Shaifali Steels Limited

Ladle Inoculation

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Addition is mainly made into the stream of metal, when emptying treatment ladle into transport ladle or from transport ladle to pouring ladle. The main advantage is of course that this method is easy to handle. Disadvantage is the inoculation fade. Experience shows that after 5 minutes only 20% of the inoculation effect is remaining. Common addition for inoculation are 0.5% in weight the most used inoculate is Ferro silicon containing 60-90% Si with 0.5-1.5% aluminium. For obtaining a maximum inoculation effect some hints and recommendations should be followed. Inoculants should be kept dry and covered to obtain pin holes free castings as inoculants trend to absorb moisture from the ambient atmosphere and oxidise. Oxidised inoculants are nearly useless for the effect of nucleation high moisture increases oxidation of the grain particles. Quantity of iron to be inoculated have to be checked is fully against each other deviations mean different results. Example: due to wear of the lining a 500 kg ladle is charged with 550 kg iron, in this case it is possible that the amount of the inoculants is insufficient and the structure shows. Carbides less and not well shaped graphite spheroids. Inaccurate weighing of the inoculants can show similar results. The inoculants agent should never be added on the bottom of the ladle as the smaller particles oxidise at high temperatures. As longer the time before the ladle is charged with iron, as higher the oxidation and smaller the inoculation effect are more over the smaller particles melt and form incrustation on the lining. Good experience is made when the inoculants added after the ladle has been charged with same iron (depending on ladle size about 50 to 200 mm). In this case mixing and inoculation effect are the best, if the aforementioned small quantity of iron has been charged into the ladle the rest of the iron should be charged as quick as possible to obtain a good mixing and dissolution of the inoculants within shortest time. Furnace slag should be hold back in order to prevent a reaction with the inoculants. It is well known that inoculants are very good deoxydants. If this happens a part of the inoculation effect is lost. Addition of inoculants should be made as close as possible to the area where the iron stream hits the bottom. This results in a good mixing and prevents a reaction between the inoculants and the slag. After charging of iron is finished, stirring for same seconds should be made by means of a steel rod to make sure that the inoculants is well dissolved difficulties concerning chill, carbide formation or bad shaped spheroids can be related to improper dissolution of the inoculants. If temperature if Mg treated iron is too low (< 1360C) inoculation should not be done. Only when proper stirring and time for complete dissolving of the inoculants is available, Inoculation should be applied. Otherwise formation of big primary carbides can occur due to improper dissolving of the inoculants. If iron is poured at too low temperature this can lead to a strong under cooling, which results in a carbide formation and bad shaped spheroids. If the temperature of the iron to be inoculated is too low (< 1360C). It is recommended to use exothermic inoculants. Inoculated iron should be poured as quickly as possible. There by the fading of the inoculation effect is avoided and a maximum efficiency of the nucleation effect is reached. Other advantages of immediately pouring after inoculation result in less oxidation and chill. Experience shows that it is advantages to minimise that distance between the pouring lip and the down Sprue. This reduces the oxidation of the iron and erosion of the moulding sand. To have a good efficiency of inoculation, It is important to follow the guidelines for an inoculation, which once was decided i.e. the temperature for the inoculation quantity of iron to be treated

Shaifali Steels Limited

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quantity of inoculation relation to the wall thickness of the casting, the method of inoculation and other should be kept constant. The grain size of the inoculants should be in accordance with temperature and quantity of the iron to be treated grain size should be small to assure a quick solution and distribution in the liquid iron. In case that grain size is too big the inoculation effect is concentrated on certain parts in the melt. In many cases coarse inoculants are not completely dissolved and can enter the casting, where by the mechanical properties and the merchantabilities are reduced. The optimum grain size should be found out by several tests. Example: Tests showed that an inoculants with grain size < 5 mm was most qualified for batches of 500 kg and temperature of 1400 for same condition a FeSi 75 grain size 10X/MM was most qualified.

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Production of S.G.Iron in the as-cast condition.

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As cast production of S.G.Iron is possible under certain circumstances e.g. qualified methods of production savings are possible by reducing the manufacturing costs more over difficulties as warping and scaling can be eliminated. It is not easy to give common limits, which have only to be followed and automatically mean as cast production, but some limits are more or less universal and are listed in the following. Slow cooling rates of the casting in the solidification range. Selection of charge materials concerning Mn, Cr, P, Sb, As and other trace elements. Recommendation Re-base Iron analysis to be followed i.e.C.Equivalent C/Si ratio for different Wall-thickness and type of S.G.Iron. Inoculation to be optimised e.g. inoculation in the stream or in the mould. Stabilizing of pearlite for B.S.500/7 by corresponding cooling conditions or for thin walled (<30mm) casting stabilizing by alloying Mn. For dominant pearlitic type (B.S.600/3 and B.S.700/2) Stabilizing of pearlite should be done by alloying Cu (0.5-1.0%) Quantity of iron for treatment and quantity of inoculants. Some useful hints for the production of ferrite S.G.Iron can be found in the following table.

Factor to be considered in the production of As-cast ferritic nodular iron.

Metal Control
1. 2. 3. 4. 5. 6. 7. Selection of raw material = Low chromium manganese and trace elements (recommended max lever = Cr 0.05% V= 0.03, B = 0.003%, Te = 0.003%. Choice of final metal composition = high total carbon and silicon contents. Selection of inoculants Choice of magnesium treatment and inoculants. Distribution of metal = repaid to preclude inoculants fade. Pouring temperature = high to minimise chill. Knockout = controlled to avoid pearlite forming after knockout.

Casting design and pattern layout

1. 2. 3. 4. 5. Thin section = avoid thin section appendages which cool very quickly. Casting edges = generous radius to minimise chilling. Flash = eliminate by provision of accurate pattern equipment. Runner and feeder system = Design to provide heat input into thin sections. Flow off = Use to reduce chilling at end of bar and plate sections.