Excellent Machinability
Supports efficient machining and precision finishing.
CAST IRON CASTINGS
Cast Iron Castings
Reliable Strength. Superior Machinability. Proven Industrial Performance.
Bhanu Special Castings offers cast iron casting solutions engineered for dimensional stability, vibration damping, wear resistance, and dependable industrial performance. Cast iron components serve diverse engineering requirements across machinery, automotive, mining, pumps, and general industrial applications.
WHY CAST IRON CASTINGS?
Understanding Grey Cast Iron
Cast iron is an iron-carbon alloy generally containing more than 2% carbon, along with silicon and other alloying elements. It is widely used in engineering applications because of its excellent castability, machinability, vibration damping, and cost-effective production.
Grey cast iron contains graphite in the form of flakes distributed throughout a metallic matrix. These graphite flakes contribute to excellent vibration absorption, thermal conductivity, and machining characteristics.
Grey cast iron is particularly suitable for complex-shaped components, machine structures, pump housings, engine blocks, and industrial wear parts.
KEY ADVANTAGES
Key Advantages
Superior Vibration Damping
Reduces noise and vibration in machinery.
Good Castability
Enables complex shapes and intricate casting geometries.
Thermal Conductivity
Supports heat dissipation in industrial components.
Dimensional Stability
Suitable for rigid machine structures and housings.
Cost-Effective Manufacturing
An economical material for high-volume industrial applications.
THE VIBRATION DAMPING & MACHINABILITY ADVANTAGE
Engineered for Stability, Precision and Performance
Unlike many steel castings, grey cast iron contains graphite flakes that help dissipate vibrational energy and interrupt the formation of continuous machining chips. This combination makes it particularly effective for machinery foundations, engine components, pump bodies, and precision equipment.
Excellent Vibration Absorption
The graphite structure helps reduce operational vibration and noise, improving the stability of industrial machinery.
Enhanced Machinability
Graphite flakes assist chip formation and reduce machining resistance, supporting efficient finishing operations.
Dimensional Stability
Proper casting design, cooling, and stress-relief treatments help maintain dimensional accuracy during machining and service.
Thermal Performance
Grey cast iron offers useful thermal conductivity and heat dissipation characteristics for components exposed to temperature variations.
05 INTERNATIONAL STANDARDS & GRADE SPECIFICATIONS
Grey Cast Iron Grades Across International Standards
Grey cast iron castings are classified under various national and international material standards that define requirements for tensile strength, graphite morphology, mechanical properties, hardness, testing methods, and material quality.
Understanding these standards helps manufacturers, equipment suppliers, and industrial buyers select suitable grey cast iron grades based on application conditions, strength, machinability, and engineering specifications.
Although grade designations may differ between countries, many standards cover comparable families of grey iron castings. Exact equivalence and grade selection must be confirmed against the applicable standard edition.
Cross-Reference: International Grey Cast Iron Standards Worldwide
| Country / Region | Applicable Standards | Representative Grades / Coverage |
|---|---|---|
