IS 210

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IS 210 : 1993

(Reaffirmed 2004)

Edition 5.1

(1998-08)

B U R E A U O F I N D I A N S T A N D A R D S

MANAKBHAVAN, 9BAHADURSHAHZAFARMARG

NEWDELHI110002

Price Group 5

BIS 2007

Indian Standard

GREY IRON CASTINGS SPECIFICATION

( Fourth Revision )

(Incorporating Amendment No. 1)

UDC 669.131.614

SU

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Pig Iron and Cast Iron Sectional Committee, MTD 6

FOREWORD

This Indian Standard (Fourth Revision) was adopted by the Bureau of Indian Standards, after thedraft finalized by the Pig Iron and Cast Iron Sectional Committee had been approved by theMetallurgical Engineering Division Council.

This standard was first published in 1950 and subsequently revised in 1962, 1970 and 1978. Whilereviewing this standard in the light of the experience gained during these years, the committeedecided to revise it to align with the present practices followed by the Indian industries and tobring it in line with the other overseas standards.

The various diameters of test bar according to the section size of the castings have been replacedby a single size of test bar. Guidance on the effect of section size of the casting on the tensilestrength is, however, given in Annex A. A comparison between grades is given in Annex B.

The production of castings in the higher grades of grey cast iron often involves special techniques.

It is recommended, therefore, that for either large or intricate castings or a casting involving boththese conditions, or where the castings have to withstand exception conditions, the grade of greycast iron selected and any heat treatment involved should be agreed between the manufacturerand the purchaser. The higher grades of grey cast iron (that is, Grade FG300, FG350 and FG400)present special difficulties for section 10 mm and thinner.

For the benefit of the purchaser, typical properties of grey cast iron have been added in Annex C.

Information to be supplied by the purchaser while ordering grey iron castings according to thisspecification is given in Annex D.

In the formulation of this standard assistance has been derived from ISO 185 Grey Cast Iron Specification issued by International Organization for Standardization.

This edition 5.1 incorporates Amendment No. 1 (August 1998). Side bar indicates modification ofthe text as the result of incorporation of the amendment.

For the purpose of deciding whether a particular requirement of this standard is complied with,the final value, observed or calculated, expressing the result of a test or analysis, shall be roundedoff in accordance with IS 2 : 1960 Rules for rounding off numerical values (revised ). The numberof significant places retained in the rounded off value should be the same as that of the specifiedvalue in this standard.

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IS 210 : 1993

1

Indian Standard

GREY IRON CASTINGS SPECIFICATION

( Fourth Revision )

1 SCOPE

This standard covers the requirements for greyiron castings.

2 REFERENCES

The following Indian Standards are necessaryadjuncts to this standard:

3 SUPPLY OF MATERIAL

General requirements relating to the supply ofgrey iron castings shall be as laid down inIS 1387 : 1993.

4 GRADES

There shall be seven grades of grey ironcastings namely, Grades FG150, FG200,FG220, FG260, FG300, FG350 and FG 400.

5 MANUFACTURE

The castings shall be made by any process, asagreed between the supplier and purchaser,that will produce castings complying with therequirements of this Indian Standard and shallbe in accordance with the pattern or working

drawing as supplied by the purchaser.

6 CHEMICAL COMPOSITION

6.1 The composition of cast iron shall be left tothe discretion of the manufacturer, but a maxi-mum limit for phosphorus and/or sulphur maybe specified by the purchaser, if he so desires.

6.2 In case of special castings, the detailedchemical composition shall be as agreed to be-tween the purchaser and the manufacturer.

7 WORKMANSHIP AND FINISH7.1 The castings shall be accurately moulded inaccordance with the pattern or workingdrawings supplied by the purchaser, with theaddition of such letters, figures or marks asmay be specified.

7.2 The purchaser shall specify tolerances,machining location and allowances withreference to all important dimensions. On otherdimensions tolerances specified in IS 5519 :1979shall apply.

8 HEAT TREATMENT

Castings are generally supplied without havingany heat treatment, However, if required by thepurchaser, the heat treatment may be carried outin accordance with 2of IS 13655 : 1993.

