Effect of Magnesium-Sulfur-Titanium-Pb content on the Stability of

Nodules in S.G Iron (Ferrtic/Pearlitic Grade) on Tractor Crank

shaft and Missile Flange Castings

Abstract. The castability, corrosion resistance, machinability and abrasion resistance are similar
to those of flake graphite (FG) grades. However, in addition, the tensile elongation can be as high
as 17%. S.G Iron are used for a wide variety of components, in the automotive industry, civil and
hydraulic engineering, etc. Their good toughness in the as-cast condition has led to the
fabrication of pipes by the centrifugal casting process, in which the liquid metal is poured into a
rapidly rotating mould and is projected against the walls, where it solidifies.

Introduction. Ductile iron is defined as a high carbon containing, iron base alloy in which the
graphite is present in compact, spheroidal shapes rather than in the shape of flakes, the latter
being typical of grey cast iron.[1] It is safe to say that all elements comprising the periodic system
influence the structure and properties of ductile irons. Some of these are present in infinitesimal
concentrations, some others exert a very minor influence. Still there remain approximately 50
elements, the effect of which one should be aware of. [2] S.G iron is produced by treating the melt
more commonly with magnesium, or cerium, or a combination of these elements, or such
elements as Ca, Ba, Li, Zr, inducing spheroidal graphite to grow during solidification. The use of
magnesium as Nodulent such that 0.04-0.06% remains as residual magnesium, is more easy to
adopt and economical, but certain elements called inhibitors, if present even in small quantities
such as 0.1% Ti, 0.009%Pb, 0.003%Bi, 0.004%Sb, prevent the process of spherodisation, but
addition of 0.005%-0.01% Ce(in addition to magnesium) nullifies their effect. [3]

To get an idea of the elements known to interfere the formation of graphite nodules and
encourage the formation of degenerate graphite shapes. The maximum permissible percentage
of deleterious elements is given below.[4]

Elements Al Sb As Bi Cd Pb Se Te Ti Zn

Permissble 0.10 0.002 0.02 0.002 0.01 0.002 0.03 0.02 0.10 0.10
maximum
values %
 *Institute Of Advanced Materials, Bahauddin Zakariya University ,Multan

**College Of Engineering and Emerging Technologies, University of the

Punjab,Lahore

Mg acts as a spherodizing element in ductile iron production, and is usually added in multi-
component form with Si, Ca, and rare earths. Such alloys are balanced to reduce the reaction
violence, to promote graphite spherodizing, to neutralize the effect of impurities on graphire
morphology and to control the matrix structure.[5]

Helpful Elements Neutral Elements Inhibitors

Mg,Ce,Ca,Ba,Li,Zr Fe,C,Ni,Si,Mo Al,Ti,Sb,As,Pb,Bi

SG cast irons are produced directly by the solidification of a melt containing sufficient silicon to
ensure graphite formation, after careful removal of sulphur and oxygen[6].Magnesium additions to
the bath tie up sulphur and oxygen and radically change the graphite growth morphology.
Magnesium reacts with oxygen to form highly stable MgO, which floats to the surface and can be
skimmed off. The oxygen content is reduced from typical levels of 90-135 ppm to about 15—35
ppm. Magnesium also reacts with sulphur to produce MgS, which again floats to the bath surface,
but is less stable than the oxide. Since magnesium has low solubility in the metal and is volatile,
the reactions can become reversible if losses are too great. Silicon in the form of ferro-silicon is
generally added to provide additional deoxidation. Other elements from groups IA, HA and IHB
can also be employed to tie up oxygen and sulphur. In particular, cerium forms highly stable
oxides and sulphides and is less volatile than magnesium, with which it is often used in
combination. Some of the inclusions formed by the inoculants act as nuclei for the graphite and
are found at the centre of the nodules [7]. The simplest explanation of the spheroidising effect of
inoculants such as magnesium is that oxygen and sulphur are adsorbed preferentially on the
hexagonal planes of graphite, inhibiting growth parallel to the c axis, leading to a lamellar
morphology. The removal of sulphur and oxygen by the inoculant allows more isotropic growth.
A careful choice of alloying additions is used to appropriately adjust the deoxidation, graphitising
and nucleation effects[8].

Effect of sulfur. A minimum sulfur level of at least 0.005 to 0.008 percent is necessary after
magnesium treatment to insure proper post-inoculation and reduce the risk of carbides. Thus,
after magnesium treatment, the presence of critical sulfur levels is considered beneficial for the
promotion of graphite nuclei. Further, the reaction of sulfur with sulfide forming elements such
as rare earths and calcium enhance nucleation of graphite in ductile irons.[9]
Effect of Titanium. A Titanium content higher than 0.10% in ductile irons tends to make them
chunk graphite. Furthermore, the graphite flakes in a Ti-contaminated iron are not only
intercellular. Several of the spheroids within the cell are also affected with flakes growing
directly out of spheroids. [10]

Experimental Work.