 India | IS 210:2009; IS 3355:1974; IS 3005 (Parts 1–4); IS 4771:1985; IS 7925:1976; IS 5519:1979; IS 13655:1993; IS 1536:2001 | FG 150, FG 180, FG 200, FG 220, FG 260, FG 300, FG 350, FG 400 |
 USA | ASTM A48/A48M; SAE J431 | Class 20, 25, 30, 35, 40, 50, 60; G1800, G2500, G3000, G3500, G4000 |
 Germany | DIN EN 1561; DIN 1691 (Legacy) | EN-GJL-150, 200, 250, 300, 350; GG-15, GG-20, GG-25, GG-30, GG-35 |
 Europe | EN 1561 | EN-GJL-100, EN-GJL-150, EN-GJL-200, EN-GJL-250, EN-GJL-300, EN-GJL-350 |
 China | GB/T 9439; GB/T 7216 | HT100, HT150, HT200, HT250, HT300, HT350 |
 Japan | JIS G 5501 | FC100, FC150, FC200, FC250, FC300, FC350 |
 United Kingdom | BS EN 1561; BS 1452 (Legacy) | EN-GJL-150, 200, 250, 300, 350; Grade 150, 180, 220, 260, 300 |
 France | NF EN 1561 | EN-GJL-150, EN-GJL-200, EN-GJL-250, EN-GJL-300, EN-GJL-350 |
 Italy | UNI EN 1561 | EN-GJL-150, EN-GJL-200, EN-GJL-250, EN-GJL-300, EN-GJL-350 |
 Australia | AS 1830 | T150, T180, T220, T260, T300, T350 |
 South Africa | SANS / SABS aligned Grey Iron Standards | Grade 150, Grade 200, Grade 250, Grade 300 |
 Russia | GOST 1412 | SCh10, SCh15, SCh20, SCh25, SCh30, SCh35 |
 Spain | UNE-EN 1561 | EN-GJL-150, EN-GJL-200, EN-GJL-250, EN-GJL-300, EN-GJL-350 |
 Sweden | SS-EN 1561 | EN-GJL-150, EN-GJL-200, EN-GJL-250, EN-GJL-300, EN-GJL-350 |
 Norway | NS-EN 1561 | EN-GJL-150, EN-GJL-200, EN-GJL-250, EN-GJL-300, EN-GJL-350 |
 South Korea | KS D 4301 | GC150, GC200, GC250, GC300, GC350 |
COUNTRY-WISE MATERIAL GRADES
Interactive Country-Wise Chemical Composition Tables
Select a country to explore grey cast iron grades and typical published chemical composition ranges (mass %).
IS 210 (India) — Grey Cast Iron Grades
| Grade | C % | Si % | Mn % | P % | S % | Min. Tensile Strength (MPa) | Brinell Hardness (HBW) |
|---|---|---|---|---|---|---|---|
| FG 150 | 3.40–3.70 | 2.10–2.60 | 0.50–0.80 | ≤ 0.20 | 0.06–0.15 | 150 | 130–180 |
| FG 200 | 3.20–3.50 | 1.80–2.30 | 0.60–0.80 | ≤ 0.20 | 0.06–0.15 | 200 | 160–220 |
| FG 220 | As agreed | As agreed | As agreed | As agreed | As agreed | 220 | 180–220 |
| FG 260 | 3.10–3.40 | 1.60–2.10 | 0.60–0.80 | ≤ 0.15 | 0.06–0.12 | 260 | 180–230 |
| FG 300 | As agreed | As agreed | As agreed | As agreed | As agreed | 300 | 180–230 |
| FG 350 | As agreed | As agreed | As agreed | As agreed | As agreed | 350 | 207–241 |
| FG 400 | As agreed | As agreed | As agreed | As agreed | As agreed | 400 | 207–270 |
Chemistry: typical foundry examples, not IS 210 limits (Clauses 6.1–6.2). Tensile strength and hardness: IS 210:2009, Table 3; tensile values apply to separately cast test bars. FG 150 testing is required only when specified by the purchaser.
ASTM A48 (USA) — Grey Cast Iron Grades
| Grade | C % | Si % | Mn % | P % | S % |
|---|---|---|---|---|---|
| Class 20 | 3.20–3.50 | 1.80–2.40 | 0.50–0.90 | ≤ 0.20 | ≤ 0.20 |
| Class 25 | 3.20–3.50 | 1.60–2.40 | 0.60–0.90 | ≤ 0.20 | ≤ 0.15 |
| Class 30 / 30B | 3.20–3.50 | 1.80–2.30 | 0.60–0.80 | ≤ 0.20 | 0.06–0.15 |
| Class 35 | 2.80–3.30 | 1.20–1.70 | 0.80–1.20 | ≤ 0.15 | ≤ 0.12 |
| Class 40 | 2.90–3.20 | 1.50–2.00 | 0.60–0.90 | ≤ 0.15 | ≤ 0.12 |
| Class 45 | As agreed | As agreed | As agreed | As agreed | As agreed |
| Class 50 | 3.25–3.50 | 1.80–2.30 | 0.50–0.90 | ≤ 0.12 | ≤ 0.15 |
| Class 55 | As agreed | As agreed | As agreed | As agreed | As agreed |
| Class 60 | As agreed | As agreed | As agreed | As agreed | As agreed |
Typical supplier examples (mass %), not ASTM limits. Casting-specific rows require a validated foundry recipe; higher classes may need alloy additions.