9 MICROSTRUCTURE

Where so required, the microstructure of greyiron castings and the location for taking thesample shall be as agreed to between thepurchaser and the manufacturer.

10 FREEDOM FROM DEFECTS

10.1 The castings shall be sound, clean and freefrom porosity, blow holes, hard spots, cracks,hot tears, coldshuts, distortion, sand and slaginclusions and other harmful defects. Theyshall be well-dressed and fettled, and shall bereadily machinable.

10.2 No welding or repairs shall be carried outwithout the prior permission of the purchaser.Welding referred to here includes fusionwelding in accordance with the commonfoundry practice. The method of repair bywelding (see IS 5139 : 1969 ) and subsequentstress-relieving shall be as agreed to between

the purchaser and the manufacturer.

IS No. Title

1387 : 1993 General requirements for thesupply of metallurgical material(second revision )

1500 : 1983 Method for Brinell hardness testfor metallic materials (secondrevision )

2078 : 1979 Method for tensile testing ofgrey cast iron (first revision )

4843 : 1968 Code for designation of ferrouscastings

5139 : 1969 Recommended procedure forrepair of grey iron castings by

oxyacetylene and manual metalarc welding

5519 : 1979 Deviations for untoleranceddimensions of grey iron castings(first revision )

13655 : 1993 Guidelines for heat treatment ofcast iron



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IS 210 : 1993

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11 PROVISION OF TEST BARS

11.1All test bars shall be cast separately insand moulds and the number of test barsrequired shall be as specified in 11. They shallbe cast at the same time and from the same

melt as the castings they represent.

11.2 The test bar material shall be identifiablewith that of the castings represented.

11.3 When castings are subjected to heat treat-ment, the test bars shall be heat-treatedtogether with the castings they represent.

11.4 The test bars shall be cast in dried, bakedor chemically bonded moulds made mainly ofan aggregate of siliceous sand with appropriatebinders. The average grain size of the sandshall be approximate to that of the sand in

which the castings are poured. Moulds for thetest bars shall be approximately at roomtemperature when poured. More than one testbar may be cast in a single mould, but each barin the mould shall be surrounded by athickness of sand which is not less than thediameter of the bar.

12 FREQUENCY OF TESTING

12.1 The number of tests required for each meltor batch of castings shall be as laid down inTable 1, various classes of castings being dividedinto five representative groups according to mass.

12.2 In the case of large tonnage of castingsbeing produced continuously, the minimumnumber of test bars to be provided shall be onetensile test representing every two hoursproduction from a melting furnace.

Table 1 Number of Tests

(Clause12.1 )

13 SIZE OF TEST BARS

A test bar from which the tensile test piece ismachined shall be cast as a uniform cylindricalbar of 30 mm diameter. The tolerance on thediameter shall be mm. The minimum length

of the test bar shall be 230 mm.

14 TENSILE TEST

The tensile test shall be carried out inaccordance with IS 2078 : 1979, using a testpiece conforming to the dimensions in Fig. 1and Table 2. The test piece shall be accuratelymachined, with a good surface finish. Thetransition between the ends and the parallellength shall be smooth, without undercuttingor a sudden step down in diameter.

NOTE Self-aligning grips are recommended toensure axial loading.

15 TENSILE STRENGTH

When tested in accordance with the requirementof 13, the test piece shall comply with theminimum requirements specified in Table 3. Thetensile strength specified is that obtained fromtest bars cast separately from the castings towhich they refer. The test values represent,therefore, only the quality of the metal fromwhich the casting have been poured.

16 HARDNESS TEST

16.1 The Brinell hardness test shall be carried

out in accordance with the method given inIS 1500 : 1983. Brinell hardness values fordifferent grades or grey iron castings shall beas specified in Table 3.

16.1.1 The hardness test shall be conducted atspecific point on the castings. These specificpoints shall be such that they are amenable forhardness checking in routine procedure.

16.1.2 The location of the specific point on acasting for hardness measurement shall be asagreed to between the purchaser and the manu-facturer.

