SOLIDIFICATION OF IRON CASTINGS

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THE INFLUENCE OF INOCULATION

CRUCIBLES

IRON-CARBON DIAGRAM INTERPRETATION OF SOLIDIFICATION USING COOLING CURVES

Carbon Equivalent in Atom % TE grey Iron-graphite eutectic solidification Fast cooling Slow cooling
temperature. High Low High Low
nucleation nucleation nucleation nucleation
Undercooling = TE max. – TE min.
TE max. TE grey TE white Iron-iron carbide solidification grey 1 2 3 4
BINDERS

Temperature
Liquid + Fe Start Finish
S4 temperature. Finish Start
Fe Start Start Finish

Temperature
TE white white
Fe + Fe TE min
Liquid TE min. Austenite and graphite are still growing; Finish
inoculation raises this temperature. grey white grey grey/white
Liquid +
M E TA L T R E A T M E N T

Austenite (Fe ) Liquid +

Graphite/Cementite
Time (sec.) Undercooling Too much undercooling tends to Time

Temperature °C
Austenite (Fe ) generate carbides. Inoculation raises TE min, reducing
Figure 1. Cooling curve for inoculated graphitic iron. undercooling. Figure 2. With both fast and slow cooling, inoculation
raises the temperatures of the curve, promoting the
Austenite (Fe ) + Graphite/Cementite The metallurgical quality of iron castings depends graphitic model of solidification.
on the solidification mode which can be modified by
S3 Recalescence. Increase in metal temperature.
Ferrite +
inoculation. The thermal analysis cooling curve can be
Austenite
interpreted as follows: TE max Maximum eutectic temperature. (1) Fast and inoculated cooling. TE min. > TE white.
Grey iron forms.
Determines recalesence (R = TE max. – TE min.),
Ferrite S1 Start of solidification. and relates to the graphitisation model.
(2) Fast and uninoculated cooling. TE min. < TE white,
(Fe α) Ferrite (Fe α) + Graphite/Cementite
M E LT S H O P R E F R A C T O R I E S

thus the iron is carbidic or white.

TL Liquidus temperature. The first solid phase starts S4 Second solidification stage. Secondary porosity
relates directly to this part of the curve.
to form. In hypoeutectic irons austenite is precipitated.
CE respectively Carbon Equivalent in Weight %
In hypereutectic irons graphite is precipitated. Differs
(3) Slow cooling, but inoculated, is entirely graphitic.
according to the silicon and carbon content.

THE EFFECTS OF INOCULATION (4) In a thick casting, slow and uninoculated cooling,
Sc Degree of Saturation mottled or mixed graphitic-carbidic structure forms.
Hypoeutectic Casting Hypereutectic Casting
S2 Start of graphite formation. Inoculation modifies the profile of the thermal
analysis curve, so that solidification follows the
%Si %C graphitic solidification model.
% Carbon Equivalent CE = %C + 3 % Saturation Coefficient Sc = 4,3 - 1/3 %Si

SELECTION OF INOCULANTS FOR PRODUCTION OF GREY IRON CASTINGS SELECTION OF INOCULANTS FOR PRODUCTION OF SPHEROIDAL GRAPHITE IRON CASTINGS
FEEDING SYSTEMS

Priority Aim Calcium Zirconium Priority Aim Calcium Strontium

1 Prevention of carbides or white iron Improves graphite germination. Reduces Improves solubility of inoculant, neutralises 1 Eliminate carbides or white iron Improves graphite germination. Reduces 1% strontium in high purity FeSi eliminates
2 Improve shape of type-A graphite tendency to chill. nitrogen and improves inoculation. Combined 2 Improve graphite form tendency to chill. carbides and increases the number of nodules,
(improved properties) with Mn, reduces melting point of inoculant. 3 Increase number of nodules provided that nodulisation is carried out with
3 Delay fading of nucleation Barium 4 Reduce fading of nucleation Barium Rare Earth-free FeSiMg.
4 Reduce microshrinkage Strong graphite promoter. Reduces inoculant Cerium and other Rare Earths 5 Eliminate microshrinkage Strong graphite promoter. Reduces inoculant
5 Reduction of graphite flotation fading. Cerium and other rare earths increase the 6 Minimise gas defects fading. Also has a nodulising effect. Risk of slag Zirconium
6 Minimise gas defects number of eutectic cells and reduce fading. 7 Eliminate ferrite skin when used in excess. Increases inoculant solubility when combined
7 Eliminate ferrite skin Strontium INOCULIN 920, which contains La, produces 8 Other with Mn. Neutralises nitrogen.
F I LT R A T I O N

8 Other Strontium eliminates carbide without increasing finer graphite, reducing flotation and associated Bismuth
the number of eutectic cells (reducing the tendency gas defects. Effects of ‘active’ elements in spheroidal graphite 0.1% Bi, combined with rare earths, increases Cerium and other Rare Earths
Effects of ‘active’ elements in grey iron to shrinkage due to excessive high cell count). iron inoculants. the number of nodules, reduces their size Improve inoculation of spheroidal graphite iron,
inoculants. and reduces tendency to white iron. Reduces whether added in treatment with Mg or to the
Aluminium graphite flotation. Can produce intercellular inoculant, and reduce inoculant fading.
Aluminium Strong ferrite promoter, so for thin sections, lamellar graphite unless offset by rare earths.
Improves ferritisation. Neutralises nitrogen. inoculants with 4% aluminium content are used.
C OAT I N G S

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