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«Inoculation of Grey and Ductile Iron»
«Gri Dökme Demir ve Duktil Dökme Demir Aşılama Uygulamaları» Kenza Soulas Michael Koch
(Zenmet)
2.Oturum: Döküm Teknolojileri Demir - Çelik 2nd Session: Casting Technologies Iron - Steel
Oturum Başkanı/Session Chairman: Hüseyin Yumak (Trakya Döküm San. Tic. A.Ş.)
Oturumlarda yer alan sunumlar 15 Eylül 2014 Pazartesi tarihinde kongre web sayfasına (kongre.tudoksad.org.tr) yüklenecektir.
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INOCULATION OF GREY AND DUCTILE IRON
Kenza Soulas Michael Koch
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Understanding of inoculation
Effect of inoculation
Inoculation materials
Practical experience
SUMMARY
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Understanding of inoculation
Effect of inoculation
Inoculation materials
Practical experience
summary
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• DEFINITION OF INOCULATION
Certain materials added in small amounts to liquid cast iron, reduce the
tendency to form « chill », enhance solidification under Iron-carbon system by promoting sufficient nucleation sites
This practice is called :
INOCULATION
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• What happens during solidification ?
– carbon can solidify under two
forms :
• graphite
• bound carbon
– This corresponds to two cases :
• Fe-graphite : stable diagram
• Fe-Fe3C : metastable diagram
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• Inoculation mecanisms
Alkaline Earths from Inoculant
Liquid Iron “O + S “
+
= Heterogeneous Nuclei
(carbides, sulfides, oxides)
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• Minimizing the undercooling phenomenon
At the eutectic temperature, there is a degree of undercooling followed by a recalescence before solidification is completed.
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Understanding of inoculation
Effect of inoculation
Inoculation materials
Practical experience
summary
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• Effect of Inoculation on Grey Iron
reduces chill and promotes graphite formation
reduces the formation of fine graphite
correct Inoculation leads to the desired Graphite size
promotes uniform structures in various sections
improves mechanical properties
improves machinability
Structures of poorly and well inoculated grey irons
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• Effect of Inoculation on Ductile Iron
reduces tendency for chill
increases the nodule count
promotes the formation of fully spheroidal graphite
Ferrite structure as-cast in thin sections possible
Increases artificially Mg fading time
Structures of poorly and well inoculated Ductile irons
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Understanding of inoculation
Effect of inoculation
Inoculation materials
Practical experience
summary
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• What is the chemistry of an Inoculant ?
Inoculants contain mainly :
Silicon: main element Calcuim: promotes graphite Aluminium: promotes ferrite and graphite
Mainly Inoculants are :
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Chemical elements and its effects :
C : promotes graphite, reduces chill
Ba : promotes ferrite, increases fading time
Mn : reduces liquidus point , better dissolution
Sr : powerfull for grey Iron
Zr : reduces chill depth, ties up N
Bi/RE : reduces chill, chunky
La : reduces micro-shrinkage
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Understanding of inoculation
Effect of inoculation
Practical experience
summary
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• ZOOM ON INOBAR : Ba based inoculant
Improvement of fading
Improved Nodularity & Reduced Carbides
An Inoculant can lose 50 % of its efficiency after only 5 minutes.
The fading effect can be reduced with Ba .
Effect of various inoculants on nodule number [Morgan]
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• ZOOM ON INOBAR : Ba based inoculant
Ba is able to reduce the Chill depth
From 9% Ba, chill depth stable at 0.3 mm
Influence of Ba on chill depth [JC.Percheron]
0,4% FeSi after Mg treatment and
inoculation Center of the casting, Nital
Attack
0,4% Inobar after Mg treatment and
inoculation Center of the casting, Nital
Attack
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• ZOOM ON SPHERIX : Bi/RE based inoculant :
Good performance in various sections castings
Excellent performance for thin sections ferritic as-cast
Improved nodularity and increased nodule count
Helps to avoid Chunky
Effect of Bismuth in ductile irons inoculated with
ferrosilicon
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• Case study with Spherix : Extremely powerful in thin sections to meet
the required structure as-cast
• Industrial trial : Clutch Plate GJS 500
Standard process :
• Nodularisation process with pure Mg (Converter)
• Ladle inoculation with 0.4% Standard FeSi
• Late inoculation 0.1% Ba based inoculant
trial process :
• Nodularisation process with pure Mg (Converter)
• Ladle inoculation with 0.4% Standard FeSi
• Late inoculation 0.1% Bi based inoculant
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• Results on “step wedge”:
Influence of Bi/RE inoculant on Nodule Count
Influence of Bi/RE inoculant on pearlite
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• ZOOM ON FeSiLa : La based inoculant Powerful against micro-shrinkage
Improves self-feeding capacity
Without La
Microshrinkage
With FeSiLa
No Microshrinkage
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• ZOOM ON FeSiLa : La based inoculant
Lanthanum promotes the Equiaxe solidification instead of the classical columnar solidification mode
Columnar zone
Equiaxe solidification
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Experimental procedure
Thickness
Melting
Emptying
Inoculation
FeSiLa
Treatment and pouring in the mold Solidification
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With La 0.8% Without La 0%
Diameter 60 mm
Thickness 6 mm
Diameter 60 mm
Thickness 2 mm
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At a given solidification stage, when “La” is added, the equiaxe solidification is favoured :
Thickness of the columnar zone is reduced: larger free flowing of liquid is favoured to move within channels for the feeding of casting sections.
Semi-solid iron contains more solid particles after filling of a given volume chamber : less liquid is needed to compensate the solidification contraction.
Promotion of Late eutectic graphite precipitation.
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CONCLUSION
• Inoculation is an important step in the production of Grey and Ductile Iron
Castings.
• Inoculants are complex Ferrosilicon based products with various elements like Bi, RE, Sr, Zr etc.
• The correct inoculation practice is absolutely necessary to obtain the required structure in the casting
The choice should be based on cost and technical considerations
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Thank you for your attention Děkuji za pozornost