HOT TOPICS

Issue # 2 2004
Chill Testing of Cast Iron
Chill testing of cast irons in general,
which includes ductile base irons, is the
old, but still used, method to measure the
nucleation potential (or chilling
tendency) of the melt prior to casting.
The term nucleation potential is just
another way of saying how the graphite
(or lack of it) will form upon
solidification. Since this graphite form or
type and amount are critical to the
mechanical properties obtained in a
particular cast section, it is wise to check
it beforehand and adjust the furnace
chemistry/nucleation if necessary.

typical chill values normally

encountered from the section cooling
rates and pouring temperatures used. The
wedge size is usually adjusted upward
(to next larger size) when the chilled
area (clear chill) typically exceeds more
than the total width of the fracture
face of the specimen. Of course the size
will depend upon whether the test is
used for base iron (often called the
constitutional wedge) or the final
(inoculated or white) iron. The sizes and
shape of each type are well described in
the standard.

The standard methods for chill testing of

cast irons is described ASTM A367.
There are two basic methods; the Wedge
test and the Chill test (see figure 1).

Measurement of the chill value is made

in increments of 32nds of an inch of
width at the location where clear chill
separates from the mottled gray structure
in a wedge test. A 3/32 inch wide
measurement is called a 3 wedge and
may be also related back to the wedge
size, if more than one size is used in a
particular foundry. Note when
measuring chill depth on a chill test
fractured specimen, the depth of chill is
measured from the chilled face in 32nds
of an inch.

Wedge test method

The wedge test is made in a sand test
core and is generally used for higher
strength irons > 25,000 psi tensile,
ductile base iron and for castings with
sections of typically 3/8 inch and over.
This method is sometimes used for final
ductile iron ductility and microstructure
testing as well.
Chill test method
The chill test method, where the metal
is cast against a chill plate is generally
used for higher C.E. (hypereutectic) &
high Si irons, thin sections and where a
specified minimum or maximum amount
of chill must be measured.
Both of these methods utilize different
wedge sizes that correspond to the

The practice of chill measurement

Consistency is important when
performing these tests. The pouring
temperature should be as high as
possible and uniformly controlled.
Lower pour temperature can produce
higher chill levels in the same test giving
erroneous measurements due to more
rapid cooling. Sample ladles should be
either of the insulating type or preheated
sufficiently so that the test can be done
1

quickly at a high temperature. They

should also be clean.

Figure 2 Actual chill wedge

Mixing (stirring) of the melt must be

done to insure that a representative
sample is obtained. Try to dip and stir
deeply into the metal bath. This is
especially true when testing inoculated
and/ or final irons.
The sample may be water cooled as soon
as it is solidified or left to air cool. The
value will not change with either
method. However the slower the
cooling, the better the definition of the
chilled section (see figure 2) becomes.
Also test piece must be dry before
fracturing to give a good reading.
Finally the measurement and recording
of the chill width or depth, depending
upon which test is done, is made. The
base melt may then be adjusted by
additions of silicon and/ or nucleation
materials (SiC, graphite or pig iron) to
obtain the correct value.

James Mullins, Mullins Professional

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Figure 1 Two methods of chill testing