Mar 17,
What is SG Casting? Properties, Benefits, and Applications
SG Casting, or Spheroidal Graphite Iron Casting, or Ductile Iron Casting, is a high-grade cast iron which has attained extremely high popularity across all industries because of its superior mechanical properties, ductility, and economical nature. As one of the top SG iron casting manufacturers, Sagar Foundry has been an industry trendsetter in manufacturing high-grade SG castings for different applications. In this blog, we’ll describe what SG casting is, its characteristics, benefits, and uses, and why industries across the globe utilize it so comprehensively.
What is SG Casting?
SG Casting refers to the casting of cast iron with spheroidal graphite microstructure. Unlike the traditional grey iron, where graphite is in flake form, SG iron contains graphite in nodular or spherical form. This special microstructure is developed by introducing minute quantities of magnesium or cerium into molten iron while casting. The resulting material is one that possesses steel’s strength and toughness but iron’s casting property and economy.
SG” is an abbreviation for Spheroidal Graphite, and it is the typical feature of this material. The spherical character of the nodules of the graphite enhances the mechanical properties of the iron that becomes tougher, more ductile, and harder to wear.
Properties of SG Casting
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SG Casting contains very good properties that make it suitable for application in different industry sectors. The most important properties of SG iron are listed below:
1. High Strength
SG iron has tensile strength that is as good as steel and is thus a very good option for parts where high load-carrying capability is needed.
2. Ductility
Unlike the brittleness of common cast iron, SG iron is very ductile. What that means is that it does not break and flexes upon impact.
3. Wear Resistance
Its cylindrical shape enables higher resistance to abrasion by SG iron, therefore making it an ideal piece of abrading pieces as well as pieces bearing friction.
4. Machinability
It is simple to machine SG iron, and that puts the producers in a place where they are capable of easily producing intricate shapes and accurate pieces.
5. Resistance to Corrosion
If surface treated well, SG iron can be corrosion resistant and therefore can be used in adverse conditions.
6. Vibration Damping
SG iron has excellent vibration damping capacity, which is used in the application of machinery as well as automotive parts.
7. Cost-Effectiveness
SG iron is cheaper than steel but with similar mechanical properties and therefore an industry favourite material.
Advantages of SG Casting
The special characteristics of SG iron have numerous advantages for the producers and customers. Some of the major advantages of SG casting are mentioned below:
1. Flexibility
SG iron is employed to make components of various shapes and sizes, ranging from small precision components to heavy-duty machinery in industry.
2. Durability
The durability and resistance to wear of SG iron make the components remain in use for a very long period with little or no replacement.
3. Light weight
Though highly resistant, SG iron is lighter than steel, and where weight considerations are of prime importance, it is the obvious choice.
4. Cost savings
Substitution of production cost of SG iron by extended life means a wonderful cost advantage for manufacturers and users.
5. Sustainability
SG iron can also be recycled and thus a sustainable choice for industries that wish to reduce their carbon footprint.
6. Design Freedom
The better castability of SG iron allows complicated structures and detailed features to be cast, which also provides design freedom to the engineers.
Applications of SG Casting
SG Casting finds uses in various industries because of its versatility and better properties. The following are the most prevalent uses of SG iron:
1. Automotive Industry
SG iron finds very extensive use in the automotive sector to produce components like crankshafts, cylinder heads, gearboxes, and suspension components. Due to its greater strength and wear resistance, it is particularly suited for such applications.
2. Agriculture
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SG iron is applied in the production of tractor and plough components and other farm equipment components. Due to its ability to withstand heavy usage on farms with wear resistance, it’s the ideal choice.
3. Construction
SG iron is also applied in the construction industry in the production of pipes, fittings, and structural elements. It’s best for infrastructure due to the fact that it’s resistant to corrosion and extremely strong.
4. Pumps and Valves
Corrosion resistance and machinability of SG iron have also found it suitable for making pumps, valves, and other fluid-handling devices.
