3.1.

DEFINITION Ol INOCULATION 9
1 be International Foundry Directory defines inoculation at follows: "An ion which consists in adding small quantities of certain substances to a liquid metal, thus provoking physicochemical changes which differ from those produced by the same substances when used as alloying elements'*. The AFS Metal Casting Directory defines it as foilows:*The addition of substances designed to form nuclei for crystallizat might expand on this definition by explaining lurga loci for HH graphite morphology, eliminating iron ^^^^^^^^^^m the eutec tie' f0B^B^aA and reducing section sensitivity. morphology, eliminating iron carbide*, increasing the CUICCIM: count and reducing section seroitivta 3.2 I 111 M l I ) TO I M M H I I

Commercial production involves Ihc manufacture of iron castings of a wide range of weight and section thickness. The basic composition of tw to be cast is usually dictated by the properties required in the fjrt'flhff* wtrinp and the (iwaslijunwii is often (heed

It
with the problem of producing chill free castings of suitable inachinabiiity and mechanical strength in iron of composition likely to give chill problems. The ability to reduce the chilling

inoculation without incurring serious changes in metal composition is of particular importance in this situation. A large tonnage of grey iron castings is inoculated in otiier to avoid the formation of chill in thinner sections and to get preferred *A
f

Type slEWture in &U types of castings,

SUILED
m

SSBBHBBBHHH ^

increase problems, due to the contamination of the iron with carbide promoting elements such as chromium. Vanadium and ipn wi inoculation has become increasingly important in order to offset the increased CffiHhng icrxlettfly.

grey iron a large number of nuclei begin to grow with little undercooling, promoting the formation of Type A as described above .The difference between the eutectic cell structure in an iron with and without inoculation is shown in figure5. 3.4. INOCULATION -A KEY TO CONTROL OF GREY IRON

In the handling of molten iron from the furnace to the mould, inoculation is an important step in controlling the structure and properties of grey irons. The main advantages
of inoculation are as follows:

3.4.1. CONTROL OF GRAPHITE MORPHOLOGY:

It promotes the formation of small, uniformly dispersed Type A graphite flakes, size ranging between 4 & 5. It does this by providing more number of nucleation centers for eutectic cells to form. Each time a eutectic cell is formed, a small amount of heat is generated which warms up the surrounding liquid and lowers the rate of solidification. Therefore, the greater will be the heat generated and slower will the iron solidifies. Type A graphite flakes will precipitate if the rate of solidification is slow enough. The graphite flake size is normally related to eutectic cell size .The smaller the cell size, the smaller will be the graphite flake.

3.4.2. REDUCTION OF CHILL:

Inoculation of grey iron minimizes chill by preventing or substantially lowering primary carbide formation. Carbides usually result is the iron solidifies too quickly i.e., if undercooling or non equilibrium solidification conditions takes place. By providing more nucleation centers, and therefore greater heat of solidification, inoculation minimizes under cooling and promotes equilibrium solidification.
15

Krcy iron a large number of nuclei begin to grow with link undercooling, promoting the formation of Type A as described above The difference between the eutectic cell structure in en iron with and without inoculation is shown in figures. 3.4. INOCt LA I ION -A KEY TO ( OMTROL OF GREY IRON

in the handling of molten iron from the furnace to the mould, inoculation is an important step in controlling the structure and properties of -r^c w^m advantages Of lnOalMfcl 3.4.1 #flHHHHHVHOLO(f oi inoculation are at follows; 3-4.1. CONTROL OF ( . K vPIUTE MORPHOLOGY It proiftot
ni&ll, uniformly dispersed Type A graphite flakes, t i ' ^ H i g between It does this by providinj number of
ic

h time a eutcctk ceil is formed, a small amount of heal is generated

wri' liquid and lowers or will be the beat generated and will th

of solidificauoa, Therefoi >lidi fies. Type A graphite

willi
ROI

4HI! I

enough. The graphite cell i die smaller will be the graphite flake,

normally related to eutectic cell sin I he smaller the cell size, the mailer will be the graphite flake. BH 3.4*2. Kl 1>UC I i o n 0 1 ( HILLt Imputation of gray .ionlminimi*es cbiU by preventing or st^etantially lowering primary carbide format ion Carbides usually result! is the iron solidifies too quickly Le^y if undercoat** or nan equilibrium MlidifictiiN conditions takes place. By providing more nu centers, and therefore greater beat of soltcmkatiua, ioocatetion minimizes undc

