Wear Resistant Irons

Wear Resistance irons are primarily used in those industries where abrasion is evident. 

The high-alloy wear resistance irons are primarily used for abrasion-resistant applications and are readily cast in the shapes needed in the machinery used for crushing, grinding, and general handling of abrasive materials. These types of cast irons contain chromium and in small quantities nickel, copper and molybdenum as alloying agents. Wear resistance irons are also known as Abrasion-resistant irons, High Chrome alloys, white irons and Ni-hard.

Irons that are cast by using this method are generally hard but they can be further hardened by heat treatment. Wear resistance irons are generally specified for applications requiring a hardness range of 200 / 300 BHN, High Chrome Alloys (typically 28% Cr addition) are specified for applications requiring BHN figures of 600 – 650 BHN and Ni-Hard castings are supplied in a range of grades that offer a hardness range of between 500 – 600 BHN.

With post-casting heat treatments, the hardness range of High Chrome Alloys can be extended to 700HBN.

Properties:

  • They possess a high wear resistance.
  • Can be cast to suit different hardness
  • Able to resist heat better at elevated temperatures.
  • Works well in highly abrasive conditions
  • Difficult to weld. Requires special machines, tools and heat treatment to cast the desired component.

Industries:

  • Power Generation
  • Cement
  • Brick
  • Mining
  • Rock, Sand and Gravel Industries

 