5. Wind Energy
SG iron is utilized in the manufacture of wind turbine parts, including hubs and gearboxes, because of its strength and fatigue characteristics.
6. Railways
SG iron is employed for rail uses in the manufacturing of brake discs, wheels, and other equipment where high strength and toughness are required.
7. General Engineering
SG iron finds large-scale usage for general engineering purposes such as tools, components of machinery, and equipment due to its general versatility and affordable nature.
Why Sagar Foundry Should Be Your SG Iron Casting Supplier?
With SG casting, the proper manufacturer to pick does matter as far as quality and performance in your components go. Sagar Foundry is one of such brands where you can trust that we have years of experience manufacturing top-quality SG iron castings. Here are the reasons you should opt for us:
• Modern Facilities: To give all of our castings accuracy and consistency, our modern manufacturing plants feature the newest technologies.
• Customised Solutions: We offer SG casting solutions tailored to meet the particular needs of our clients.
• Quality Checking: Our stringent quality checking systems ensure that products are international standards.
•Timely Delivery: We respect timetables and do our best to deliver on schedule, each time.
•Reasonable Charges: We provide quality SG castings at reasonable prices, value for money.
Grey casting is usually produced as cast iron with lamellar graphite and has excellent casting properties as well as a high cost efficiency. The material is used across the industry to produce components with high wear resistance requirements.
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The most common type of cast iron is cast iron with laminated graphite. This variety is characterized in that the graphite carbons are present in the form of thin, irregular lamellas. In the structure of the grey cast iron, these lamellae act like notches and thereby give the material its characteristic properties: While the tensile strength is comparatively low, cast iron scores a very high compressive strength.
Casting - casting process at EMG Casting AG
According to DIN EN , gray cast iron is also abbreviated as GJL, where the individual letters have the following meanings:
G = Cast material
J = Iron
L = Lamellar
The lamellae form three-dimensional harassment in the cast iron and thus provide a very low stretchability on one side, but on the other side also a high wear resistance and a good casting capability. At the same time, the notch effect in the gray cast iron ensures that components made of gray cast iron are not susceptible to structurally caused external notches. In contrast to cast steel, the material is therefore very suitable for applications with vibrational stress.
In the production of cast iron with lamellar graphite, the mechanical properties of the end product can be changed by varying the process parameters according to requirements. The most widely used variants of cast iron are briefly presented below with their most important technical data:
Tensile strengthN/mm²150 – – – – – 450Brinell hardnessHB – – – – – 250Bending strengthN/mm²Fracture toughnessN/mm²
In addition to the grey cast iron with graphite carbon, a so-called white cast iron is also produced. This is also an iron material in which the carbon is present as a carbide in the form of cementite (Fe C). The material can be seen from its characteristic white fracture surfaces.
The cast iron with spherical graphite (GJS) comparable with cast iron is also referred to as sphero casting and has better mechanical properties. The graphite is present in this material in spherical form, since the melt is desulphurized shortly before casting. Cast iron with spherical graphite is suitable, due to its mechanical properties, for example, for pipelines in the centrifugal casting process.
In addition, the so-called tempering casting is also related to the gray casting. This material is distinguished by the fact that it is subjected to an annealing treatment after solidification and thus also slight plastic deformations are possible. Depending on the glowing process, it is distinguished between white and black tempering.
Cast iron with lamellar graphite can be not only excellently cast, but also particularly easy to process. The iron-carbon casting alloy is therefore one of the most used casting products and is used in many different industries for the production of components with high wear resistance. Some of the typical products at a glance:
- Gear housing
- Cylinder blocks
- Machine beds
- brake discs
- Pallets
- Frame
- Light poles
- Channel construction
Parts of cast iron
In comparison with other, less well castable materials such as steel, grey cast iron is distinguished by some advantages:
- High corrosion resistance
- Economic production
- High compression strength
- Insensitivity to external notches
- High design strength with vibrational stress
- High wear resistance
- Excellent casting properties
Casting process at EMG Casting AG
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