. notingandpromotes equilibrium solid i tkatkNi^ IA3. REDUC 1 ION Of SKCl ION SENSTI l V I I \ Proper ittvity in gray irons.
tivity is a condition resulting from stfyotural differences existing between thick and thm aocfHMf in the nmc castina* it ia normally caused by different rales of solidification in the various areas of a
cast*

can help this by pro1

thitc flakes of more uniform size if there is too great a variation p section s
ieauire the

along with thftinoculants to obtain more uniform

NIC AL PROPERTIES

3,44. IMPROVBM* NT IN MECHANICAL PROPERTIES

1HB9

Considerable improvement in such properties as tensile strength, toughness, wear resistance, impact strength can result from proper and adequate inoculation. The fact that the addition of an inoculums to grey iron promotes the formation of Type A graphite flakes uniformly

dispersed and small in size* is the reason for improved toughness, tensile and impact properties. Grey cast irons containing Types B D and E graphite flakes, as well as carbides* have inferior mechanical properties to those containing small type A flakes. Wear resistances of gi^y oB BBflH are improved if they have a peaiiitk matrix structure free from (aximJbim^A^siife larta^fcstituent can cause scoring and galling during sliding A. ENHAN KS

MAC

HlNABILin

Inoculation by preventing the formation of Type* B and D graphite usually associated with areas of ferritc. promotes a pcariitk matrix in the castings. So far as the machinablity if MI the mom uniform the matrix structure of the casting, the better will be the surface

h after machining
th matrix structures ting of fcrrite and pearlite and therefore oilm less resistance to cutting force, the cutung tool tends to chatter or jump when going (jwitjfcrifii to paariitic area* Jpb results 1$ jagged finish on the casting. Carbidic

WSm
maehiiiability and chip ti from the cutting

HHHBHHh9 W Promotes uniform matrix structures in grey

f iron iifiniiii Hiiii I nhalnintt HiW%
3.4.6. I ' R t \ t NTS I \ t | s s | \ K O \ I I > a I lov An innucuhtni. being a good dootddiaer. will help prevent caccsivc q3
of the

iron. If grey iron it too highly oxidized, excessive chill cm result m eastings poured fi
tt3tt such iam tooculants* especially the proprietary tyoes contain* such element* as Banum,

ticium* Zirconium* Manganese,Titanium, Strontium, Cerium, Alumi

jid Silk

\11
Ot IJIC JC ei

Often, deoxi ier certain conditions, can function as dcoxidi cts cao act as nuclei, thus enhancing the e
Ale

of the nocuiants in reducing chill and promoting Type A graphite flakes. Usually, the more
highly

orated I the more is die amount iiknts required for proper inocutaiQa. fa any raj iron is iy oxidized, suBcient time should be allowed after inoculation to allow H of of deoxidation to rise to the tc where thev can be scnMVcd *"'tUi| M^pouriiig in to moulds. Othcrwim the cjrtnfifwill (N . -v^hiifucai properties could bo adversely Effected*

I OF INOCULATION icthods which m

V 01 n t of undercooling at various cooling rates. Jepth on standard te cy arc lis formed during solidification. ng a combination of chill test with estimates of eutectic ceil are 3.6. FACTORS TO BE < ONSIDEKED FOR THE USE OF INOCULANTS: 3.64, I HE ANA1 YS1S OF BASE IRON COMPOSITION OF THE IRON:
In considering the analysts of base iron, such things as Carbon Equivalent and residual clement contents are important. I) A grey iron with low carbon equivalent requires more inoculation than irons with high carbon equivalents. U) A grey iron low in element such as Chromium, Manganese, Vanadium and Molybdenum requires less inoculation than grey irons containing these alloying H^HHnHHwier amounts of Gf Mo and V. a higher degree of inoculation ASSESS*!I M OF INOCULATION:

