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Alloy Cast Irons

Revised by Richard B. Gundlach, Climax Research Services; and Douglas V. Doane, Consulting Metallurgist

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Effects of Inoculants

Certain elements, when added in minute amounts in the pouring ladle, have relatively strong effects on the size, shape, and
distribution of graphite in graphitic cast irons. Other elements are equally powerful in stabilizing carbides. These elements,
called inoculants, appear to act more as catalysts than as participants in the reactions.

The main graphitizing inoculant is ferrosilicon, which is often added in detectable amounts (several kilograms per tonne) as
a final adjustment of carbon equivalent in gray or ductile irons. In ductile irons, it is essential that the graphite be present in
the final structure as nodules (spherulites) rather than as flakes. Magnesium, cerium, rare-earth elements, and certain
proprietary substances are added to the molten iron just before pouring to induce the graphite to form in nodules of the
desired size and distribution.

In white irons, tellurium, bismuth, and sometimes vanadium are the principal carbide-inducing inoculants. Tellurium is
extremely potent; an addition of only about 5 g/t (5 ppm) is often sufficient. Tellurium has one major drawback. It has been
found to cause tellurium halitosis in foundry workers exposed to even minute traces of its fumes; therefore, its use as an
inoculant has been discouraged and sometimes prohibited.

Bismuth, in amounts of 50 to 100 g/t (50 to 100 ppm), effectively suppresses graphite formation in unalloyed or low-alloy
white iron. In particular, bismuth is used in the low-carbon compositions destined for malleabilizing heat treatment. It has
been reported that bismuth produces a fine-grain microstructure free from spiking, a condition that is sometimes preferred
in abrasion-resistant white irons.

Vanadium, in amounts up to 0.5%, is sometimes considered useful as a carbide stabilizer and grain refiner in white or
chilled irons. Nitrogen- and boron-containing ferroalloys have also been used as inoculants with reported beneficial effects.
In general, however, the economic usefulness of inoculants in abrasion-resistant white irons has been inconsistent and
remains unproved. Inoculants other than appropriate graphitizing or nodularizing agents are used rarely, if ever, in
high-alloy corrosion-resistant or heat-resistant irons.
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