S.G Iron Grade to Achieve

S.G Iron/E.N GJS C Si Mn Cr Ni Cu Mg S P

700-2 3.4- 2.4- 0.25- 0.05ma 0.2max 0.15- 0.025- 0.02 0.08
(Perlite) 3.7 2.65 0.4 x 0.4 0.06 max max

The “sandwich” process was used for S.G iron.

Charge Calculation for S.G Iron:

- Nodulant(Fe-Mg-Si) 2% of Melt
- 5-6% Mg and 45% Si in the Nodulant
- Burning losses of Mg, taken as 50% i.e 0.05+0.05 = 0.1%
Basis 200 Kg:
- 200 * 0.1 /5 = 4 Kg

- Inoculant(Fe-Si) 0.5% of Melt

- 75% Si in Inoculant
- 200 * 0.5/75 = 1.33 Kg
- Si from Inoculent = 1.33 * 75/100 = 0.997 apprx. 1 Kg
- Total silicon from Nodulant and Inoculent = 1.8 + 1 = 2.8 Kg
- Percentage of Si that will be attained from Nodulent and Inoculent = 2.8/200*100=1.4%
- Required Si-coontent is 2.5% therefore the silicon remaining in balance will be 1.1%.

The composition attained for treating melts of slightly different compositions with 2% Nodulent
and 0.5% Inoculent are given below.

Sampl C Si Mn P S Cr Ni Cu Mg Ti Pb
e
01. 3.43 2.43 0.28 0.0380 0.0140 0.0170 0.46 1.44 0.0310 0.00860
2 5
 02. 3.50 2.48 0.28 0.0500 0.0190 0.0290 0.46 1.54 0.0440 0.00890
0 1
03. 3.42 2.48 0.21 0.320 0.015 0.0300 0.44 1.43 0.0390 0.00670
5 5
04. 3.47 2.45 0.20 0.0460 0.0170 0.0130 0.46 1.43 0.0300 0.00640
3 1
05. 3.48 2.49 0.31 0.0440 0.0220 0.0220 0.49 1.49 0.0280 0.00970
1 8
06. 3.44 2.45 0.30 0.0420 0.0210 0.0210 0.46 1.59 0.0300 0.00765
1 3

Microstructures.

References :
1. Ductile Iron I Production(Revised in 1976) , Stephen I. Karsay , Quebec Iron and
Titanium Corporation
2. Ductile Iron I Production(Revised in 1976) , Stephen I. Karsay , Quebec Iron and
Titanium Corporation
3. Heat Treatment of Metals , Vigendra Singh , Second Edition, Jan., 2004
4. Foundry Technology , Dharmendra Kumar , S.K. Jain
5. Nucleation Mechanisms in Ductile Iron , T. Skaland , Alkam ASA, Foundry Products ,
Kristiansand , Norway . Proceedings of the AFS Cast Iron Inoculation Conference ,
September 29-30 , 2005 , Schuamburg , Illinois
6. Ductile Iron Handbook, Ed. Pub. American Foundrymen's Society (1992, revised
1993)USA.
7. T. SKALAND, 0. GRONG, and T. GRONG, "A Model for the Graphite Formation in Ductile
Cast Iron: Part I: Inoculation Mechanisms; Part II: Solid State Transformation Reactions",
Metall. Trans. 24A (Oct. 1993), 2321-2345 and 2347-2353
8. Microstrucrure of Steel and Cast Iron , Madeleine Durand-Charre 2003, Translated by
James H. Davidson 2004
9. Magnesium-Sulfur Relationships in Ductile and Compacted Graphite Cast Irons as
Influenced by Late Sulfur Additions , I. Riposan, M. Chisamera, University Politehnica
of Bucharest, Romania, R. Kelley, Jencast, Coffeyville, KS USA M. Barstow, U.S. Pipe
and Foundry, Birmingham, AL USA R. L. Naro, ASI International, Ltd., Cleveland, OH
USA , AFS Transactions 03-093
10. Ductile Iron I Production(Revised in 1976) , Stephen I. Karsay , Quebec Iron and
Titanium Corporation
11.
12. ASM Handbook Vol. 9 , Metallography and Microstructures
13. Microstrucrure of Steel and Cast Iron , Madeleine Durand-Charre 2003,
Translated by James H. Davidson 2004