Issued hy the Ductile Iron Saciety for the eof suheebing companies Not for general distbution “HOT TOPICS” Issue #3, 1999 Inverse Chill in Ductile Iron Castings Issued hy the Ductile ron Society for the we of subsenbing companies Nat or poneraldsribation ‘Types of Chill: Chill structure or carbidic areas in DI castings can be classified as normal chill or inverse chill. With normal_chill, the carbide areas occur at comers, along edges, may extend for some distance in from the cast surface, or could be sprinkled throughout the cross section. Normally, it is the result of solidification in the mold, at a rate greater than can be tolerated by the total iron composition. Inverse chill, sometimes called centerline carbides, is a dense concentration of a carbidic microstructure, only at the casting midsection, or at the center of an isolated section of thin or light section castings. (Some light section castings may experience both types of chills.) Steps to Eliminate General Chill: + Raise the final silicon level. + Raise the carbon equivalent ( % Si) [%C+ above Cl 4. Some allowable levels for different sections are: 4.5 for 1", 4.6 for 1/2", 4.7 for 1a" + Make sure all carbide producing alloy levels are as low as practical (Cr and V are particularly bad). + Increase casting pouring temperature. + Add additional mold and late stream FeSi inoculation. + Increase casting density per mold and increase mold wall thickness. + If these steps are not adequate ~ a high temperature full annealing heat treatment may be the last resort. Sectioned Inverse Chill Castings Sectioned and Etched Wedge neInverse Chil Typical examples are shown in the accompanying figures on Page 1. Inverse chill is not detectable at casting shake-out or by inspection hardness _ testing. However, it is readily detected in the machine shop when attempting to drill, tap and mill into. the cross _ sectional unmachinable structure. In a few cases, the fracture face of the gate section may indicate the presence of centerline carbides, Causes of Inverse Chill (IC): + IC occurs in the last area of the casting to solidify. This is the midline of a thin section; or at the center of an isolated heavier section such as a boss. + Carbide formers, even if present in small quantities, lose solubility during solidification and segregate to the last iron to freeze. + Residual magnesium and cerium in “over treated iron" segregate to thermal centers. + Dissolved hydrogen loses solubility and diffuses to the last area to solidify. + IC is often associated with micro- shrinkage at an under-fed casting centerline, Preventing Inverse Chill: * Consider all the recommended steps for eliminating general chill. + Avoid over treatment, Target final magnesium and cerium levels at <0.040% and <0,008%, respectively. + Add inmold inoculation (in pouring eup or in the mold). + Prevent hydrogen pickup by assuring all refractory vessels, metal launders, etc., are 100% dried and cured (there should be zero residual moisture) + Make sure inoculants and magnesium alloys are kept dry. + Don't store or hold molds in an environment that will cause excess water to condense in the mold cavity. Can Inverse Chill Be Heat Treated ‘Away? Yes, but these carbides are extremely stable, requiring a long and slow cool, high temperature annealing eycle. Consequences if IC is Undetected: + The biggest problem is machinability. + If machined, excessive wear in assemblies may be experienced by the end user. + If all the carbides are concentrated at the centerline, this may not affect service life for the customer (failures generally originate at _—_ surfaces). However, under fast fracture loading, such an impact or low cycle, high stress metal fatigue, early service failures are possible + Once the customer identifies IC, they usually insist on 100% elimination. Typical microstructure in the inverse chill area of the Etched Cross Section shown on Page |