DIN / EN (Germany/EU) — Grey Cast Iron Grades
| Grade | C % | Si % | Mn % | P % | S % |
|---|---|---|---|---|---|
| EN-GJL-150 | 3.20–3.60 | 2.10–2.60 | 0.50–0.90 | ≤ 0.20 | ≤ 0.15 |
| EN-GJL-200 | 3.10–3.50 | 1.90–2.40 | 0.50–0.90 | ≤ 0.15 | ≤ 0.12 |
| EN-GJL-250 | 3.00–3.40 | 1.80–2.30 | 0.60–1.00 | ≤ 0.12 | ≤ 0.12 |
| EN-GJL-300 | 2.95–3.30 | 1.70–2.20 | 0.70–1.10 | ≤ 0.10 | ≤ 0.12 |
| EN-GJL-350 | 2.90–3.20 | 1.60–2.10 | 0.80–1.20 | ≤ 0.10 | ≤ 0.12 |
Typical foundry ranges (mass %), not EN 1561 limits. Higher grades may also use Cr, Cu, Mo, Ni or Sn additions.
GB/T 9439 (China) — Grey Cast Iron Grades
| Grade | C % | Si % | Mn % | P % | S % |
|---|---|---|---|---|---|
| HT100 | 3.40–3.90 | 2.10–2.60 | 0.50–0.80 | ≤ 0.30 | ≤ 0.15 |
| HT150 | 3.20–3.50 | 1.90–2.30 | 0.50–0.80 | ≤ 0.20 | ≤ 0.12 |
| HT200 | 3.10–3.40 | 1.50–1.80 | 0.80–1.00 | ≤ 0.15 | ≤ 0.12 |
| HT250 | 2.90–3.20 | 1.30–1.60 | 0.90–1.10 | ≤ 0.15 | ≤ 0.12 |
| HT300 | 2.90–3.20 | 1.20–1.50 | 0.90–1.10 | ≤ 0.15 | ≤ 0.10 |
| HT350 | 2.80–3.10 | 1.20–1.50 | 1.00–1.30 | ≤ 0.15 | ≤ 0.12 |
Published production examples (mass %), not GB/T limits. HT150–HT350 examples use 30–50 mm sections; chemistry changes with section thickness.
JIS G 5501 (Japan) — Grey Cast Iron Grades
| Grade | C % | Si % | Mn % | P % | S % |
|---|---|---|---|---|---|
| FC100 | 3.50–3.70 | 2.20–2.60 | 0.50–0.80 | ≤ 0.30 | ≤ 0.15 |
| FC150 | 3.50–3.70 | 2.00–2.40 | 0.50–0.80 | ≤ 0.20 | ≤ 0.15 |
| FC200 | 3.30–3.50 | 1.40–2.40 | 0.70–1.00 | ≤ 0.20 | ≤ 0.15 |
| FC250 | 3.20–3.40 | 1.40–2.20 | 0.70–1.00 | ≤ 0.20 | ≤ 0.15 |
| FC300 | 3.00–3.20 | 1.30–1.90 | 0.70–1.00 | ≤ 0.20 | ≤ 0.12 |
| FC350 | 2.90–3.00 | 1.20–1.50 | 0.70–1.10 | ≤ 0.20 | ≤ 0.12 |
Typical supplier examples (mass %), not JIS limits. Final chemistry depends on casting geometry, cooling conditions and the required properties.
CAST IRON PRODUCT RANGE
Industrial Cast Iron Components
for Diverse Applications
The following categories represent potential grey cast iron product applications. Contact BSCPL to confirm manufacturing suitability for your component and specification.
01Pump Castings
Cast iron components designed for fluid-handling equipment, dimensional accuracy, and structural stability.
