As strong as cast iron but lighter?

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In summary, the conversation is about finding a metal for casting that is slightly lighter than iron but equally strong and with similar cost and availability. There was a recommendation to use ZA12, but few companies cast this alloy. The options discussed were Zn and Cr alloys, with the possibility of alloying Cr with Fe, Ni, Mo, and V to achieve desired density and strength. It was also mentioned that steels can be cast, but cast iron may be too brittle due to its high carbon content.
  • #1
Photon713
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Good Evening, all...

Trying to find a metal for casting that has a density slightly lighter than iron (.28 lbs per
cubic inch). I'm looking for a material that is as strong as cast iron, but, reduces the weight of the cast item by 10%. Secondly, the cost and availability should be approximately equal to cast iron. I have had a recommendation to use ZA12, but, not finding many companies casting this alloy. Any suggestions greatly appreciated. If you recommend a metal, could you also identify any company casting it. Thanks
 
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  • #2
Fe has a density of 7874 kg/m3. So 10% less would be about 7100 kg/m3. Zn has a density of about 7140 kg/m3, but it may not be as strong as iron.

On the other side would be Cr with a density 7140 kg/m3, and this could be alloyed with Fe, Ni, Mo, V. Cr-Mo alloys exist but the Mo has a density of ~10280 kg/m3, but this could be offset with additions of V(dens = 6110 kg/m3).

Steels can be cast also. Cast iron is relatively high carbon iron and is therefore can be brittle.
 
  • #3


Good evening, it sounds like you are looking for a material that has a high strength-to-weight ratio, similar to cast iron but with a lighter weight. One option to consider is aluminum alloy, which has a density of 0.098 lbs per cubic inch and can be just as strong as cast iron. There are many companies that cast aluminum alloys, so it should be readily available and cost-effective. I recommend researching different aluminum alloys and their properties to find the best fit for your project. Additionally, you may want to reach out to casting companies directly to inquire about their capabilities and availability for your specific needs. I hope this helps and good luck with your project!
 

1. What is the material that is as strong as cast iron but lighter?

The material that is as strong as cast iron but lighter is called ductile iron. It is also known as nodular cast iron or spheroidal graphite iron.

2. How is ductile iron made?

Ductile iron is made by adding magnesium to molten cast iron, which helps to form graphite nodules instead of flakes. This change in the microstructure of the iron makes it stronger and more ductile.

3. What are the advantages of using ductile iron over cast iron?

The main advantage of using ductile iron is its strength and ductility. It is also more resistant to impact and fatigue compared to cast iron. Additionally, ductile iron is easier to machine and has better corrosion resistance.

4. In what industries is ductile iron commonly used?

Ductile iron is commonly used in industries such as automotive, construction, and agriculture. It is also used in the manufacturing of pipes, gears, and other machinery parts.

5. Is ductile iron more expensive than cast iron?

Yes, ductile iron is more expensive than cast iron due to the additional processing steps required to make it. However, the benefits it offers in terms of strength and durability make it a cost-effective choice in many applications.

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