17 TRANSVERSE TEST

If required, the transverse test may be carriedout by the manufacturer in accordance with themethod given in Annex E. The minimum testrequirements shall be agreed upon at the timeof enquiry and order.

18 HYDROSTATIC TEST

If specified at the time of enquiry and order thecastings may be tested for the hydrostatic testpressure. The requirements for the testpressure shall be mutually agreed to between

the purchaser and the manufacturer.

Group Mass of IndividualCastings

Test Requirements

11) Up to 12.5 kg One test for each 500 kg of castings or part thereof

21) Over 12.5 kg andup to 50 kg

One test for every 1 tonne ofcastings or part thereof

31) Over 50 kg andup to 500 kg

One test for every 2 tonnesof castings or part thereof

41) Over 500 kg andup to 1 tonne

One test for every 3 tonnesof castings of part thereof

5 Over 1 tonne One test for every 4 tonnesof castings or part thereofor one test for everycasting weighing 4 tonnesor more

1) In addition Groups 1, 2, 3, and 4 all castings repre-sented by one test shall be poured from the same ladle orsame heat as the bar or bars provided for the test.

2+0



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Table 2 Dimensions of Machined Tensile Test Piece

(Clause14 )

Table 3 Mechanical Test Requirements

(Clauses15 and16.1 )

19 RETESTS

19.1 If on being tested any test piece showsobvious signs of a casting defect, the results ofthe test may be discarded and a further test

made.19.2 If any sound test piece fails, two furthertests shall be made, should either of these testpieces fail, the castings represented shall notcomply with the requirements of this IndianStandard.

19.3 In the absence of further separately casttest bars, the manufacturer shall have theoption of submitting test bars, sectioned froman agreed position in the castings. Therequirements of the test shall be as agreed tobetween the purchaser and the manufacturer.However, the guidance may be obtained from

Annex A.

20 INSPECTION

By agreement with the manufacturer, the pur-chaser or his representative shall have acrossat all reasonable times to those parts of themanufacturers works engaged on his order, heshall be at liberty to inspect the manufacturerat any stage, to witness the required tests andto reject any material that does not comply withthis standard. When the castings are to be

inspected during manufacture and tested in thepresence of the purchasers representative, thisshall be stated on the enquiry and order.

21 TESTING FACILITIES

21.1 The manufacturer in supplying the testsamples as required for testing shall preparefrom them the necessary test pieces and supplythe labour and appliances for making all tests onhis premises in accordance with this standard.

21.1.1 Failing facilities for carrying out theprescribed tests at his own works the manufac-turer shall carry out the tests elsewhere.

22 MARKING22.1 Each casting, if feasible, shall be legiblymarked with a number of identification markswhich it can be traced to the melt, and thebatch of heat treatment, if done, from which itwas made.

22.2 By agreement between the purchaser andthe manufacturer, castings complying with therequirements of this standard shall be, afterinspection, legibly marked with an acceptancemark.

23 STANDARD MARK

The castings may also be marked with the

Standard Mark.

FIG. 1 MACHINEDTENSILETESTPIECE

GaugeDiameter

MachiningTolerance

for theGauge

Diameter

MinimumParallelLength

MinimumRadius

Plain Ends Screwed Ends

MinimumDiameter

MinimumLength

MinimumDia atRoot

MinimumLength

Lc R d1 Lp d2 Ls

(1) (2) (3) (4) (5) (6) (7) (8)

mm mm mm mm mm mm mm mm

20 0.5 55 25 23 65 25 30

NOTE With screwed-ends, any form of thread may be used provided that the diameter at the root of the thread is notless than that specified.

Grade( See IS 4843 : 1968)

TensileStrength

Min

BrinellHardness

MPa (N/mm2) HB

(1) (2) (3)

FG 150 150 130 to 180

FG 200 200 160 to 220

FG 220 220 180 to 220

FG 260 260 180 to 230

FG 300 300 180 to 230

FG 350 350 207 to 241

FG 400 400 207 to 270

NOTE Although mechanical properties are specifiedfor Grade FG 150 the material shall be only tested ifrequired by the purchaser.