Subproducts
02Valve & Pipeline Components
Cast components used in industrial flow-control systems and pipeline assemblies.
Subproducts
03Machine Tool Castings
Rigid, vibration-damping components for precision manufacturing machinery.
Subproducts
04Industrial Machinery Castings
Engineered structural components for equipment assemblies and rotating machinery.
Subproducts
05Automotive & Engine Castings
Cast iron components designed for heat dissipation, wear performance, and machining precision.
Subproducts
06General Engineering Castings
Custom components manufactured for industrial machinery and engineering assemblies.
Subproducts
Step-by-Step Manufacturing Process
From Raw Material to
Finished Cast Iron Components
Our manufacturing workflow is structured around material control, casting accuracy, process consistency, and quality inspection.
Raw Material Selection
Selection and preparation of suitable iron-bearing charge materials, returns, and alloying additions.
Pattern & Mould Preparation
Development of patterns, cores, and moulds according to approved component drawings.
Melting & Composition Control
Melting of charge materials with adjustments to achieve the targeted chemical composition.
Inoculation & Melt Treatment
Controlled inoculation to promote the desired graphite formation and casting structure.
Molten Metal Pouring
Pouring at controlled temperatures using suitable gating and feeding arrangements.
Cooling & Solidification
Controlled solidification to develop the required graphite and metallic matrix structure.
Shakeout & Fettling
Removal of moulding materials, runners, risers, and surface irregularities.
Heat Treatment (If Required)
Stress relieving or other specified treatments to improve dimensional stability or microstructure.
Machining & Finishing
Machining, dimensional finishing, and surface preparation according to customer requirements.
Inspection & Dispatch
Final verification, documentation, protection, and packaging for delivery.
MECHANICAL & PHYSICAL PROPERTIES
Typical Properties of
Grey Cast Iron Castings
The mechanical and physical properties of grey cast iron depend on chemical composition, graphite flake morphology, matrix structure, casting section thickness, cooling conditions, and manufacturing process.
TYPICAL MECHANICAL PROPERTIES
OF GREY CAST IRON (IS 210:2009)
Grey cast iron grades are classified based on minimum tensile strength as per IS 210:2009. Hardness values are specified ranges for the respective grades.
| Grade | Nominal Minimum Tensile Strength (MPa) | Brinell Hardness Range (HBW) (as per IS 210:2009) |
|---|---|---|
| FG 150 | 150 | 130–180 |
| FG 200 | 200 | 160–220 |
| FG 220 | 220 | 180–220 |
| FG 260 | 260 | 180–230 |
| FG 300 | 300 | 180–230 |
| FG 350 | 350 | 207–241 |
| FG 400 | 400 | 207–270 |
Tensile strength values are specified for separately cast test bars under IS 210:2009 conditions. They do not guarantee identical properties at every location within a finished casting. Hardness verification should be performed at agreed inspection locations.
TYPICAL PHYSICAL PROPERTIES
The following values are general engineering reference ranges for grey cast iron.
| Property | Representative Range |
|---|---|
| Density | 7.0–7.3 g/cm³ |
| Elastic Modulus | 70–140 GPa |
| Thermal Conductivity | 35–55 W/m·K |
| Specific Heat Capacity | 450–550 J/kg·K |
| Coefficient of Thermal Expansion | 10–13 × 10⁻⁶/K |
| Poisson’s Ratio | Approximately 0.20–0.28 |
| Melting / Solidification Range | Approximately 1,150–1,250°C |
These are typical values and may vary depending on chemical composition, microstructure, temperature, casting section thickness, and test conditions. Grade-specific certified values should be used for critical design calculations.
FACTORS AFFECTING PROPERTIES
OF GREY CAST IRON CASTINGS
The final properties of grey cast iron components are influenced by several metallurgical and manufacturing factors. Proper control of these factors helps achieve the desired mechanical, physical, and machining characteristics.
CARBON (C)
Influences graphite formation and matrix structure. Higher carbon content promotes graphite flakes, improving machinability but reducing tensile strength.
