Effect of mould inoculation on formation of chunky graphite in heavy section spheroidal graphite cast iron parts

The manufacturing process of heavy section ductile iron castings is strongly influenced by the risk of graphite degeneration under slow cooling rates. Appearance of this kind of defect is commonly linked to significant reductions in the mechanical properties of large castings. Studies on the effect of inoculation on chunky graphite formation in heavy sections have led to contradictory results in the literature and this triggered the present work. New experimental data are presented on the effect of mould inoculation on chunky graphite appearance during solidification of nodular irons which clearly demonstrate that mould inoculation increases the risk of chunky graphite formation in heavy sections. This is in agreement with some previous works which are reviewed, and it is suggested that the contradiction with other results could relate to the fact that these latter works dealt with chill casting

Effect of antimony on the eutectic reaction of heavy section spheroidal graphite castings

There is a strong demand for heavy section castings made of spheroidal graphite with a fully ferritic matrix, e.g. for manufacturing hubs for windmills. Such castings with slow solidification process are prone to graphite degeneration that leads to a dramatic decrease of the mechanical properties of the cast parts. Chunky graphite is certainly the most difficult case of graphite degeneracy, though it has long been known that the limited and controlled addition of antimony may help eliminate it. The drawback of this remedy is that too large Sb additions lead to other forms of degenerate graphite, and also that antimony is a pearlite promoter. As part of an investigation aimed at mastering low level additions to cast iron melts before casting, solidification of large blocks with or without Sb added was followed by thermal analysis. Comparison of the cooling curves and of the microstructures of these different castings gives suggestions to understand the controlling nucleation and growth mechanisms for chunky graphite cells

Effect of alloying on mechanical properties of as cast ferritic nodular cast irons

The development of low temperature applications for ferritic nodular cast irons calls for improved materials in the as cast state, e.g. for off-shore windmills components. Within this line of work, a series of 68 castings were prepared with the same casting procedure and slight changes in composition. The tensile properties at room temperature, as well as the impact energy for rupture at room temperature, 220 °C and 240 °C, were measured. Outputs from multivariate analysis performed on the data are then discussed and compared to literature results, putting emphasis on the properties of the ferritic matrix

Effect of various dopant elements on primary graphite growth

Five spheroidal graphite cast irons were investigated, a usual ferritic grade and four pearlitic alloys containing Cu and doped with Sb, Sn and Ti. These alloys were remelted in a graphite crucible, leading to volatilization of the magnesium added for spheroidization and to carbon saturation of the liquid. The alloys were then cooled down and maintained at a temperature above the eutectic temperature. During this step, primary graphite could develop showing various features depending on the doping elements added. The largest effects were that of Ti which greatly reduces graphite nucleation and growth, and that of Sb which leads to rounded agglomerates instead of lamellar graphite. The samples have been investigated with secondary ion mass spectrometry to enlighten distribution of elements in primary graphite. SIMS analysis showed almost even distribution of elements, including Mg and Al (from the inoculant) in the ferritic grade, while uneven distribution was evident in all doped alloys. Investigations are going on to clarify if the uneven distribution is associated with structural defects in the graphite precipitates

Effect of Antimony and Cerium on the Formation of Chunky Graphite during Solidification of Heavy-Section Castings of Near-Eutectic Spheroidal Graphite Irons

Thermal analysis is applied to the study of the formation of chunky graphite (CHG) in heavysection castings of spheroidal graphite cast irons. To that aim, near-eutectic melts prepared in one single cast house were poured into molds containing up to four large cubic blocks 30 cm in size. Four melts have been prepared and cast that had a cerium content varying in relation with the spheroidizing alloy used. Postinoculation or addition of antimony was achieved by fixing appropriate amounts of materials in the gating system of each block. Cooling curves recorded in the center of the blocks show that solidification proceeds in three steps: a short primary deposition of graphite followed by an initial and then a bulk eutectic reaction. Formation of CHG could be unambiguously associated with increased recalescence during the bulk eutectic reaction. While antimony strongly decreases the amount of CHG, it appears that the ratio of the contents in antimony and cerium should be higher than 0.8 in order to avoid this graphite degeneracy

Active Mg Estimation Using Thermal Analysis: A Rapid Method to Control Nodularity in Ductile Cast Iron Production

Appropriate nodularity in ductile iron castings is strongly associated with the presence of high enough not combined Mg dissolved in the melt to cast. However, the residual Mg which is commonly measured for production control accounts for both dissolved Mg and Mg combined as oxides and sulfides. To account for the uncertainties associated with such a control, it is quite usual to over treat the melt with the risk of porosity appearance. A new methodology based on thermal analysis has been developed in the present work so as to estimate the amount of free Mg dissolved in the melt ready for pouring. A combination of Te mixture and a new “reactive mixture” composed of sulfur plus a commercial inoculant has been prepared for this purpose. This reactive mixture is able to transform the magnesium remaining dissolved in the melt to combined forms of this element. Experiments performed both during start of production (when Mg overtreatment is usual) and during normal mass production indicate that important variations of free Mg occur without relevant changes in residual Mg content as determined by spectrometry. The method developed in the present work has shown to be highly effective to detect those melt batches where active Mg content is not high enough for guaranteeing a correct nodularity of castings. Selection of proper active Mg thresholds and a correct inoculation process are critical to avoid “false”-negative results when using this new method