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THE MOST IMPORTANT PART
OF DUCTILE IRON PRODUCTION - INOCULATION
by
James D. Mullins, Sorelmetal Technical Services
Proper inoculation of graphitic cast irons cannot be
over emphasized, because this step defines the final
microstructure and resultant properties and minimizes
problems. Inoculation, if done correctly, controls the
nodule count, reduces or eliminates carbides,
produces the correct mechanical properties, improves
machinability, and will decrease shrinkage.
Overall chemistry control, magnesium treatment, and
magnesium fading are all important steps in iron
processing, but all these can be dominated in
importance to a certain extent through good
inoculation. Simply stated, inoculation is necessary
because of the chilling tendency of the low sulphur
content of the base Ductile Iron and the addition of
magnesium (and cerium), which both increase the
undercooling of the metal. Inoculation introduces
additional nuclei which cause graphite precipitation.
This reduces the undercooling and formation of
carbides.
Below are some examples of problems encountered in
foundries by our technical services engineers. All of
which have been overcome through effective
inoculation.
· Deterioration of nodule shape is often attributed to
low magnesium content, but in many cases is
caused by fading of the inoculant. A small addition
of inoculant will restore the shape and often
increase the nodule count. A good case for using a
small late inoculation in addition to the ladle
inoculation step if pouring time is to be extended.
· More often carbides in castings are caused by poor
practice or faded inoculation and fast cooling rates
rather than by higher levels of carbide promoting
elements, such as chromium.
· Excessive cerium and/or magnesium content can
increase carbides and/or deteriorate nodule shape.
The solution can be as simple as reducing or
changing the content of nodularizing alloy elements
and possibly increasing the amount or
effectiveness of the inoculation. In very thin
sectioned castings often a higher rare earth content
will improve the effectiveness of the inoculation.
· Many foundries add the same amount of
inoculation for all sizes of castings produced. This
is usually never correct. Castings with thin
sections and fast cooling rates will require more
inoculation. The addition rate used for gray cast
iron will almost always be less than the amount
used for Ductile Iron.
· Reducing the melting and pouring temperatures
where possible will usually make the same
inoculant addition as before, more effective and
reduce the fading.
· Changing the type of inoculant from a regular 50 or
75% FeSi (relatively weak) to one which is stronger
and more cost effective (possibly containing
barium) may reduce not only the amount to be
added, but will also decrease the fading tendency.
Inoculation can be accomplished in one or all of three
ways; prior to the magnesium treatment (also called
preconditioning), simultaneously with treatment, and
after the treatment (called late inoculation). Normally
the later in the process that inoculation is performed
the more effective it will be. This is the reason that in-
stream and in-mold techniques have become so
popular. However, there are many procedures that
must be followed to make the inoculation process
effective.
PRINCIPLES OF EFFECTIVE INOCULATION
· Check and maintain a low base iron chill value
before treatment and inoculation.
· Add the correct amount, type, and size of inoculant
for the amount of metal to be treated and the
casting section size/cooling rate. Excessive fines
in the inoculant may give poor results because they
are already oxidized.
· Do not over inoculate. It may increase shrinkage.
· Add inoculant and pour metal at the correct
temperature for the casting section. High
temperatures increase fading tendency and low
temperatures promote carbide formation.
· Insure proper mixing of the inoculant into the metal
to give homogeneous final microstructures.
· Minimize oxidation of the metal after the inoculant
has been added.
· Keep metal holding time after inoculation as short
as possible.
Figure 1. Dimensions of step-plate casting.
- Evaluate the effectiveness of the inoculation
process.
INOCULANT EVALUATION
There are a number of ways to check the
effectiveness of an inoculant on the microstructure
and hardness. A faulty one is to wait until the
customer complains about machinability or another
problem. The best, but often most expensive, is to cut
up and evaluate the microstructure of individual
castings in a number of areas on an ongoing basis.
Several easier and often effective methods are shown
in Figures 1 and 2. The preferred methos is the step
plate (or step wedge) (Fig. 1). This casting is easily
cut up to check the effectiveness of inoculants and
alloys on the microstructure and hardness of many
sections poured from the same metal at the same
time. Another test is the eared casting as shown in
Figure 2. The eared test is more for carbide
evaluation. Both of these specimens show the effect
of cooling rate on a particular section.
Figure 2. Dimensions of eared casting.
REV – March 2006