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ANNEX A

(Foreword and Clause19.3 )

APPROXIMATE VARIATION OF STRENGTH

A-1 The Indian Standard grades of grey castiron are based on the minimum tensile strengthobtained when metal is cast into test bars of30 mm diameter. The strength developed by agiven metal shall vary with the cooling rate inthe mould higher strengths being obtained ifthe same metal is cast into smaller bars than30 mm diameter and lower strengths if themetal is cast into bars larger than 30 mmdiameter. Similarly, the cooling rate of a flatplate is slower than that of a bar whosediameter is equal to the thickness of the plateso that the strength developed in the plate willbe lower than that developed in the bar.

A-1.1 The cooling rate of a casting in a mould(hence the strength developed in any particularsection thickness by the metal employed for itsmanufacture) is influenced also by the presenceof cores, changes in section thickness, thepresence of bosses projections and intersections,such as the junctions of ribs and bosses. Thus, incastings of other than simple shape and uniformthickness the cooling rate of any part can beexpected to differ from that of a flat plate ofsimilar section thickness.

A-2 Figure 2 gives a guide to the likelyvariation in tensile strength in differentsections when a given grade of grey iron is castinto a casting of simple shape and uniformthickness or containing cored holes where thecooling rate in the mould of a given sectionshall differ from that in a casting of sampleshape and uniform thickness, the diagramprovides only an approximate guide to thelikely tensile strength in different sections anddesign should be based on the measured tensilestrength in critical parts of the casting.

A-2.1 Table 4 gives guidance to the likely varia-tion in tensile strength for different castingsection thicknesses when a given grade of greycast iron is cast into a casting of simple shapeand uniform thickness. For casting ofnon-uniform section or castings containing coredholes, the table provides only an approximateguide to the likely tensile strength in differentsections, and casting design should be based onthe measured tensile strength in critical parts ofthe casting.

This diagram is for guidance and should not be used for acceptance purposes.

FIG. 2 VARIATIONOFTENSILESTRENGTHWITHCROSS-SECTIONALTHICKNESSOFGREYIRONCASTINGS



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Table 4 Anticipated Tensile Properties for the Castings (for Information Only)

(ClauseA-2.1 )

ANNEX B

(Foreword )

Grade Casting Section Thickness,mm

Anticipated TensileStrength

MPa (N/mm2)

Over Up to andIncluding

FG 150 2.5 10 155

10 20 130

20 30 115

30 50 105

FG 200 2.5 10 205

10 20 180

20 30 160

30 50 145

FG 260 4.0 10 260

10 20 235

20 30 215

30 50 195

FG 300 10 20 27020 30 245

30 50 225

FG 350 10 20 315

20 30 290

30 50 270

CONVERSION FACTOR 1N/mm2 = 1MPa = 0.1020 kgf/mm2.

FIG. 3 COMPARISONBETWEENGRADESINTHISEDITIONANDTHEPREVIOUSEDITION

BASEDONMINIMUMTENSILESTRENGTH



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ANNEX C

(Foreword )

TYPICAL PROPERTIES OF GREY CAST IRON

C-1 The following information is given for the guidance of engineers and designers. It does notform part of the standard and should not be used for acceptance purposes:

Properties Unit Grade

FG 150 FG 200 FG 220 FG 260 FG 300 FG350 FG 400

Tensile strength MPa (N/mm2) 150 200 220 260 300 350 400

0.01 percent proofstress

MPa (N/mm2) 42 56 62 73 84 98 112


MPa (N/mm2) 98 130 143 169 195 228 260

Total strain atfailure

Percent 0.60-0.751) 0.48-0.671) 0.39-0.631) 0.57 0.50 0.50 0.50

Elastic strain at

failure

Percent 0.15 0.17 0.18 0.20 0.22 0.25 0.28

Total minus elasticstrain at failure

0.45-0.601) 0.31-0.501) 0.21-0.451) 0.37 0.28 0.25 0.28

Notched tensile stre-ngth (see Note 2)(Circumferential45 V-notch, rootradius 0.25 mm orNotch depth 2.5mm, notch dia 20mm or notch depth3.3 mm, notchdiameter 7.6 mm)