SILICON (Si)
Acts as a graphitizing element. Improves fluidity, castability, and thermal conductivity. Helps stabilise graphite and influences matrix structure.
GRAPHITE FLAKE MORPHOLOGY
Size, distribution, and orientation of graphite flakes affect tensile strength, machinability, vibration damping, and thermal conductivity.
MATRIX STRUCTURE
Ferritic, pearlitic, or mixed matrix structures influence hardness, strength, wear performance, and machining characteristics.
COOLING RATE
Affects graphite flake size and matrix structure. Controlled cooling helps achieve uniform properties and reduces the risk of internal defects.
CASTING SECTION THICKNESS
Thicker sections cool slowly, leading to coarser graphite and lower tensile strength. Thinner sections cool faster, resulting in finer graphite and higher strength.
KEY PERFORMANCE CHARACTERISTICS
OF GREY CAST IRON
Good
Machinability
Excellent
Vibration Damping
High
Thermal Conductivity
Dimensional
Stability
MICROSTRUCTURE OF CAST IRON CASTINGS
Understanding Flake Graphite
and Matrix Structure
The microstructure of grey cast iron primarily consists of graphite flakes distributed within a ferritic, pearlitic, or mixed ferrite-pearlite matrix. The morphology, distribution, and size of graphite flakes play a significant role in determining the casting’s strength, machinability, thermal conductivity, and vibration-damping behaviour.
01Flake Graphite Structure
Graphite flakes dispersed throughout the metallic matrix provide vibration damping and machinability.
02Pearlitic Matrix
A pearlite-rich matrix generally improves strength and hardness compared with a ferrite-rich matrix.
03Ferritic Matrix
A ferrite-rich matrix provides lower hardness and generally favourable machinability.
04Ferrite-Pearlite Matrix
A mixed matrix offers a balance between machinability, strength, and hardness.
Microstructural Characteristics
| Characteristic | Description |
|---|---|
| Graphite Form | Flake / lamellar graphite |
| Graphite Distribution | Commonly Type A; other distributions may occur |
| Matrix Structure | Ferritic, pearlitic, or ferrite-pearlite |
| Carbide Content | Controlled according to required properties |
| Graphite Size | Influenced by cooling rate and section thickness |
| Inspection Method | Metallographic examination |
The micrographs shown are illustrative references. Production micrographs should be obtained from actual tested BSCPL samples before publication as company test evidence.
QUALITY ASSURANCE & INSPECTION
Quality Control Throughout
the Casting Process
Our quality approach focuses on material verification, dimensional accuracy, structural integrity, and compliance with customer-defined specifications.
Inspection / Testing Activities
A range of tests and inspections are carried out to ensure that castings meet the required mechanical, dimensional, and quality standards.
| Inspection / Test | Purpose |
|---|---|
| Chemical Composition Analysis | Verification of alloying elements |
| Tensile Strength Testing | Confirmation of specified mechanical strength |
| Brinell Hardness Testing | Assessment of hardness |
| Metallographic Examination | Evaluation of graphite distribution and matrix |
| Dimensional Inspection | Verification against approved drawings |
| Visual Inspection | Identification of surface imperfections |
| Ultrasonic Testing (where applicable) | Assessment of internal discontinuities, subject to material limitations |
| Pressure / Leak Testing (where specified) | Verification of pressure-retaining components |
| Surface Inspection | Assessment of surface quality and finish |
01Chemical Composition Analysis
Verification of alloying elements
02Tensile Strength Testing
Confirmation of specified mechanical strength
03Brinell Hardness Testing
Assessment of hardness
04Metallographic Examination
Evaluation of graphite distribution and matrix
05Dimensional Inspection
Verification against approved drawings
06Visual & Surface Inspection
Identification of surface imperfections.
07Ultrasonic Testing (where applicable)
Assessment of internal discontinuities.
08Pressure / Leak Testing (where specified)
Verification of pressure-retaining components.
Inspection procedures and acceptance criteria are selected according to applicable standards, purchase specifications, and component requirements.
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Cast Iron Castings
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