ASTM A159-83(2006)
(Specification)Standard Specification for Automotive Gray Iron Castings
Standard Specification for Automotive Gray Iron Castings
ABSTRACT
This specification covers gray iron castings for products of the automobile, truck, tractor and allied industries. The materials shall be classified into eight grades (G1800, G2500, G3000, G3500, G4000, G2500a, G3500b and G3500c) based on the range of their casting hardness, chemical composition and microstructure. Grades G1800 and G2500 shall be annealed. Alloy gray iron automotive camshafts of grade designation G4000d shall conform to the required values of casting hardness, chemical compositions of chromium, molybdenum, and nickel and microstructure. The cam areas of camshaft casting shall undergo selective hardening by flame or induction hardening and shall conform to the required values of depth and surface hardness.
SCOPE
1.1 This specification applies to gray iron castings, cast in sand molds, used in the products of the automobile, truck, tractor, and allied industries.
1.2 The values stated in inch-pound units are to be regarded as the standard.
General Information
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Standards Content (Sample)
NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
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Designation: A159 – 83 (Reapproved 2006)
Standard Specification for
Automotive Gray Iron Castings
This standard is issued under the fixed designation A159; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the Department of Defense. This specification replaces Federal specification
AA-I-653A.
TABLE 1 Grades of Gray Iron
1. Scope
1.1 This specification applies to gray iron castings, cast in
Grade Casting Hardness Range Description
sand molds, used in the products of the automobile, truck,
tractor, and allied industries. G1800 HB 187 max ferritic-pearlitic
A
4.4 BID min or as agreed
1.2 The values stated in inch-pound units are to be regarded
G2500 HB 170-229 pearlitic-ferritic
as the standard. A
4.6–4.0 BID or as agreed
G3000 HB 187-241 pearlitic
A
2. Referenced Documents 4.4–3.9 BID or as agreed
G3500 HB 207-255 pearlitic
2.1 The following documents of the issue in effect on the A
4.2–3.8 BID or as agreed
G4000 HB 217-269 pearlitic
dateofmaterialprocurementformapartofthisspecificationto
A
4.1–3.7 BID or as agreed
the extent referenced herein:
A
Brinell impression diameter (BID) is the diameter in millimetres of the impres-
2.2 ASTM Standards:
sion of a 10 mm ball at 3000-kg load.
A247 Test Method for Evaluating the Microstructure of
Graphite in Iron Castings
4.1.3 If special heat treatment is required (see Section 6),
E10 Test Method for Brinell Hardness of Metallic Materials
4.1.4 If special microstructure requirements are needed (see
2.3 Military Standard:
Section 7),
MIL-STD-129 Marking for Shipment and Storage
4.1.5 Surface where hardness test is to be performed (see
2.4 Federal Standard:
9.4),
Fed. Std. No. 123 Marking for Shipment (Civil Agencies)
4.1.6 Depth and surface hardness of case required (see 9.6),
4.1.7 Inspection lot and sampling plan required (see Section
3. Grades
10),
3.1 The specified grades, hardness ranges, and metallurgical
4.1.8 If additional requirements are needed (see 11.3), and
description are shown in Table 1 and Table 2 and in Section 9.
4.1.9 Whether special packaging and marking is required
(see Section 12).
4. Ordering Information
4.1 Orders for materials under this specification shall in-
5. Hardness
clude the following information:
5.1 The foundry shall exercise the necessary controls and
4.1.1 ASTM designation,
inspection techniques to ensure compliance with the specified
4.1.2 Grade designation of gray iron required (3.1),
hardness range, Brinell hardness shall be determined in accor-
dance with Test Method E10, after sufficient material has been
removed from the casting surface to ensure representative
This specification is under the jurisdiction of ASTM Committee A04 on Iron
hardness readings. The 10-mm ball and 3000-kg load shall be
CastingsandisthedirectresponsibilityofSubcommitteeA04.01onGrayandWhite
used unless otherwise agreed upon. The area or areas on the
Iron Castings.
Current edition approved Oct. 1, 2006. Published October 2006. Originally
casting where hardness is to be checked shall be established by
approved in 1935. Last previous edition approved in 2001 as A159 – 83 (2001).
agreement between supplier and purchaser and shall be shown
DOI: 10.1520/A0159-83R06.
2 on the drawing.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
6. Heat Treatment
Standards volume information, refer to the standard’s Document Summary page on
the ASTM website.
6.1 Unless otherwise specified, castings of Grades G1800
Available from Standardization Documents Order Desk, DODSSP, Bldg. 4,
and G2500 may be annealed in order to meet the desired
Section D, 700 Robbins Ave., Philadelphia, PA 19111-5098, http://
www.dodssp.daps.mil. hardness range.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
A159 – 83 (2006)
TABLE 2 Brake Drums and Clutch Plates for Special Service
A
Grade Carbon min, % Microstructure
Casting Hardness
Graphite Matrix
B
G2500a 3.40 HB 170-229 Type VII, size 2–4 lamellar pearlite
4.6–4.0 BID or as agreed A distribution ferrite if present not to exceed 15%
C B
G3500b 3.40 HB 207-255 Type VII, size 3–5 lamellar pearlite
4.2–3.8 BID or as agreed A distribution ferrite or carbide if present not to exceed 5%
C B
G3500c 3.50 HB 207-255 Type VII, size 3–5 lamellar pearlite
4.2–3.8 BID or as agreed A distribution ferrite or carbide, if present not to exceed 5%
A
The chemical analysis for total carbon shall be made on chilled pencil-type specimens or from thin wafers approximately 1/32 in. (0.8 mm) thick cut from test coupons.