MPa (N/mm2) 120 160 176 208 240 280 320

Circumferentialnotch, Radius 9.5mm (Notch depth2.5 mm, notch dia-meter 20 mm)

MPa (N/mm2) 150 200 220 260 300 350 400

Compressive strength MPa (N/mm2) 600 720 768 864 960 1 080 1 200


MPa (N/mm2) 84 112 123 146 168 196 224


MPa (N/mm2) 195 260 286 338 390 455 520

Shear strength MPa (N/mm2) 173 230 253 299 345 403 460

Torsional strength MPa (N/mm2) 173 230 253 299 345 403 460

Shear strain atfailure

Percent >4 >4 >4 >4 Up to 4 Up to 4 Up to 4

Modulus of elasticityTension GPa 100 114 120 128 135 140 145

Compression GPa 100 114 120 128 135 140 145

Modulus of rigidity GPa 40 46 48 51 54 56 58

Poissons ratio 0.26

Fatigue limit (Woh-ler)

Unnotched (8.4mm dia)

MPa (N/mm2) 68 90 99 117 135 149 152

V-notched (Cir-cumferential 45

V-notch with 0.25mm root radius,Diameter at notch8.4 mm depth ofnotch 3.4 mm)

MPa (N/mm2) 68 87 94 108 122 129 127

Hardness Refer Table 3 for hardness values



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ANNEX D

(Foreword )

INFORMATION TO BE SUPPLIED BY THE PURCHASER

D-1 BASIS FOR ORDER

D-1.1 While placing an order for the purchaseof grey iron casting covered by this standard,the purchaser should specify the following:

a) Material specification;

Properties Unit Grade

FG 150 FG 200 FG 220 FG 260 FG 300 FG350 FG 400

Coefficient of ther-mal expression

100C to 20C 106/K 10.0 10.0)

20C to 200C 106/K 11.0 11.0) (See

20C to 400C 106/K 12.5 12.5) Note 3)

Thermal conductivity

100C W/mk 52.5 50.8 50.1 48.8 47.4 45.7 44.0

200C W/mk 51.5 49.8 49.1 47.8 46.4 44.7 43.0

300C W/mk 50.5 48.8 48.1 46.8 45.4 43.7 42.0

400C W/mk 49.5 47.8 47.1 45.8 44.4 42.7 41.0

500C W/mk 48.5 46.8 46.1 44.8 43.4 41.7 40.0

Specific heat capacity

20C to 200C J/kgK 265 375 420 460 460 460 460

20C to 300C J/kgK 355 435 455 495 495 495 495

20C to 400C J/kgK 400 465 465 505 505 505 505

20C to 500C J/kgK 425 480 475 515 515 515 515

20C to 600C J/kgK 445 500 495 535 535 535 535

20C to 700C J/kgK 490 555 560 605 605 605 606

Relative density 7.05 7.10 7.15 7.20 7.25 7.30 7.30

Magnetic and elec-trical properties

Maximum magne-tic permeability

H/m 301 to 380

Remanent magne-tism

T 0.4 to 0.5

Coercive force A/m 560 to 720

Hysceresis loss at50Hz J/m2

2 500 to 3 000

W/kg 17.6 to 20.9

Electrical resistivity m 0.800 0.770 0.760 0.730 0.700 0.670 0.640

NOTES

1 The typical properties given in this Annex are the properties in a 30 mm diameter separately cast test bar or in acasting section correctly represented by this size of test bar. Where the tensile strength does not correspond to thatgiven, other properties may differ slightly from those given.

2 Notched tensile strengths increase slightly as notch severity ratio, notch radius, notch diameter, increase above 0.47.

3 The values quoted for coefficient of thermal expansion of Grade FG 400 are for material in pearlitic iron. Whereaccicular iron is used for this grade appropriate values are:

20C to 200C 15.0 10-6/K20C to 400C 16.5 10-6/K

1)Values depend on the composition of iron.

b) Any required limits on the sulphur andphosphorus content

c) Drawing or reference number of thepattern (if supplied by the purchaser),

along with a copy of the drawing;



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ANNEX E

(Clause17 )

TRANSVERSE TEST FOR GREY CAST IRON

E-1 OBJECT OF THE TEST

The object of this test is to determine the trans-verse bending strength of grey cast iron byapplying constantly increasing single load atthe centre of a test bar arranged as a beam

between two supports until fracture occurs.E-2 TEST BARS

E-2.1 The cast test bars shall have thedimensions given in Table 5.