Material Designation   C (%) Si (%) Mn(%) Ni(%) Cr(%) Mo(%) S(%) P(%)
Type 1A NiLCr 30/500 2.7-3.3 0.3-0.6 0.3-0.6 3.0-5.5 1.5-2.5 0.5max 0.15 0.3
  NiLCr 34/500 3.2-3.6 0.3-0.6 0.3-0.6 3.0-5.5 1.5-2.5 0.5max 0.15 0.3
Type 1B NiHCr 27/500 2.5-2.9 1.5-2.2 0.3-0.6 4.0-6.0 8.0-10.0 0.5max 0.15 0.3
  NiHCr 30/550 2.8-3.3 1.5-2.2 0.3-0.6 4.0-6.0 8.0-10.0 0.5max 0.15 0.3
  NiHCr 34/600 3.2-3.6 1.5-2.2 0.3-0.6 4.0-6.0 7.5-9.5 0.5max 0.15 0.3
Type 2 CrMoHC 34/500 3.1-3.6 0.3-0.8 0.4-0.9 0.5 max 14.0-18.0 2.5-3.5 0.15 0.3
  CrMoLc 28/500 2.4-3.1 0.3-0.8 0.4-0.9 0.5 max 14.0-18.0 2.5-3.5 0.15 0.3
Type 3 HCrNi 27/400 2.3-3.0 0.2-1.5 1.5 max 1.2 max 24.0-28.0 0.6 max 0.15 0.3
  HCr 27/400 2.3-3.0 0.2-1.5 1.5 max 0.5 max 24.0-28.0 0.6 max 0.15 0.3
Material Designation   MINIMUM BRINELL
HARDNESS VALUES (HBW)
    Sand-Cast Hardened Annealed
Type 1A NiLCr 30/500 500
  NiLCr 34/500 550
Type 1B NiHCr 27/500 500
  NiHCr 30/550 550
  NiHCr 34/600 600
Type 2 CrMoHC 34/500 500 600 380 max
  CrMoLc 28/500 500 550 380 max
Type 3 HCrNi 27/400 400 550
  HCr 27/400 400 550 380 max
Class Type Designation C Mn Si Ni Cr Mo Cu P S
I A Ni-Cr-Hc 2.8-3.6 2.0 max 0.8 max 3.3-5.0 1.4-4.0 1.0 max —- 0.3 max 0.15 max
I B Ni-Cr-Lc 2.4-3.0 2.0 max 0.8 max 3.3-5.0 1.4-4.0 1.0 max —- 0.3 max 0.15 max
I C Ni-Cr-GB 2.5-3.7 2.0 max 0.8 max 4.0 max 1.0-2.5 1.0 max —- 0.3 max 0.15 max
I D Ni-HiCr 2.5-3.6 2.0 max 2.0 max 4.5-7.0 7.0- 11.0 1.5 max —- 0.10 max 0.15 max
II A 12% Cr 2.0-3.3 2.0 max 1.5 max 2.5 max 11.0- 14.0 3.0 max 1.2 max 0.10 max 0.06 max
II B 15% Cr 2.0-3.3 2.0 max 1.5 max 2.5 max 14.0- 18.0 3.0 max 1.2 max 0.10 max 0.06 max
II D 20% Cr 2.0-3.3 2.0 max 1.0-2.2 2.5 max 18.0- 23.0 3.0 max 1.2 max 0.10 max 0.06 max
III A 25% Cr 2.0-3.3 2.0 max 1.5 max 2.5 max 23.0- 30.0 3.0 max 1.2 max 0.10 max 0.06 max
  Sand Cast
Class Type Designation As Cast of As Cast and Stress Relieved Hardened or Hardened and Stress Relieved Chill Cast, min Softened, max
  HB HRC HV HB HRC HV HB HRC HV HB HRC HV HB HRC HV
I A Ni-Cr-HiC 550 53 600 600 56 660 650 59 715 600 56 660 ——— ——— ———
I B Ni-Cr-LoC 550 53 600 600 56 660 650 59 715 600 56 660 ——— ——— ———
I C Ni-Cr-GB 550 53 600 600 56 660 650 59 715 600 56 660 400 41 430
I D Ni-HiCr 500 50 540 600 56 660 650 59 715 550 53 600 ——— ——— ———
II A 12% Cr 550 53 600 600 56 660 650 59 715 550 53 600 400 41 430