Drillings are not reliable because of the probable loss of graphite.
B
See Method A247.
C
Grades G 3500b and G 3500c normally require alloying to obtain the specified hardness at the high carbon levels specified.
6.2 Appropriate heat treatment for removal of residual 9.6 Selective Hardening—The cam areas of camshaft cast-
stresses,ortoimprovemachinabilityorwearresistancemaybe ing are usually selectively hardened by flame or induction
specified by agreement between supplier and purchaser. hardening by the supplier. The depth and surface hardness of
thehardenedcaseshallbeasagreeduponbetweensupplierand
7. Microstructure
purchaser.
7.1 The microstructure shall consist of flake graphite in a
matrix of ferrite or pearlite or mixtures thereof. 10. Quality Assurance Provisions
7.2 As graphite size and shape somewhat affect hardness-
10.1 Responsibility for Inspection—Unless otherwise speci-
strength ratio and other properties, the type size and distribu-
fied in the contract or purchase order, the producer is respon-
tion of the graphite flakes at a designated location on the
sible for the performance of all inspection and tests require-
casting may be specified by agreement between supplier and
ments specified in this specification. Except as otherwise
purchaser in accordance with Method A247.
specified in the contract or purchase order, the producer may
7.3 Unless otherwise specified, the matrix microstructure of
use his own or any other suitable facilities for the performance
castingscoveredbythisspecificationshallbesubstantiallyfree
of the inspection and test requirements specified herein, unless
of primary cementite. Castings in Grades G1800 and G2500
disapproved by the purchaser. The purchaser shall have the
may have a matrix of ferrite or pearlite or both. Grades G3000,
right to perform any of the inspection and tests set for in this
G3500, and G4000 shall be substantially pearlite in matrix
specification where such inspections are deemed necessary to
structure.
assure that material conform to prescribed requirements.
10.2 Lot—For the purpose of inspection, lot and sampling
8. Heavy-Duty Brake Drums and Clutch Plates
plans shall be agreed upon between the purchaser and the
8.1 These castings are considered as special cases and are
producer.
covered in Table 2.
11. General
9. Alloy Gray Iron Automotive Camshafts
11.1 Castings furnished to this specification shall be repre-
9.1 These castings are considered as special cases.
sentative of good foundry practice and shall conform to
9.2 Grade Designation—G4000d.
dimensions and tolerances specified on the casting drawing.
9.3 Chemistry—Alloy gray iron camshafts shall contain
11.2 Minor imperfections usually not associated with the
alloys within the following range or as agreed upon between
structural function may occur in castings. These are often
supplier and purchaser.
repairable but repairs shall be made only where allowed by the
Chromium 0.85–1.25 %
purchaser and only by approved methods.
Molybdenum 0.40–0.60 %
11.3 Additional casting requirements may be agreed upon
Nickel as agreed
by purchaser and supplier. These should appear as product
9.4 Casting Hardness—HB 241-321 determined on a bear-
specifications on the casting or part drawing.
ing surface as agreed by supplier and purchaser.
9.5 Microstructure—Extending 45° on both sides of the
12. Preparation for Delivery
centerline of the cam nose and to a minimum depth of 1 8 in.
/
(3.2 mm), the surface shall consist of primary carbides (of 12.1 Unless otherwise specified in the contract or purchase
order, castings shall be cleaned, preserved, and packaged in
acicular or cellular form or a mixture thereof) and graphite in
accordance with supplier’s standard commercial practice.
a fine pearlitic matrix. The graphite shall be Type VIIAand E
12.2 Government Procurement—When specified for Gov-
distribution, 4 to 7 flake size in accordance with MethodA247.
The amount of primary carbides and location at which the ernment procurement, castings shall be marked for shipment in
accordance with MIL-STD-129 for military procurement and
structureischeckedshallbeamatterofagreementbetweenthe
supplier and the purchaser. Fed. Std. No. 123 for civil agency procurement.
A159 – 83 (2006)
APPENDIX
(Nonmandatory Information)
X1. GRAY IRON
TABLE X1.2 Usual Composition of Brake Drums and Clutch
X1.1 Definition
Plates for Special Service
X1.1.1 gray iron—a cast iron in which the graphite is
present as flakes instead of temper carbon nodules as in
Chemical Compo- Grade Grade Grade
malleable iron or small spherulites as in ductile iron. sition, % G2500a G3500b G3500c
Carbon, total (mandatory) 3.40 min 3.40 min 3.50 min
X1.2 Chemical Composition
Silicon (as required) 1.60–2.10 1.30–1.80 1.30–1.80
Manganese (as required) 0.60–0.90 0.60–0.90 0.60–0.90
X1.2.1 The ranges in composition generally employed in
Sulfur, max 0.12 0.12 0.12
producing the various grades of most automotive gray iron
Phosphorus, max 0.15 0.15 0.15
castings are shown in Table X1.1. The composition ranges for
Alloys as required as required as required
such special applications as heavy duty brake drums and clutch
plates and camshafts are shown in Table X1.2 and Table X1.3,
respectively. The contents of certain elements for these appli- TABLE X1.3 Usual Chemical Composition of Alloy Gray Iron
Automotive Camshafts
cations are critical in terms of service requirements and the
ranges are specified in the standard.
Grade G4000d, %
X1.2.2 The specific composition range for a given grade
may vary according to the prevailing or governing section of
Total carbon 3.10–3.60
Silicon
...
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