containing about load. Before testing, specimens were ground silicon carbide
5% Mg and 0.3% Ce balanced by about 9% Ti was used in abrasive paper 1000CW.
order to obtain different amounts of residual Mg, different
amounts of residual Ti, and low levels of cerium in the final III. RESULT AND DISCUSSION
cast iron (see Table 1). All the Y-block specimens were
poured from the same base melt to keep the carbon equivalent Four levels of graphite nodularity in a ferritic
and alloying elements constant. The samples material in pearlitic matrix were obtained and were examined in the as-
current research was used in other research in heat treated cast condition by metallographic techniques (see Fig. 1). The
condition [4]. determination of nodularity, ferrite and pearlite were counted
using image analyzer program (Table 2). It is evident that
TABLE I ferritic fraction for all levels of graphite nodularity are
CHEMICAL ANALYSIS OF CAST IRON SAMPLES AND approach to the same value. As shown in Figure 1(d), the
CHEMICAL COMPOSITION OF TREATMENT ALLOYS, WT-%. graphite phase in law graphite nodularity iron (CGI) appears
95% 77% 52% 21% as individual ‘worm-shaped’ or vermicular particles.
graphite graphite graphite graphite (a)
nodularity nodularity nodularity nodularity
C 3.61 3.59 3.58 3.60
Si 2.26 2.19 2.25 2.21
Mn 0.22 0.22 0.21 0.22
S 0.01 0.02 0.02 0.01
P 0.03 0.03 0.03 0.03
100 m
Ni 1.51 1.48 1.50 1.50
Mo 0.31 0.31 0.30 0.32 (b)
Cr 0.03 0.03 0.03 0.03 (b)
Ti 0.02 0.22 0.21 0.24
Mg 0.03 0.05 0.03 0.02
Fe Bal. Bal. Bal. Bal.

B. Metallographic analysis
100 m
Specimens used for metallographic examination in (C)
the as-cast condition were ground, polished and hen etched
with 3% nital. After etching the specimens were examined and
photo micrographed using optical microscope fitted with a
35mm camera. The nodularity was determined by the ratio
between the number of type I and II (nodular) graphite
particles (ASTM A247) and the total number of graphite
particles [5]. 100 m
International Journal of Civil & Environmental Engineering IJCEE-IJENS Vol: 10 No: 03
Fig.1 Typical as-cast structure for samples containing different
graphite nodularity. Fig. 3 Influence of graphite nodularity on the Elongation

The particles are elongated and randomly oriented as

in gray iron; however they are shorter and thicker, and have
The graphite morphology plays an important rule and
rounded edges. the more the graphite shape deviates from the ideal spherical
shape the lower is the ductility and strength [6,7] . Damaging
TABLE II micromechanisms are strongly affected by microstructure;
QUANTITATIVE MEASUREMENT OF both graphite elements and metal matrix are involved[8]. The
STRUCTURE FEATURE OF CAST IRON. difference in strength properties for different graphite
Specimens Nodularity Ferrite Pearlite Graphite nodularity levels seams to be principally due to the easier
(%) (%) (%) (%) crack propagation with lower degree of graphite nodularity.
A 95 64.8 25.7 9.4
25
B 77 65.8 25.0 9.2
C 52 68.5 22.0 9.5
D 21 70.0 20.7 9.3 20

Impact strenght,J
15

800
750 Tensile strength
0.2% offset yield strenght 10
700
Strength, N/mm2

650
Minimum tensile strength required
600
by ISO 3531 International Stander 5
550 for fitting and accessories
500
450 0
400 10 20 30 40 50 60 70 80 90 100
350
Graphite nodularity
300
250 Fig.4 Influence of graphite nodularity on the impact strength.
200
150
100
Fig. 5 shows the wear rate as a function of graphite
10 20 30 40 50 60 70 80 90 100 nodularity in dry wear test condition. It is clear that decreasing
Graphite nodularity in graphite nodularity results in a significant increase in wear
rate. This is due to a relatively better continuity condition of
the matrix in case of high graphite nodularity iron and its
Fig. 2 Influence of graphite nodularity on the strength.
relatively smaller stress concentration effect of graphite [9].
The as-cast tensile properties, impact strength wear
rate were measured and were summarized as a function of 350
graphite nodularity in Figs.2 - 5. The current study and
previous study[5] in a good agreement that all of properties 300
Wear rate,mm3/s*10-3

related to strength, decreases as the proportion of non-nodular 250

graphite increase, and those relating to failure, such as tensile
strength and impact strength, are more affected by small 200
amount of non-nodular graphite.
150
14
100
13
12
50
11
Minimum e lo ngatio n re quire d by
10 IS O 3531 Inte rnatio nal S tande r
0
Elongation,%

9 fo r fitting and ac c e s s o rie s

10 30 50 70 90 110
8
7 Graphite nodularity
6
5 Fig.5 Influence of graphite nodularity on the wear rate.
4

