ASTM A159-83(2011)

NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
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Designation:A159 −83(Reapproved 2011)
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.
1. Scope 4.1.2 Grade designation of gray iron required (3.1),
4.1.3 If special heat treatment is required (see Section 6),
1.1 This specification applies to gray iron castings, cast in
4.1.4 If special microstructure requirements are needed (see
sand molds, used in the products of the automobile, truck,
Section 7),
tractor, and allied industries.
4.1.5 Surface where hardness test is to be performed (see
1.2 The values stated in inch-pound units are to be regarded
9.4),
as standard. No other units of measurement are included in this
4.1.6 Depth and surface hardness of case required (see 9.6),
standard.
4.1.7 Inspection lot and sampling plan required (see Section
10),
2. Referenced Documents
4.1.8 If additional requirements are needed (see 11.3), and
2.1 The following documents of the issue in effect on the
4.1.9 Whether special packaging and marking is required
dateofmaterialprocurementformapartofthisspecificationto
(see Section 12).
the extent referenced herein:
5. Hardness
2.2 ASTM Standards:
A247 Test Method for Evaluating the Microstructure of
5.1 The foundry shall exercise the necessary controls and
Graphite in Iron Castings inspection techniques to ensure compliance with the specified
E10 Test Method for Brinell Hardness of Metallic Materials
hardness range, Brinell hardness shall be determined in accor-
2.3 Military Standard: dance with Test Method E10, after sufficient material has been
MIL-STD-129 Marking for Shipment and Storage
removed from the casting surface to ensure representative
2.4 Federal Standard: hardness readings. The 10-mm ball and 3000-kg load shall be
used unless otherwise agreed upon. The area or areas on the
Fed. Std. No. 123 Marking for Shipment (Civil Agencies)
casting where hardness is to be checked shall be established by
3. Grades
agreement between supplier and purchaser and shall be shown
on the drawing.
3.1 The specified grades, hardness ranges, and metallurgical
description are shown in Table 1 and Table 2 and in Section 9.
6. Heat Treatment
4. Ordering Information
6.1 Unless otherwise specified, castings of Grades G1800
4.1 Orders for materials under this specification shall in- and G2500 may be annealed in order to meet the desired
clude the following information: hardness range.
4.1.1 ASTM designation,
6.2 Appropriate heat treatment for removal of residual
stresses,ortoimprovemachinabilityorwearresistancemaybe
specified by agreement between supplier and purchaser.
This specification is under the jurisdiction of ASTM Committee A04 on Iron
CastingsandisthedirectresponsibilityofSubcommitteeA04.01onGreyandWhite
Iron Castings.
7. Microstructure
Current edition approved March 1, 2011. Published September 2011. Originally
7.1 The microstructure shall consist of flake graphite in a
approved in 1935. Last previous edition approved in 2006 as A159 – 83 (2006).
DOI: 10.1520/A0159-83R11.
matrix of ferrite or pearlite or mixtures thereof.
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
7.2 As graphite size and shape somewhat affect hardness-
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Standards volume information, refer to the standard’s Document Summary page on
strength ratio and other properties, the type size and distribu-
the ASTM website.
tion of the graphite flakes at a designated location on the
Available from Standardization Documents Order Desk, DODSSP, Bldg. 4,
casting may be specified by agreement between supplier and
Section D, 700 Robbins Ave., Philadelphia, PA 19111-5098, http://
www.dodssp.daps.mil. purchaser in accordance with Method A247.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
A159−83 (2011)
TABLE 1 Grades of Gray Iron
structure is checked shall be a matter of agreement between the
Grade Casting Hardness Range Description supplier and the purchaser.
9.6 Selective Hardening—The cam areas of camshaft cast-
G1800 HB 187 max ferritic-pearlitic
A
4.4 BID min or as agreed
ing are usually selectively hardened by flame or induction
G2500 HB 170-229 pearlitic-ferritic
hardening by the supplier. The depth and surface hardness of
A
4.6–4.0 BID or as agreed
thehardenedcaseshallbeasagreeduponbetweensupplierand
G3000 HB 187-241 pearlitic
A
4.4–3.9 BID or as agreed
purchaser.
G3500 HB 207-255 pearlitic
A
4.2–3.8 BID or as agreed
10. Quality Assurance Provisions
G4000 HB 217-269 pearlitic
A
10.1 Responsibility for Inspection—Unless otherwise speci-
4.1–3.7 BID or as agreed
A fied in the contract or purchase order, the producer is respon-
Brinell impression diameter (BID) is the diameter in millimetres of the impres-
sion of a 10 mm ball at 3000-kg load.
sible for the performance of all inspection and tests require-
ments specified in this specification. Except as otherwise
specified in the contract or purchase order, the producer may
use his own or any other suitable facilities for the performance
7.3 Unless otherwise specified, the matrix microstructure of
of the inspection and test requirements specified herein, unless
castingscoveredbythisspecificationshallbesubstantiallyfree
disapproved by the purchaser. The purchaser shall have the
of primary cementite. Castings in Grades G1800 and G2500
right to perform any of the inspection and tests set for in this
may have a matrix of ferrite or pearlite or both. Grades G3000,
specification where such inspections are deemed necessary to
G3500, and G4000 shall be substantially pearlite in matrix
assure that material conform to prescribed requirements.
structure.