There are three methods which may be used to assess the potency of inoculants. They are The measurement of undercooling at various cooling rates. Measurement of chill depth on standard test place. Counting of eutectic cells formed during solidification. For shoo floor, testing a combination of chill test with estimates of eutectic cell are ^^Hpparison of the behavior of inoculants by measurement of chilling tendency and should only be by the examination of similar sections which have cooled at the same lit castings used for this purpose should be made in moulds of similar type and poured le temperature.
AH iiwi WILD ^Uipiiur to u\c

nog* of (M&% to <M29t Wi#W frigid nvorbi> i.. than U* ir am* u men amount oi
025-03%

the anoint
mm'm03$*0M wmWf Tl IE WETAI :

I H E T I M I ' E K A M K E O I I H E M l I Al Mill nlm i of the iron at the time of tapping is important. Normally, the higher the
IOCU AHIS rcuuircd

THE SECTION SIZE OF THE CASTOK

The
M| IS important factor to be unlettered in the

JHtmort inoculants. tocas&tgs with both heavy and hould be geared to the lightest section of the casting.

"gni sections, the inoculation practice should be geared to the lightest section of the casting. 3.6.4THE< H A K i . E M \ k i - t I ' : Another important factor to be considered is the charge make up. Normally the less pig rgc the greater is the amount of inoculation required.
111

ELTING MEDIA:
^&/^tom& md affects the response of grey cast iron to the ma usually requires more inoculation than a cupola melted tror cast irons melted in ate furnaces usually responds to a degree in betim& that of the induction furnace and cupola

SjMJLEHI MOULDING MATERIAL 0>KY OR GREEN SAND): materials are oot It ften eratty requires more iwradstion to

and n
IVJ

at it factory nuclcatton m iron pouted in to green mod moulds at compared to dry sand That it because chilling is naore in groeo sand moulds.
HE TIME IM VOI V I I ) IN I Hi Hit K I V # OPKK \ I ION I ina^laaoiw AU inocuUntts fadt with time If more than 15 pour a ladle of iron after it has been tnoculaicd, then a greater

Hi

4. CONTROL TESTS FOR INOCULATED GREY CAST IKON There are three method* which may be used to assess the potency of inoculants kgjfcf H H| of under cooling at various cooling rates. UKSitfeM cutectic cells or the nl of nodules formed during solidification. Tint lamds are complementary.-The first has the advantage that when combined with the HHnPpftj cm provide greater understanding of the way in whkh inoculants causes its effect. I techniques of thermal analysis may encourage the wider use of these criteria in the

20 tuturc. For sbop tloor testing a combination of chill test with estimate of eutectic cell or noduk no. are widely used. Comparison of the behavior of inoculants by measurement of chilling tendency and eutectic cell should only be by the examination of similar sections which have cooled at the same rate. AH test castings used for this purpose should be made in mould* ef similar &pc and pouted at the same temperature Sections for eutectic cell nodule coast should be cut from similar positions in the test castings. The evaluations of inoculants should not be Wide 00 the basis of its effect open eutectic cell alone. No unique relationship applicable to all i0oculafit|psxtsts between eutectic cell and chilling tendency. Some inoculants piocuwus less vvitb a smaller increase in the no. of eutectic cells than is given by inoculants.

Am K A t U > N ffl 1N( K D L A I K D G K K V ( A S I IKON

Engineering machines tools and automotive industry requires higher strength and cltaviiNit*1 flUf* properties are not net through inoculation without alloy addition. Due c^fcastmgisteducedfWmsanwquantit

cast irons which arc the higher strength available from the grey irons. quently sold under trade names of meehanite, Ni-Tenstle Gtimite etc gre y cast iron, the meehanite cast iron has an added advantage of responding to
Iicai trcaiiikcitt

engine
miu

kai til

block*, pump*, valves, to arc subjected to presence Mill genes. Tbu*e castings should ftp ugliness and resistance to ftgkil liui should be fm Irom any defect which would impair the working

machine tools with times me ccfl count of i he role O! ion in the production of modem caM iron has increased in importance and if

u Weill

ct

Iplting practice
11 cominue t< fi ihe bai

\mum metal]urgicai

major control procedures for com i This will enable a range of as cast

directed towards formulating new arid more potent structure

la the past
have bom directed towards formulating new and more potent
it

fried with continued n hd&it for UDocuiaitts composition selection

ere ts mm interest fat better inocu

ures

cspec

inocul
SHI attitudes towi noculatton process. Piupcas in mould

Ion practice, and m flp engineering and control required to carry > make these technioues
almost as widely mod as ladle inoculations