3
It has been established that all of the mechanical and
2
1
physical properties characteristic of DI are a result of the
0 graphite being substantially or wholly in the spheroidal
10 20 30 40 50 60 70 80 90 100
/nodular shape such that its bulk physico-mechanical
Graphite nodularity
International Journal of Civil & Environmental Engineering IJCEE-IJENS Vol: 10 No: 03
properties are determined primarily by the steel -like matrix. graphite nodularity of 60 % can be considered for design as
Any departure from this shape or a proportion of the graphite satisfactory values of DI fittings and accessories for all DN
will cause a drastic deviation from these properties. values.
Occasionally, a consistent spheroidal type of graphite is not

obtained in regular production of DI. This may result from The impact strength Shown in Fig. 4 and wear rate shown
insufficient or excessive nodulariser, or non -uniform in Fig. 5 as a function of graphite nodularity have relatively
treatment or the presence of inhibiting elements. Also, the considerable values at graphite nodularity value of 60%.
problem may be the choice of nodulariser, mode of addition, IV. CONCLUSION
and environmental and/or human considerations. However,
unlike other renowned engineered materials, requirements Effect of graphite nodularity on mechanical
concerning graphite “nodularity” in DI seldom appear in properties of as-cast ductile iron for waterworks fittings and
users’ specifications. In essence, commercial DI castings are accessories has been investigated and the following
designed on the basis of their properties and rarely on the conclusions may be drawn:
basis of their graphite morphology, shape or structure. 1. Different degrees of graphite nodularity, from low graphite
Graphite nodularity, usually evaluated by visual assessment, nodularity of about 21% to high graphite nodularity of about
might be utilized as a simple form of selection for castings to 95% were produced by treatment cast iron of suitable base
determine which should and should not be accepted [10, 11]. composition by different amount of spherodizing(Mg) and
antispherodizing(Ti) elements.
Waterworks fittings and accessories are important 2. All of properties related to strength, decreases as the
applications for ductile cast irons. Although, in the design of proportion of non-nodular graphite increase, and those relating
these components the graphite nodularity is a critical attribute to failure, such as tensile strength and impact strength, are
for material selection, the international standard ISO 2531 more affected by small amount of non-nodular graphite.
does not include the minimum required value of graphite 3. The minimum graphite nodularity of 38 and 52 % can be
nodularity and its definite effect on mechanical properties. As considered as satisfactory values of DI fittings and accessories
a result there are lot of confusion and misconceptions between for DN 100 to 1000 and DN> 1000 respectively.
the produces and investigators who decided the quality of the 4. The minimum graphite nodularity of 60 % can be
products and its matching to the standard. According to considered for design as satisfactory values of DI fittings and
international standard ISO 2531 the DI for waterworks fittings accessories for all DN values.
and accessories, the graphite of DI must in a good nodularity. 5- The obtained data help in establishing complete criteria to
It is still badly needed to determine a specified range for investigate and select DI for waterworks fittings and
graphite nodularity which should and should not be accepted. accessories.

TABLE III Acknowledgements

MINIMUM TENSILE PROPERTIES OF PIPE
AND FITTINGS, ISO2531. The authors would like to thank staff of Central
Minimum Minimum elongation
Metallurgical R&D Institute, CMRDI for their kind help in
tensile after fracture,% measurements, Prof. Dr. Adel A. Nofal of Foundry
strength, Technology Lab., CMRDI, Egypt, for the useful discussion
Type of casting N/mm2 and technical support.
DN 100 to 1600 DN 100 DN> 1000
to 1000 REFERENCES
Pipe 420 10 7
centrifugally [1] Fredriksson H, Stjerndahl J, and Tinoco J. On the solidification
Fittings and 400 4 5 of nodular cast iron and its relation to the expansion and contraction.
accessories Materials Science and Engineering A 2005;413–414: 363–372.
[2] Sun X J, Li Y X, and Chen X. Controlling melt quality of
Table 3 shows the minimum tensile properties of compacted graphite iron. Materials Science and Engineering A
pipe and fittings according the international standard ISO 2007; 466:1–8.
2531. For fittings and accessories the minimum accepted [3] Hatate M, Shiota T, Takahashi N and Shimizu K. Influences of
graphite shapes on wear characteristics of austempered cast iron.
value of tensile strength is 400 N/mm 2 and the minimum
Wear 2001; 251: 885–889.
accepted value of elongation is 4 or 5 depend on the diameter [4] Ramadan M, Nofal A A, Elmahalawi I, Abdel-Karim R.
DN. Here by applying these values of tensile strength and Influence of graphite nodularity on microstructure and processing,
elongation in Fig. 2 and Fig 3, the minimum Value of graphite window of 1.5% Ni–0.3% Mo austempered cast iron. Materials
nodularity can be determined. As a result the minimum Science and Engineering A 2006; 435–436:
graphite nodularity of 38 and 52 % can be considered as 564–572.
satisfactory values of DI fittings and accessories for DN 100 [5] Stefanescu R, Hummer and Nechtelberger E. ASM handbook,
to 1000 and DN> 1000 respectively. Also the minimum Casting, 9th edn, (1998) 15, USA, ASM International, 670.
International Journal of Civil & Environmental Engineering IJCEE-IJENS Vol: 10 No: 03
[6] Goodrich G M. Cast Iron Microstructure Anomalies and Their [10] Imasogie B I, and Wendt U. Characterization Of Graphite
Causes. American Foundry Society, Cast iron Quality Control Particle Shape In Spheroidal Graphite Iron Using A Computer-
Committee 5J Report, AFS Transactions 1997;105: 669–683, Based Image Analyzer." Journal of Minerals & Materials
Characterization & Engineering 2004; 3: (1), 1-12.
[11] Fuller A G. Evaluation of the Graphite Form
[7] Iwabuchi Y, Narita H, Tsumura O. Toughness and Ductility of in Pearltic Ductile Iron by Ultrasonic and Sonic
Heavy-Walled Ferritic Spheroidal-Graphite Iron Castings. Research Testing and the Effect of Graphite Form on
Reports Kushiro National College 2003; 37: 1–9. Mechanical Properties. AFS Trans. 1977; 77-102:
[8]Iacoviello F, Bartolomeo O, and Cocco V. Piacente Damaging
micromechanisms in ferritic–pearlitic ductile cast irons" Materials 509-526.
Science and Engineering A 2008; 478: 181–186
[9]Hatate M, Shiota T, Takahashi N and Shimizu K. Influences of
graphite shapes on wear characteristics of austempered cast iron.
Wear 2001; 251: 885–889.