No. 7. White Cast Iron
So the softer cast irons which are used for valves and fittings, machine parts, radiators, hollowware, etc., have high silicon. Parts that do not have to be machined can be of “harder” iron; i. e., made of iron having lower silicon content.
Manipulation of the silicon content is not the only method by which the hardness of cast iron can be influenced. Graphite can “precipitate” (i.e., separate throughout the casting) only if sufficient time is given it to do so. That is, the cooling of the casting after pouring must be sufficiently slow. In a sand mold the iron remains molten for a time, and after solidification it cools slowly enough that the greater portion of the carbon separates as graphite. Therefore, castings of proper composition made in sand molds are soft and machinable.
If the iron is poured into a mold the surfaces of which are made of iron, the molten metal upon entering becomes solid almost as soon as it takes the form of the mold, and it cools with great rapidity. Under such conditions the carbon of the alloy is denied the time necessary to change into the graphitic form and the casting has a white fracture and is so hard that it cannot be machined.
Section of Chilled Car Wheel
Showing white iron rim.
There are many purposes for which the alloy should have extreme hardness and the great resistance to wear which accompanies such hardness. The wearing faces of gears, brake shoes, rolls, and car wheels, for instance, must be hard. For such products, white cast iron, the extremely hard condition of the alloy, just referred to, is utilized. Such castings are usually produced with a white cast iron face, but with a gray iron interior, gray iron being less brittle and less likely to break under shock or strain. A car wheel, for instance, has approximately an inch in depth of white iron on the surface which lies next to the rail on which it runs.
Chilled Cast Iron
The white edge resulted from the more rapid cooling against an iron chill, as did the white rim of the wheel shown above.