Director of Technology Elkem Foundry DivisionElkem Foundry Division Kristiansand, Norway€¦ ·...

InoculationTheories & Reality

Dr. Torbjörn Skaland

Director of TechnologyElkem Foundry DivisionElkem Foundry Division

Kristiansand, Norway

Elkem Foundry SeminarElkem Foundry SeminarWeinheimWeinheim GermanyGermany, 10 , 10 –– 11 September 201211 September 2012

Effects of InoculationEffects of Inoculation

Un inoculated ductile iron Inoculated ductile iron

100X 100X

Un-inoculated ductile iron Inoculated ductile iron


Inoculation IngredientsgPrimary: Silicon

Calcium Barium StrontiumCalcium, Barium, Strontium

Beneficial: Aluminum, Zirconium, ManganeseBeneficial: Aluminum, Zirconium, ManganeseCerium, Bismuth

Pure inoculantCa = 0

0.8%Ca-inoculantCa = 10 ppmCa 0 Ca 10 ppm


Heterogeneous Nucleationg


Mi ti l i D til IMicro-particles in Ductile Iron

100X 1,000X 70,000X

Micro-particles: 100,000 pr mm3

N d l 1 000 3Nodules: 1,000 pr mm3

100 pr mm2


The Silicate Nucleation ModelThe Silicate Nucleation Model

X = Ca, Sr, or Ba

Hexagonal Ca-, Ba-, and Sr silicatessettle on surface of heterogeneitiesformed during magnesium treatmentg g

Critical role of group IIA elements andSi, S and O described by this model

Important difference between Mg andother elements Ca, Ba, and Sr


The CaO-Al O -SiO SystemThe CaO-Al2O3-SiO2 System

DeoxidationCaOSiO2

SrOSiO2

BaOSiO2

CaOAl2O32SiO2

SrOAl2O32SiO2

BaOAl2O32SiO2BaO Al2O3 2SiO2


The Role of CalciumThe Role of Calcium

Ferrosilicon 75%0.5 – 2% Ca (Ba, Sr, etc.)


Planar Lattice DisregistryPlanar Lattice Disregistry

Inclusion

PhaseOrientation

RelationshipLattice

Disregistry

CaOSiO2 (001)I (001)G 7.5 %

SrOSiO2 (001)I (001)G 3.5 %

BaOSiO2 (001)I (001)G 1.5 %

CaOAl2O32SiO2 (001)I (001)G 3.7 %

SrOAl2O32SiO2 (001)I (001)G 6.2 %

BaO Al O 2SiO (001) (001) 7 1 %BaOAl2O32SiO2 (001)I (001)G 7.1 %


Nitrides in Ductile IronNitrides in Ductile Iron

Nitride particle TEM EDX Mg, Al, Si, N Crystal [001]-axis

Mg-Al-Si Nitride (AlN-structure)

Mg2.5AlSi2.5N6


Inoculation of Gray IronInoculation of Gray Iron

100X

Inoculated gray iron

100X

Un-inoculated gray iron

100X


MnS Particles in Gray IronMnS Particles in Gray Iron

0.04 0.04 –– 0.12 %S0.12 %S

%Mn = %S x 1.7 + 0.3


Graphite Nucleation in Gray Iron

XO-Al2O3

M S

A graphite A graphiteGraphite

MnS

g p g p

D graphiteD graphite D graphiteD graphite


Oxides in Gray IronAl Zr

A graphite A graphite

Ti

A graphite A graphite

D graphiteElkem Foundry SeminarElkem Foundry Seminar

WeinheimWeinheim GermanyGermany, 10 , 10 –– 11 September 201211 September 2012

Aluminum in Gray IronAluminum in Gray Iron

<0.001% Al 0.006% Al


Inoculation MethodsInoculation MethodsTransfer Ladle P i L dl In-streamTransfer Ladle Pouring Ladle In stream

11 3322

4444In-Mold

Position 1 2 3 4Position 1 2 3 4

Addition rate [wt%] 0.3 – 1.0 0.3 – 0.5 0.05 – 0.2 0.04 – 0.2Sizing [mm] 0.5 – 15 0.5 – 10 0.2 – 1 0.5 – 5


Inoculant Addition RateInoculant Addition Rate


Fading of Inoculationg


Inoculation Selection• Casting thickness & size• Nitrogen contentNitrogen content• Shrinkage tendency• Fade time • Required properties• Required properties• Temperature• Inoculation method

M lti

Gray IronGray Iron Ductile IronDuctile Iron

• Melting process

• Base Sulphur• CEV in iron

Gray IronGray Iron• Treatment process• Nodularizer

Ductile IronDuctile Iron

• CEV in iron• Nitrogen

• Nodularizer• Base composition


Inoculation – Primary Elements

BaBa SrSrCaCa BaBa SrSr

Graphite promotingMost commercial High potency in GI

CaCa

Graphite promoting

Slag conditioning

Fade resistance

Most commercial inoculants

Low potent vs Ba, Sr

High potency in GI

Powerful chill reducer

Effective in small tCost effective vs Ca

Especially effective in DI and low-S GI

Effect fade fast

Critical element in most inoculants

amounts

Low cell count

Reduce shrinkageDI and low S GI Reduce shrinkage

Powerful in low temperature DI


Inoculation – Beneficial Elements

AlAl ZrZrCeCe MnMnAlAl

Normally

ZrZr

R d hill i

CeCe MnMn

Neutralize Reduce alloyNormally present in FeSi

H-pinholes

Reduce chill in thin sections

High nodule count

Neutralize subversive elements

High nodule

Reduce alloy melting point

Improve dissolution rateHigh level in

mold alloys

Enhance A

Neutralize N

Use with Ca, Sr, Ba

Refine cell

High nodule count in DI

Especially effective in

dissolution rate

May increase pearlite

S (G )graphite

Max. 1.5% is advised

Refine cell structure in GI

effective in converter iron

Low chill and shrink

Neutralize S (GI)

shrink


Inoculation and Nodule CountInoculant BInoculant BInoculant AInoculant A

5 mm

310300

section

310300

40 mmsection

150 340


Inoculation Turning off Shrinkageg gInoculant AInoculant A Inoculant BInoculant B Inoculant CInoculant C

150 250 350

Some shrink More shrink Little shrinkSome shrink More shrink Little shrink


Inoculation and Thermal AnalysisInoculant BInoculant BInoculant AInoculant A

TElow = 1145oCUndercooling = 19oCR l 2 3

TElow = 1139oCUndercooling = 25oCR l 6 2 Recalescence = 2.3Recalescence = 6.2

GRF2 70GRF2 115 GRF2 = 70GRF2 = 115


Inoculation and Pearlite

Inoculant A :Inoculant A :Inoculant A :Inoculant A :

190 Nodules/mm190 Nodules/mm22

80 % Nodularity80 % Nodularity80 % Nodularity80 % Nodularity

25 % Pearlite25 % Pearlite

Inoculant B :Inoculant B :Inoculant B :Inoculant B :

360 Nodules/mm360 Nodules/mm22

90 % Nodularity90 % Nodularity

13 % Pearlite13 % Pearlite


Thank You !Thank You !

Any Questions ?


Director of Technology Elkem Foundry DivisionElkem Foundry Division Kristiansand, Norway€¦ ·...

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