II B 15% Cr 450 46 485 600 56 660 650 59 715 ——— ——— ——— 400 41 430
II D 20% Cr 450 46 485 600 56 660 650 59 715 ——— ——— ——— 400 41 430
III A 25% Cr 450 46 485 600 56 660 650 59 715 ——— ——— ——— 400 41 430
Material Designation Vickers Hardness Chemical Composition (%)
Symbol Number HV (Min) C Si Mn P S Ni Cr Mo Cu
EN-GJN-HV350 EN-JN2019 350 2.4-3.9 0.4-1.5 0.2-1.0 Max 2.0
EN-GJN-HV520 EN-JN2029 520 2.5-3.0 Max 0.8 Max 0.8 Max 0.10 Max 0.10 3.0-5.5 1.5-3.0
EN-GJN-HV550 EN-JN2039 550 3.0-3.5 Max 0.8 Max 0.8 Max 0.10 Max 0.10 3.0-5.5 1.5-3.0
EN-GJN-HV600 EN-JN2049 600 2.5-3.5 1.5-2.5 0.3-0.8 Max 0.08 Max 0.08 4.5-6.5 8.0-10.0
EN-GJN-HV600(XCr11) EN-JN3019 600 1.8-2.4 Max 1.0 0.5-1.5 Max 0.08 Max 0.08 Max 2.0 11.0-14.0 Max 3.0 Max 1.2
      2.4-3.2                
      3.2-3.6                
EN-GJN-HV600(XCr14) EN-JN3029 600 1.8-2.4 Max 1.0 0.5-1.5 Max 0.08 Max 0.08 Max 2.0 14.0-18.0 Max 3.0 Max 1.2
      2.4-3.2                
      3.2-3.6                
EN-GJN-HV600(XCr18) EN-JN3039 600 1.8-2.4 Max 1.0 0.5-1.5 Max 0.08 Max 0.08 Max 2.0 18.0-23.0 Max 3.0 Max 1.2
      2.4-3.2                
      3.2-3.6                
EN-GJN-HV600(XCr23) EN-JN3049 600 1.8-2.4 Max 1.0 0.5-1.5 Max 0.08 Max 0.08 Max 2.0 23.0-28.0 Max 3.0 Max 1.2
      2.4-3.2                
      3.2-3.6              
Material Designation Chemical Composition Min Hardness value
  C% Si% Mn% Ni% Cr% Mo% Cu% (max) P% (max) S% (max) HB*
2A 2.7 – 3.2 0.3 – 0.8 0.2 – 0.8 3.0 – 5.5 1.5 – 3.5 0.5 max 0.15 0.15 500
2B 3.2 – 3.6 0.3 – 0.8 0.2 – 0.8 3.0 – 5.5 1.5 – 3.5 0.5 max 0.15 0.15 550
2C 2.4 – 2.8 1.5 – 2.2 0.2 – 0.8 4.0 – 6.0 8.0 – 10. 0.5 max 0.1 0.15 500
2D 2.8 – 3.2 1.5 – 2.2 0.2 – 0.8 4.0 – 6.0 8.0 – 10. 0.5 max 0.1 0.15 550
2E 3.2 – 3.6 1.5 – 2.2 0.2 – 0.8 4.0 – 6.0 8.0 – 10.0 0.5 max 0.1 0.15 600
3A 1.8 – 3.0 1 0.5 – 1.5 2.0 max 14 – 17 2.5 max 2.0 max 0.1 0.1 600
3B 3.0 – 3.6 1 0.5 – 1.5 2.0 max 14 – 17 3.0 max 2.0 max 0.1 0.1 650
3C 1.8 – 3.0 1 0.5 – 1.5 2.0 max 17 – 22 3.0 max 2.0 max 0.1 0.1 600
3D 2.0 – 2.8 1 0.5 – 1.5 2.0 max 22 – 28 1.5 max 2.0 max 0.1 0.1 600
3E 2.8 – 3.5 1 0.5 – 1.5 2.0 max 22 – 28 1.5 max 2.0 max 0.1 0.1 600
3F 2.0 – 2.7 1 0.5 – 1.5 2.0 max 11 – 13 2.5 max 2.0 max 0.1 0.1 600
3G 2.7 – 3.4 1 0.5 – 1.5 2.0 max 11 – 13 3.0 max 2.0 max 0.1 0.1 650