Table 5 Dimensions of TransverseTest Bars

(ClausesE-2.1 andE-2.2 )

E-2.2 Test bar is normally tested unmachined.The surface of the test bar shall be free fromunevenness and seams which may be removedby careful grinding. The diameter shall bemeasured at the centre of the test bar in twodirections perpendicular to one-another. Thedifference between two measurements shall notexceed 5 percent of the normal diameter. Themean value of the two diameters shall be thediameter do (see E-4 ) of the test bar. For itspermissible variations from the nominal

diameter and the accuracy of measurement ofthe diameter, the values indicated in Tables 5and 6 shall apply.

E-3 PROCEDURE

E-3.1 Place the two ends of the test bar on hori-zontal supports. The support and the point ofapplication of the load shall be rounded to aradius of 5 to 20 mm. Apply a single load verti-

cally at the centre of the bar (seeFig. 4 ).

E-3.2 Increase the load uniformly withoutshock until the bar fracture. The load should beapplied in such a way that the increase of stressdoes not exceed 3 MPa per second. Find out theload at the fracture of the test bar with theaccuracy indicated in Table 6.

E-3.3 Determine the deflection of the test barfrom the motion of the thrust relative to thefixed supports or to the supporting table of themachine. In order to eliminate any errors inmeasuring the deflection, the measurement

should be started after applying a smallpreload as given in Table 6.

Table 6 Testing Conditions andAccuracy of Readings

(ClausesE-2.2, E-3.2, E-3.3 andFig. 4 )

d) Tests required;

e) Whether the castings are to be inspectedand tested in the presence of the purcha-sers representative;

f) Condition of delivery;

g) Any special requirement of the purchaser,for example, hardness tests and locationsof non-destructive testing, quality assu-rance, etc; and

h) Test reports, if required.

Diameterof the Cast

Test Bar

Permissible Variationfrom Nominal

Diameter

Length ( L )Min

Unmachined Machined(1) (2) (3) (4)

mm mm mm mm

30 1.2 0.2 500

NominalDiameter

d

DistanceBetweenCentre ofSupports,

Ls

Accuracy of Readings Pre-Load

ApproxDiame-ter ofBar

d

LoadP,Max

Deflec-tion atFrac-ture

(1) (2) (3) (4) (5) (6)

mm mm mm N mm N

30 450 0.1 100 0.2 200 to400

FIG. 4 TRANSVERSETESTBAROFGREYCASTIRON



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E-4 TEST RESULT

The test report shall include:

where

c) deflection at fracture in mm.

a) load at fracture in N;b) bending strengthfb, to an accuracy of 0.5

MPa calculated from the formula:

fb8PLsd 3o----------------=

P= maximum load at fracture in N,

Ls = distance between centres of supportsin mm, and

do = mean diameter in mm, and



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Bureau of Indian Standards

BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promoteharmonious development of the activities of standardization, marking and quality certification of goods andattending to connected matters in the country.

Copyright

BIS has the copyright of all its publications. No part of these publications may be reproduced in any formwithout the prior permission in writing of BIS. This does not preclude the free use, in the course ofimplementing the standard, of necessary details, such as symbols and sizes, type or grade designations.Enquiries relating to copyright be addressed to the Director (Publications), BIS.

Review of Indian Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards are alsoreviewed periodically; a standard along with amendments is reaffirmed when such review indicates that nochanges are needed; if the review indicates that changes are needed, it is taken up for revision. Users ofIndian Standards should ascertain that they are in possession of the latest amendments or edition byreferring to the latest issue of BIS Catalogue and Standards : Monthly Additions.

This Indian Standard has been developed by MTD 6

Amendments Issued Since Publication

Amend No. Date of Issue

Amd. No. 1 August 1998

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