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Nitrogen fissures defects
in iron castings
J. F. Meredith Casting Solutions Pty Ltd
Introduction
itrogen fissure defects can occur in grey iron castings
N when nitrogen levels exceed 80 to 100 parts per
million (ppm); this is especially the case when the
cooling rate is low such as in heavy section castings. Nitrogen
is dissolved in the iron during melting and may increase further
as parts of the iron come in contact with mould and core parts
that employ nitrogen bearing binder systems.
As the iron cools, the solubility of nitrogen decreases and it
is rejected from the melt. If it is unable to escape through the
surface of the casting, the gas remains in the form of fissures
such as shown in figure 1.
Identification
Nitrogen fissure blowholes generally appear more frequently in
heavy castings section and are often orientated perpendicular
to the casting surface. They generally have a distinctive irregular
crack-like "wormy" appearance as shown in figure 2 and can
appear at the surface or sub-surface of castings such as shown
in the example in figure 3.
Nitrogen fissure defects are sometimes confused with
shrinkage cavities as they can both appear as irregular voids
and are often more severe in the thermal centres of a casting.
Microscopic examination of high nitrogen iron will often
reveal the presence of compacted graphite form such as shown
Figure 1. Typical appearance of nitrogen fissures in an iron casting
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in figure 4, this is particularly so in heavy casting sections.
Whilst this graphite form results in an increase in tensile
strength, it also lowers the thermal shock resistance of the
iron. The inner surface of a nitrogen fissure is often dendritic
and may show a discontinuous graphite lining and subsequent
depletion of graphite in the immediate surrounding matrix.
These characteristics are sure indications of excessive nitrogen.
Chemical analysis can also be used to confirm if nitrogen is
responsible for a gas defect. In heavy casting sections nitrogen
in excess of 80 ppm can result in fissure defects whereas in
light sections, up to 120 ppm may be tolerable.
It is often difficult to distinguish between nitrogen and
hydrogen gas defects and chemical analysis of the defective
sample may show both elements are within control parameters.
In such cases it is likely there is a synergistic effect where the
elements have combined to form a gas hole.
Causes
The main sources of nitrogen pick-up in liquid iron originate
from melting operations and mould and core binder systems.
In general their effects are cumulative, so that the greater the
number of potential sources of nitrogen the greater the danger
that pin-hole or fissure defects will occur.
Charge make-ups consisting of a large proportion of steel
scrap will generally result in high nitrogen levels. Typically, a
Figure 2. Typical appearance of nitrogen fissure blowholes

Figure 3. Severe nitrogen fissure defects at the surface and sub-
surface of an iron casting
cast iron produced from a charge consisting of less than 15%
steel scrap will have nitrogen levels less than 50 ppm whilst
a charge consisting of more than 50% steel scrap can result in
nitrogen level of more than 100 ppm.
Some low quality carburisers can contain high levels of
nitrogenous compounds and can easily increase the nitrogen
level in the melt to dangerous levels. This is particularly
the case if a high percentage of steel scrap in the charge
necessitates large additions of carburising materials.
The absorption of nitrogen from the atmosphere is unlikely,
due to the high bonding energy of the nitrogen molecule.
The absorption of nitrogen from mould and core binders is far
more significant. The use of high nitrogen containing mould
or core binders or the build-up of nitrogen in reclaimed sand
can contribute to fissure defects as can inadequate mixing that
results in poor distribution of the binder components.
Cold-setting and hot-setting resin binders frequently contain
proportions of urea resin with a high nitrogen content. The
hot-box shell process uses hexamethylene tetramine as the
hardener and the isocyanate components of the cold-box
hardener also contain nitrogen. Furane binder systems are
basically composed of furfuryl alcohol which is nitrogen
free, however, these resins may be modified with urea,
urea-formaldehyde and phenolic resins. The urea and urea-
Figure 4. Micrograph of high nitrogen cast iron showing compac-
tion of graphite flakes
formaldehyde components contain nitrogen so the percentage
of nitrogen in the binder system can vary significantly
depending on the proportion of these components.
The presence of even a small amount of hydrogen will
serve to lower the overall solubility of nitrogen and enhance
porosity formation.
Remedies
Limit the nitrogen level in cast iron to less than 80 ppm in
heavy casting sections and less than 120 ppm in thin sections.
Limit the amount of steel scrap in the charge, particularly
with heavy section castings.
Use low nitrogen mould and core binder systems and limit
the addition. Ensure that the sand mixer is well maintained
so that binder components are evenly distributed throughout
the mix.
Small additions of red iron oxide to moulding sand or the use
of mould coatings containing red iron oxide can be effective in
limiting pick-up of nitrogen from binders.
Vent mould and cores generously.
If possible increase carbon equivalent as carbon and silicon
increase the solubility of nitrogen in iron.
The harmful effects of free nitrogen can be neutralised by
the addition of stabilising elements such as titanium or
zirconium. Proprietary inoculants containing these elements
are very effective in this regard and typically titanium additions
of 0.025% or zirconium additions 0.05% are sufficient to
suppress porosity. ■
References
1. Control and Prevention of Casting Defects, BCIRA Publication
2. Common Metallurgical Defects in Grey Iron, Elkem Publication
3. Porosity Defects in Iron Castings, Dr. R. L. Naro, AFS Casting Congress 1999
METAL Casting Technologies September 2011 65