In this work, different percentages of copper were added to grey cast iron to investigate its effect on microstructures, mechanical properties and corrosion behavior of the tested cast iron. Mechanical testing included hardness, tension, compression and impact, while corrosion testing was conducted by immersing specimens in 1 mol HCl for different exposure times (120, 240, 360, 480, and 600 hrs). It was found that the copper addition had a remarkable effect on graphite morphology, as well as, pearlite and ferrite existing. Copper content proved to affect mechanical properties, improving these properties up to 2 percent, after which a decrease was noticed. Copper addition has no noticeable effect on percentage tensile strain to fracture, however, it has an obvious effect on the percentage compressive strain to fracture, especially for 2.0 percent copper addition. The alloys containing 0.0 percent and 1.0 percent copper recorded the lower corrosion resistance, while those containing 2.0 percent and 4.0 percent copper addition gave the higher corrosion resistance. Also, the corrosion rate decreased with the increase of copper content. A change in the angle of fracture in compression was noticed for corroded specimens from about 55 to 90 degrees as exposure time increases.
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