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Informative Annex 12
Nodular Iron

These Informative Annexes are for the use of the Task Force and are not to be
included in the API Standards

6.11.2.5.1 The keel or Y block cast at the end of the pour shall have a thickness not less
than the thickness of critical sections of the main casting. This test block shall be tested
for tensile strength and hardness and shall be microscopically examined. Graphite
nodules shall be classified under microscopic examination and shall be in accordance
with ASTM A 247. There shall be no intercellular flake graphite.
Note 1: Critical sections are typically heavy sections, section changes, high-stress points such as drilled
lubrication points, the cylinder bore, valve ports, and flanges. Normally, bosses and similar sections are not
considered critical sections of a casting. If critical sections of a casting have different thicknesses average
size keel or Y blocks can be selected in accordance with ASTM A 395.
Note 2: ASTM A395 requires the microstructure of Grade 60-40-18 nodular iron to be essentially ferritic,
contain no massive carbides, and have a minimum of 90 % Type I and Type II Graphite nodules as in Fig. 1
or Plate I of Test Method A 247.

Note 3: ASTM A395 requires the microstructure of Grade 60-45-15 nodular iron to be 45 % pearlitic,
maximum, contain no massive carbides, and have a minimum 90 % Type I and Type II Graphite nodules as
in Fig.1 or Plate I of Test Method A 247

Discussion: Ensures tests are representative of casting properties. The cooling rate,
determined in pad by the section thickness, can affect the casting toughness and
chemical segregation. In general, Charpy V-notch impact specimens from a more
rapidly cooled thinner section will be non-representative of the main casting. Thicker
critical sections that are cooled more slowly are also less likely to give non-
representative properties. ASTM A247 is specifically referenced because it is the only
recognized standard available today. In most cases, acceptance levels depend on the
service application.

The quality of the nodules depends on the innoculant such as magnesium additive.
This changes the surface tension and causes the graphite to form as nodules rather
than flakes. The efficiency of the innoculant decays as time and that is the reason for
requiring the test blocks to be taken at the end of the pour.
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The Following is Extracted from http://www.ductile.org/didata/Section3/3part1.htm

Area highlighted in red might be a useful addition.

Effect of Graphite Shape

As would be expected from the dramatic differences in mechanical properties between Gray and
Ductile Irons, that modularity plays a significant role in determining properties within the Ductile
Iron family. Figure 3.10 illustrates the correlation between modularity and Dynamic Elastic
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Modulus. This relationship not only emphasizes the strong influence of modularity on DEM, but
also indicates that DEM values obtained by sonic testing can be used to measure modularity
(graphite volume and nodule count should be relatively constant).

Nodularity, and the morphology of the non-spherical particles produced as modularity decreases,
exert a strong influence on the yield and tensile strengths of Ductile Iron. Figure 3.11 shows the
relationships between strength and nodularity for ferritic irons in which modularity has been
changed by two methods: through magnesium control, or through lead control. When nodularity is
decreased by reducing the amount of residual magnesium (the most common spheroidizing
agent used in commercial Ductile Iron) the nodules become elongated, but do not become sharp
or "spiky". The result is a 10% decrease in yield strength and a 15% decrease in tensile strength
when modularity is reduced to 30%. Small additions of lead reduce modularity by producing
intergranular networks of "spiky" or plate-like graphite which result in dramatic reductions in
tensile properties.
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Figure 3.11

The effect of nodularity on pearlitic Ductile Irons can be determined in Figure 3.12 and Figure
3.13 by comparing the tensile properties, at constant carbide levels, of irons with nodularities of
90, 70 and 40%. These Figures reveal two important features. First, compared to the Mg-
controlled loss of nodularity for the ferritic iron in Figure 3.11, the pearlitic iron is much more
sensitive to reduced nodularity. Second, at low carbide levels typical of good quality Ductile Iron,
there is relatively little loss of strength as the nodularity decreases to 70% but as nodularity
deteriorates further, strength decreases more rapidly.

Although not shown in Figures 3.11, 3.12, 3.13, the effect of nodularity on elongation can be
inferred by considering the influence of nodularity on the difference between the yield and tensile
strengths, which is proportional to elongation. Both Mg- and Pb-controlled losses in nodularity
reduce the difference between the yield and tensile stresses, indicating that loss of nodularity
results in reduced elongation. The dramatic decrease in tensile strength produced by lead control
indicates that the formation of spiky, intercellular graphite can severely embrittle Ductile Iron.

Designers can virtually eliminate the effect of nodularity on tensile properties by specifying that
the nodularity should exceed 80-85% and that there should be no intercellular flake graphite.
These criteria can be met easily by good production practices which ensure good nodularity
through Mg control and prevent flake or spiky graphite by a combination of controlling flake-
producing elements and eliminating their effects through the use of small additions of cerium.
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Figure 3.12

Figure 3.13
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Effect of Nodule Count

Nodule Count, expressed as the number of graphite nodules/MM 2, also influences the mechanical
properties of Ductile Iron, although not as strongly and directly as graphite shape. Generally, high
nodule count indicates good metallurgical quality, but there is an optimum range of nodule count
for each section size of casting, and nodule counts in excess of this range may result in a
degradation of properties. Nodule count per se does not strongly affect tensile properties, but it
has the following effects on microstructure, which can significantly influence properties,

 Nodule count influences the pearlite content of as-cast Ductile Iron. Increasing the nodule
count decreases the pearlite content, decreasing strength and increasing elongation.
 Nodule count affects carbide content. Increasing the nodule count improves tensile
strength, ductility and machinability by reducing the volume fractions of chill carbides,
segregation carbides, and carbides associated with "inverse chill".
 Matrix homogeneity is influenced by nodule count. Increasing the nodule count produces
a finer and more homogeneous microstructure. This refinement of the matrix structure
reduces the segregation of harmful elements which might produce intercellular carbides,
pearlite or degenerate graphite
 Nodule count affects graphite size and shape. Increasing nodule count results in a
decrease in nodule size which improves tensile, fatigue and fracture properties.
Inoculation practices used to improve nodule count often make the nodules more
spherical. Thus, high nodule count is generally associated with improved nodularity.
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