Cast Iron or Billet Steel Flywheel?
If you are involved in the automotive, locomotive, marine, or aerospace industry—or indeed any application where an engine is used—you have probably encountered a flywheel. Flywheels, originally invented to power steam engines, have been used since the 1800s.
The world has changed considerably since then, and engines nowadays have moved on. But the flywheel remains an important component of the internal combustion engine. Its design has been improved and developed, but the principle of operation remains the same – the rotational effect stores energy, which feeds the engine.
Historically, flywheels were made from cast iron, but engines have progressed over time. Here, we will discover why alternative materials are used in certain flywheel applications and why restoring original cast iron flywheels is still an important process.
What on Earth is a Flywheel?
A flywheel is an integral piece of machinery. It is primarily used in the automotive and locomotive industry and has been relied upon since James Watt contributed to its invention during the Industrial Revolution. It is a heavy wheel attached to a rotating shaft, and its efficient rotation acts as a power bank, storing kinetic energy and deploying it when required. The flywheel distributes power evenly, allowing the motor to run smoothly regardless of fluctuations in momentum. This creates less wear on the engine. The weight is around the wheel’s rim, away from the centre, and when speed and kinetic energy increase, the stress on the outer rim also increases.
Cast Iron vs Billet Steel Flywheel
Depending on its purpose, a flywheel can be manufactured using different weights and different materials. Its efficiency is determined by the maximum amount of energy it can store per unit of weight.
Stress tolerance levels must be calculated when producing a flywheel. As rotational speed increases, the amount of stored energy increases, creating stress on the material. Too much material stress will cause the flywheel to break apart.
Historically, cast iron was the preferred material for a flywheel. It has great durability and castability, but for safety reasons, it is only suitable for engines operating below 6000 rpm. At speeds in excess of this, the cast iron could break apart, causing significant injury.
More recently, newer engines capable of high speeds and increased stress have caused a shift to billet steel in the production of flywheels. Billet steel is formed using a casting process that produces a material of higher strength than cast iron. Billet steel flywheels should be used in engines producing power in excess of 6000 rpm.
Why Restore A Flywheel?
You may be surprised to learn that cast iron machinery remains in operation in traditional factories nationwide. Like modern machinery, its components need to be maintained and restored. Correct upkeep will ensure that the cast iron elements will continue to run for years to come, which is important to the smooth running of businesses all over the country.
Restoring and reusing benefits the environment too, and costs much less than manufacturing a new item.
Cast iron flywheels have been used traditionally in steam engines and other vintage machinery applications since the Industrial Revolution. Since then, these vintage motors have been restored and preserved for others to enjoy, as they are an important part of our history.
Vintage machinery and vehicles are valuable historical resources. They help us learn about engineering processes from the past and the many theories we still apply today. Examples of historic engines are available to view in museums up and down the country, and the restoration process is vital in populating these institutions.
At Cast Iron Welding Services, we are passionate about heritage restoration. Over the years, we have perfected our restoration techniques and processes and consider ourselves experts in the field. We can restore your cast iron components back to their original glory.
Marie Palmer
Director
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