Ni-Resist Irons

Ni-Resist Irons are divided further into two types. They are the standard or flake graphite alloys and the ductile or spheroidal graphite alloys. Flake resistant alloys are more in common because of their thermal conductivity, better machinability combined with lower costs makes a popular choice. Spheroidal alloys with their higher strength, ductility and resistance to elevated temperature are making them a prominent choice.

Properties:

  • Corrosion Resistant
  • Wear Resistant
  • Erosion Resistant
  • Toughness and low-temperature stability
  • Controlled Expansion
  • Magnetic and Electrical Properties
  • Heat Resistance
  • Machinability
  • Castability

Industries:

  • Automobiles
  • Petrochemical
  • Chemical
Alloy Tensile Strength Compressive Strength Elongation Modulus of Elasticity Brinell Hardness
  MPa(ksi) MPa(ksi) % MPa(ksi)x103  
NiMn 13 7 140-220 630-840 70-90 120-150
  (20-31) (90-120)   (10-13)  
Ni-Resist 1 170-210 700-840 2 85-105 120-215
  (24-30) (100-120)   (12-15)  
Ni-Resist 190-240 860-1100 1-2 98-113 150-250
  (27-34) (123-157)   (14-16)  
Ni-Resist 2 170-210 700-840 2-3 85-105 120-215
  (24-30) (100-120)   (12-15)  
Ni-Reslst 190-240 860-1100 1-2 98-113 160-250
  (27-34) (123-157)   (14-16)  
Nicrosibl 190-280 2-3 140-250
  (27-40)        
Ni-Resist 3 190-240 700-910 1-3 98-113 120-215
  (27-34) (100-130)   (14-16)  
Ni-Resist 4 170-240 560 105 150-210
  (24-34) (80)   (15)  
Ni-Resist 5 120-180 560-700 1-3 74 120-140
  (17-26) (80-100)   (11)  
Ni-Resist 6 170-210 700-840 130-180
  (24-30) (100-120)    
Alloy Tensile Strength Compressive Strength Elongation Modulus of Elasticity Brinell Hardness
  MPa(ksi) MPa(ksi) % MPa(ksi)x103  
NiMn 13 7 140-220 630-840 70-90 120-150
  (20-31) (90-120)   (10-13)  
Ni-Resist 1 170-210 700-840 2 85-105 120-215
  (24-30) (100-120)   (12-15)  
Ni-Resist 190-240 860-1100 1-2 98-113 150-250
  (27-34) (123-157)   (14-16)  
Ni-Resist 2 170-210 700-840 2-3 85-105 120-215
  (24-30) (100-120)   (12-15)  
Ni-Reslst 190-240 860-1100 1-2 98-113 160-250
  (27-34) (123-157)   (14-16)  
Nicrosibl 190-280 2-3 140-250
  (27-40)        
Ni-Resist 3 190-240 700-910 1-3 98-113 120-215
  (27-34) (100-130)   (14-16)  
Ni-Resist 4 170-240 560 105 150-210
  (24-34) (80)   (15)  
Ni-Resist 5 120-180 560-700 1-3 74 120-140
  (17-26) (80-100)   (11)  
Ni-Resist 6 170-210 700-840 130-180
  (24-30) (100-120)    
Common Name ASTM A439-83 A571-84 Ni Cr Si Cu Mn C max Other
NiResist D-2W Type D-2 18.0-22.0 1.50-2.20 1.5-2.2 0.5max 0.5-1.5 3.0 .12-20Nb
NiResist D-2B 18.0-22.0 2.75-4.00 1.5-3.0 0.5max 0,70-1.25 3.0
Nicrosilal Spheronic Type D-2B 18.0-22.0 10-2,5 4.5-5.5 0.5max 0.5-1.5 3.0
NiResist D-2C 21.0-24.0 0.5max 1.0-3.0 0.5max 1.8-2.4 2.9
NiResist D-2M Type D-2C 22.0-24.0 0.2max 1.5-2.5 0.5max 3.75-4.50 2.6
NiResist D-3A Type D-3A 28.0-32.0 1.0-1.5 1.0-2.8 0.5max 1.0max 2.6
NiResist D-3 Type D-3 28.0-32.0 2.5-3.5 1.0-2.8 0.5max 1.0max 2.6
NiResist D-4A 29.0-32.0 1.5-2.5 4.0-6.0 0.5max 0.5-1.5 2.6
NiResist D-428 Type D-4 0.0-32.0 4.5-5.5 5.C-6.0 0.5max 1.0max 2.6
NiResist D-534 Type D-5 0.0-36.0 0.1 max 1.0-2.8 0.5max 1.0max 2.4
NiResist D-5B Type D-5B 34.0-36.0 2.0-3.0 1.0-2.8 0.5max 1.0max 2.4
NiResist D-5S Type D-5S 34.0-37.0 1.15-2.25 4.9-5.5 0.5max 1.0max 2.3
NiResist D-6 12.0-14.0 0.2max 2.0-3.0 0.5max 6.0-7.0 3.0
Alloy Tensile Strength Yield Strength Elongation Modulus of Elasticity Charpy Impect Brinell Hardness
  MPa(ksi) 0.2% Offset Mpa(ksi) % MPa(ksi)x103 Kg-m(ft-lb)  
Ni-Resist 370-480 210-250 7-20 112-130 14-27 140-200
D-2 (53-69) (30-36)   (16-19) (101-197)  
Ni-Resist 370-480 210-250 8-20 112-130 14-27 140-200
D-2W (53-69) (30-36)   (16-19) (101-197)  
Ni-Resist 390-500 210-260 7-15 112-133 12 150-255
D-2B (56-71) (30-37)   (16-19) (87)  
Nicrosilal 370-440 210-260 10-18 180-230
Spheronic (53-63) (30-37)        
Ni-Resist 370-450 170-250 20-40 85-112 21-33 130-170
D-2C (53-64) (24-36)   (12-16) (153-240)  
Ni-Resist 440-480 210-240 25-45 120-140 24-34 150-180
D-2M (63-69) (30-34)   (17-20) (175-248)  
NI-Resist 370-450 210-270 13-18 112-130 16 130-190
D-3A (53-64) (30-39)   (16-19) (117)  
Ni-Resisl 370-480 210-260 7-18 92-105 8 140-200
D-3 (53-69) (30-37)   (13-15) (59)  
Ni-Resist 380-500 210-270 10-20 130-150 10-16 130-170
D-4A (54-71) (30-39)   (19-21) (73-117)  
Ni-Resist 390-500 240-310 1-4 91 170-250
D-4 (56-71) (34-44)   (13)    
Ni-Resist 370-420 210-240 20-40 112-140 20 130-180
D-5 (53-60) (30-34)   (16-20) (145)  
Ni-Resist 370-450 210-290 7-10 112-123 7 140-190
D-5B (53-64) (30-41)   (16-18) (56)  
Ni-Resist 370-500 200-290 10-20 110-145 12-19 130-170
D-5S (53-71) (29-41)   (16-21) (87-138)  
Ni-Resist 390-470 210-260 15-18 140-150 120-150
D-6 (56-67) (30-37)   (20-21)  

