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WHAT IS THE OPTIMUM BASE SULPHUR

CONTENT PRIOR TO NODULATISATION?
by
Reginald D. Forrest, Sorelmetal Technical Services

Sulphur control in the production of Ductile Iron

has long been recognized as being essential.
Most foundries are fully aware of the dangers
involved in allowing the level of sulphur to
increase in the base iron. The risk is undertreatment (Mg content too low) with consequent
poor graphite shape (Figure A). Higher sulphur
levels call for increased additions of nodularizing
alloy with consequent higher treatment costs and
dangers of sulphite dross defects (Figure B).
With these higher sulphur levels there is an
increased tendency for nodularity fade and of
course
problems
in
meeting
required
specifications.

shrinkage,
and
poor
machinability and
brittleness. These problems with excessive Mg
do not take into account the additive effect of Ce
as a desulphurizer and nodularizer.

FIGURE B. The Microscopic Appearance of Magnesium Silicate Inclusions.

Indeed, there is increasing evidence that small

amounts of sulphides (possibly Ca, Ba, Ce
and/or Mg) may assist the nucleation of graphite
as well as influencing the surface tension of the
liquid phase and thereby further influencing the
nucleation and growth of graphite, Figure D.

FIGURE A. Under-Treatment with Poor Nodularity.

What is not so well recognized are the dangers

of too low a sulphur content. When the
sulphur content in the base iron is very low - for
example 0.004% S and a magnesium treatment
is made which results in a residual Mg of say
0.045% Mg, then the effective Mg level is too
high. The result is that undesirable carbides
(chill Figure C) may be formed with all of the
unwanted problems of high hardness, low
nodule counts, poor graphite shape, increased

RIT Technical Services metallurgists, as well as

many others in the field, have been frequently
confronted with problems associated with
unsatisfactory graphite forms, low nodule counts,
carbides etc. in Ductile Iron. There can be many
and varied causes for such structures - including
the
presence
of
subversive
elements,
metal/mould reactions, excessive amounts of
carbide stabilizing elements, etc. - but unsuitable
and variable levels of sulphur in the base iron
have, in our experience, often been found to be
responsible for many of these such problems.

Where the sulphur level of the base iron is

too high, action is required to reduce it.
Use charge materials of known and consistent
analysis (Sorelmetal), low S graphite.
Desulphurize metal.
Change melting practice.
Where the sulphur level of the base iron is
too low (below 0.008%) it is necessary to
increase it in order to bring it within the
recommended range (0.008 - 0.012% S).
FIGURE C. Carbides (chill)

Where melting is made by Induction or rotary

furnaces, this can be done easily by the
controlled addition of iron sulphide (iron pyrite).
For each 0.001% of sulphur increase required an
addition of 30 g (0.067 lb) FeS per ton should be
made.
(eg. Where the base S content of a 1 ton of
liquid base iron is analyzed at 0.004% S an
addition of 180 g of pyrite is required).

FIGURE D. Optimum nodular graphite shape

In order to control and avoid the problems

associated with sulphur in Ductile Iron therefore
it is essential to regularly measure (analyze) the
sulphur content of the liquid base iron prior to
nodularizing.
In foundries where induction
melting is used, this is a fairly easy control to
establish and monitor frequently. In cupola
melting foundries, where desulphurisation prior
to nodularizing is practiced, it becomes a little
more problematic since the effectiveness of the
desulphurisation can vary depending on several
factors. Nevertheless, it is necessary to know
with reasonable accuracy the sulphur content of
the iron prior to the Mg treatment.
It is
RIT/Sorelmetal experience that the optimum
level of sulphur in the liquid base metal, prior to
Mg treatment should be approximately 0.01% S
(+/- 0.002). Above and below these levels there
is increasing risk of encountering problems.
WHAT MUST BE DONE
Regularly and routinely check the sulphur
content of your base liquid iron prior to
nodularization.

Where
cupola
melting
followed
by
desulphurisation (eg. porous plug / calcium
carbide) is practiced, it is necessary to
constantly adjust the practice (amount of carbide
addition or dwell time based upon the
temperature of the metal and degree of
agitation).
In situations where pure magnesium is used as a
one step desulphurisation/nodularization treatment, the control of the sulphur content is less
critical because the reaction removes most of
the sulphides.
However, in this case the
inoculation practice becomes more difficult and
other materials need to be considered to achieve
good nodularity.
REFERENCES

1.

2.
3.
4.

The effect of sulphur on the occurrence of

carbides in nodular cast iron. Paper by P.C. van
rd
Eldijk presented at the 53 World Foundry
Congress, September 1986.
Ductile Iron Handbook, published by AFS Chapter 4 pages 77-78.
Numerous unpublished QIT/RIT investigational
reports and field experiences.
Also see Suggestion Sheet 76.
REV March 2006