Inoculation is the term used to describe the process of increasing the numbers of

nucleating sites from which eutectic graphite can grow during the solidification of flake,
nodular and compacted graphite irons. The main aim of inoculation is to minimize the
degree of under cooling of liquid iron during eutectic solidification, and hence to make
sure that the resultant cast microstructures are completely free from eutectic carbides.
Inoculation also plays a major part in the control of eutectic graphite morphology and
distribution, and hence in control of the levels of pearlite and ferrite in matrix
structures.

Effect of inoculation on eutectic cell size and chill depth in wedge samples
(schematic).(a) before inoculation (b) immediately after inoculation (c) fading due to
holding time after inoculation before pouring

Under-cooled graphite formed in grey iron as a result of low melt nucleation

Presence of eutectic carbides in thin section ductile iron

Table 1: Approximate compositions of some typical Ferrosilicon based inoculant

materials, in each case the balance is Iron

The FeSi-RE type can also contain small controlled amounts of Oxygen and Sulphur to
boost nucleation where high nodule numbers are needed in producing ferritic ductile
iron.

Magnesium ferrosilicons used as nodularising agents normally contain around 45%Si

and have a range of Mg levels from 3 – 10%, some grades may contain up to 3%Ca,
1%Al, and 3%RE.

Nodularising agents and inoculants are supplied in controlled size ranges to suit their
intended modes of application e.g. 3-25mm for MgFeSi, 2-6mm for ladle inoculant,
and 0.2-0.6 for late in stream inoculant.

Inoculant materials

Foundries are often confused by the extensive range of both inoculants and nodularising
agents that are available from the ferroalloy producers. Examples of some typical
compositions are listed in Table 1. Most inoculants are based on ferrosilicons containing
about 70-75% Silicon, or on ferrosilicon - graphite mixtures. In flake irons the normal
levels of inoculant ladle addition raise the silicon content by about 0.2%, whereas in
ductile irons larger additions are used, raising Si level by around 0.5%. Inoculant grades
containing around 45-50% Si are also used where pick up of
Si must be limited. Research into understanding the effects of inoculation, and into the
development of more potent ferrosilicon compositions, has been continuing since the
early 1960’s. Important observations from some of this work (4-10) can be summarised
as follows:

The effect of silicon on eutectic graphite nucleation and chill reduction is much more
marked if the silicon is added as an inoculant than if it were just added to the furnace
charge.

• The relationship between graphite nucleation and chill reduction is not simple one in
that inoculants giving the finest eutectic cells (high cell counts) do not always give the
greatest chill reduction.

• For ferrosilicon to be an effective inoculant then it must contain small amounts of

minor elements such as calcium, aluminium, zirconium, cerium, barium, manganese
and strontium.

• Lack of control in the use of inoculants can give rise to other problems such as
shrinkage defects caused by excessive mould dilation, pinholes due to Al pick up, and
inclusions of undissolved inoculant and slag.

• The rates of fading of inoculation treatments are most rapid during the first few
minutes after treatment and the effects of the treatment are halved after about five
minutes of holding.

• Barium containing ferrosilicons tend to be more persistent and can show a reduced
tendency to fade in ductile irons.

• Graphitic carbons with suitable crystal structures can inoculate flake irons but not
ductile irons. Amorphous carbons do not act as inoculants.

• It is difficult to effectively inoculate grey irons with sulphur contents below 0.05%,
especially below 0.03%, using conventional ferrosilicon inoculants.