Grey cast Iron

Grey iron is an alloy of iron, carbon and silicon that has been melted and poured into a mould to form a shape. If molten iron is allowed to cool normally the carbon comes out of solution and forms flakes of graphite which run through the ferrite/pearlite matrix.

Properties

  • Good under compression. Not good under tension, bending or shock loading.
  • A range of tensile strength and hardness to suit different applications.
  • The free graphite expands on solidifying, giving sharp, well defined castings.
  • Good corrosion resistance when compared to mild steel.
  • The graphite acts as a lubricant, improving wear resistance.
  • Good thermal conduction and vibration damping properties Works well under continual heating and cooling cycles.
  • Good machinability.
  • Difficult to weld.

 

Uses

  • Spares and consumables in forges and rolling mills.
  • Brake disks and drums particularly where castings are subject to repeated heating and cooling cycles.
  • Valve and pump applications.
  • Marine castings
  • Motor housings, gearboxes, engine blocks and machinery components.
  • Architectural, decorative and sculptural castings.
  • Suited to low, medium and high production quantities.
1. Country/International Organisation Standard Designation C(%) Si(%) Mn (%) P. Max. (%) S. Max. (%) Brinell Hardness
INDIA IS-210 – Grade FG-220 3.3 – 3.6 1.8 – 2.4 0.6-0.8 0.35 0.15 180-220
UK BS – 1452 – Grade 14            
USA ASTM – Grade – 30A            
INDIA IS-210 – Grade FG-260 3.2 – 3.5 1.5 – 2.1 0.6-0.8 0.25 0.15 180-230
UK BS – 1452 – Grade 17            
USA ASTM – Grade – 35A            
INDIA IS-210 – Grade FG-300 3.1 – 3.3 1.3 – 1.8 0.7-09 0.15 0.1 180-230
UK BS -1452 – Grade 20            
USA ASTM – Grade – 40A            
INDIA IS-210 – Grade FG-350 3.0 – 3.2 1.1 – 1.5 0.8-1.0 0.1 0.1 207-241
UK BS -1452 – Grade 23            
USA ASTM – Grade – 50A            
2. Bending Strength Min. MPa (kgf/mm2) FG 220 FG 260   FG 300   FG 350  
  390(40) 430(44)   470(48)   550(56)
Country Standard Equivalent Grades of Gray Iron (Grey Cast Iron)
India IS 210 FG150 FG200 FG260 FG300 FG350 FG400
ISO ISO 185 100 150 200 250 300 350
USA ASTM A48 NO.20 NO.30 NO.35 NO.40 NO.50 NO.55
      NO.25     NO.45   NO.60
European EN 1561 EN-GJL-100 EN-GJL-150 EN-GJL-200 EN-GJL-250 EN-GJL-300 EN-GJL-350  
Italy UNI 5007 G10 G15 G20 G25 G30 G35
UK BS 1452 100 150 200 250 300 350