10.2 Lot—For the purpose of inspection, lot and sampling
plans shall be agreed upon between the purchaser and the
8. Heavy-Duty Brake Drums and Clutch Plates
producer.
8.1 These castings are considered as special cases and are
covered in Table 2.
11. General
11.1 Castings furnished to this specification shall be repre-
9. Alloy Gray Iron Automotive Camshafts
sentative of good foundry practice and shall conform to
9.1 These castings are considered as special cases.
dimensions and tolerances specified on the casting drawing.
9.2 Grade Designation—G4000d.
11.2 Minor imperfections usually not associated with the
structural function may occur in castings. These are often
9.3 Chemistry—Alloy gray iron camshafts shall contain
repairable but repairs shall be made only where allowed by the
alloys within the following range or as agreed upon between
purchaser and only by approved methods.
supplier and purchaser.
Chromium 0.85–1.25 % 11.3 Additional casting requirements may be agreed upon
Molybdenum 0.40–0.60 %
by purchaser and supplier. These should appear as product
Nickel as agreed
specifications on the casting or part drawing.
9.4 Casting Hardness—HB 241-321 determined on a bear-
12. Preparation for Delivery
ing surface as agreed by supplier and purchaser.
12.1 Unless otherwise specified in the contract or purchase
9.5 Microstructure—Extending 45° on both sides of the
order, castings shall be cleaned, preserved, and packaged in
centerline of the cam nose and to a minimum depth of ⁄8 in.
accordance with supplier’s standard commercial practice.
(3.2 mm), the surface shall consist of primary carbides (of
acicular or cellular form or a mixture thereof) and graphite in
12.2 Government Procurement—When specified for Gov-
a fine pearlitic matrix. The graphite shall be Type VIIAand E ernment procurement, castings shall be marked for shipment in
distribution, 4 to 7 flake size in accordance with Method A247.
accordance with MIL-STD-129 for military procurement and
The amount of primary carbides and location at which the Fed. Std. No. 123 for civil agency procurement.
A159−83 (2011)
TABLE 2 Brake Drums and Clutch Plates for Special Service
A
Grade Carbon min, % Microstructure
Casting Hardness
Matrix
Graphite
B
G2500a 3.40 HB 170-229 Type VII, size 2–4 lamellar pearlite
A distribution
4.6–4.0 BID or as agreed ferrite if present not to exceed 15%
C B
G3500b 3.40 HB 207-255 Type VII, size 3–5 lamellar pearlite
A distribution
4.2–3.8 BID or as agreed ferrite or carbide if present not to exceed 5%
C B
G3500c 3.50 HB 207-255 Type VII, size 3–5 lamellar pearlite
A distribution
4.2–3.8 BID or as agreed ferrite or carbide, if present not to exceed 5%
A 1
The chemical analysis for total carbon shall be made on chilled pencil-type specimens or from thin wafers approximately ⁄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.
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
Chemical Compo- Grade Grade Grade
present as flakes instead of temper carbon nodules as in
sition, % G2500a G3500b G3500c
malleable iron or small spherulites as in ductile iron.
Carbon, total (mandatory) 3.40 min 3.40 min 3.50 min
Silicon (as required) 1.60–2.10 1.30–1.80 1.30–1.80
X1.2 Chemical Composition
Manganese (as required) 0.60–0.90 0.60–0.90 0.60–0.90
Sulfur, max 0.12 0.12 0.12
X1.2.1 The ranges in composition generally employed in
Phosphorus, max 0.15 0.15 0.15
producing the various grades of most automotive gray iron
Alloys as required as required as required
castings are shown in Table X1.1. The composition ranges for
such special applications as heavy duty brake drums and clutch
plates and camshafts are shown in Table X1.2 and Table X1.3,
TABLE X1.3 Usual Chemical Composition of Alloy Gray Iron
Automotive Camshafts
respectively. The contents of certain elements for these appli-
cations are critical in terms of service requirements and the
Grade G4000d, %
ranges are specified in the standard.
Total carbon 3.10–3.60
X1.2.2 The specific composition range for a given grade Silicon 1.95–2.40
Manganese 0.60–0.90
may vary according to the prevailing or governing
...