EP2341154B1 - Verfahren zur Herstellung von Gusseisen mit Kugelgraphit - Google Patents

Verfahren zur Herstellung von Gusseisen mit Kugelgraphit Download PDF

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Publication number
EP2341154B1
EP2341154B1 EP10382002.3A EP10382002A EP2341154B1 EP 2341154 B1 EP2341154 B1 EP 2341154B1 EP 10382002 A EP10382002 A EP 10382002A EP 2341154 B1 EP2341154 B1 EP 2341154B1
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European Patent Office
Prior art keywords
ladle
casting
cast iron
furnace
added
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EP10382002.3A
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English (en)
French (fr)
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EP2341154A1 (de
Inventor
Pedro Fernandez Teran
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Priority to ES10382002.3T priority patent/ES2537435T3/es
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    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C1/00—Refining of pig-iron; Cast iron
    • C21C1/10—Making spheroidal graphite cast-iron
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C1/00—Refining of pig-iron; Cast iron
    • C21C1/10—Making spheroidal graphite cast-iron
    • C21C1/105—Nodularising additive agents

Definitions

  • the invention starts from the use of a metal chilled casting installation, with a further annealing heat treatment, which produces ferritic flake graphite gray cast iron.
  • the object of the present invention is a process which allows obtaining ferritic-perlitic nodular gray cast iron in the as-cast condition in a metal chill-mold (without heat treatment) in one and the same casting installation which produces ferritic flake graphite gray cast iron.
  • An embodiment variant provides obtaining in parallel nodular gray cast iron in metal chill-mold and flake graphite gray cast iron, starting from a common load in the melting furnace.
  • the foundries are specialized in flake graphite type or nodular type casting. Thus, when they are required to produce the two casting qualities due to certain circumstances, it is necessary to separate the materials and the material transfer and casting elements, among other modifications of the foundry.
  • US Patent 2 855 336 discloses a method for obtaining centrifugated tubing in steel molds of white cast (cementite), therfore the tubing should be treated in an annealing oven in order to produce nodular structure in the product.
  • US Patent 4 252 559 discloses the use of an electric arc furnace in order to obtain base cast iron.
  • the carbon content of the cast iron can be brought to the desired value by adding carburizing agents in the furnace.
  • this document of the prior art only makes improvements in only one equipment of the foundry. The problem of producing both casting qualities using the same equipments of a foundry is not disclosed.
  • GB Patent 1 527 054 discloses an automatic treatment system wherein inoculation is carry out with Fe Si Mg and inoculants in the melted material in order to obtain nodular cast, the inoculation is carry out at temperatures of 1380°C to 1430° C. The inoculation step is performed during pouring and not by the addition inoculants into the ladle.
  • disamatic ® The most currently used and common nodular casting process is the so-called disamatic ®, in which green sand molds are used without metal cases, and the molding is carried out under high pressure.
  • disamatic ® system is preferably used for the automotive industry and more specifically for manufacturing several components of vehicle brake systems.
  • nodular casting process produces very high quality parts for many sectors of the industry in general and particularly for the automotive sector, for example, the nodular casting allows obtaining parts for disc brakes (actuators) the components of which are clamps and forks.
  • brake parts such as the controls (master cylinders, wheel cylinders, compensators and clutch controls) have always been mainly cast in a metal chill-mold.
  • brake manufacturers require: that it has a good internal quality by a controlled variable process, that it has a high productivity, without intermediate stocks, that the lead time is the lowest possible, that the costs are very competitive and that the release of new products is very fast.
  • a flake graphite gray cast iron in metal chill-mold installation has at least one melting furnace, and its corresponding loader; at least one maintenance furnace; a transfer ladle for transferring the molten load from the melting furnace to the maintenance furnace; a distribution ladle for feeding the casting ladle; a carousel with a plurality of metal molds (chill-molds) in which the hot melt is cast; feeding and classification belts and an annealing heat treatment furnace.
  • a loader feeds the metal and non-metal load to the melting furnace and when the metal is molten, with an equivalent carbon content of 4.40 to 4.60%, it is transferred to the maintenance furnace by means of the transfer ladle.
  • the composition and the temperature are adjusted.
  • the molten load is passed from the maintenance furnace to the distribution ladle and from the latter to the casting ladle.
  • the casting ladle casts the cast iron in the molds and when the parts have solidified they are demolded.
  • the demolded parts are transported to the heat treatment furnace and from the latter to the different phases of the process of classification, unitary control and finishing.
  • the invention which is the object of this application is based on a conventional installation, such as the one described above and based
  • the process object of the present application i.e., the process for obtaining nodular gray cast iron in metal chill-mold in the as-cast condition, comprises the following steps:
  • the metal base In the maintenance furnace, the metal base is completely refined in terms of composition and temperature. When the base metal is correct, it is treated with Fe-Si-Mg and inoculant in the distribution ladle itself and then an additional amount of inoculant is added into the casting stream in the casting ladle.
  • Fe-Si-Mg is the nodulizing agent and 7 to 10% by weight of the load to be treated is added.
  • the inoculant which is added together with Fe-Si-Mg is to reduce the formation of metal carbides (cementite) of the latter and to increase the power of nucleation (nodularization) at the time of the treatment.
  • the amount of inoculant which is added in the distribution ladle is 0.15 to 0.22% the weight of the load.
  • the inoculant which is added into the casting stream in the casting ladle is to reinforce the non-precipitation of cementite due to the quick solidification of the metal in the chill-mold.
  • This addition of inoculant into the casting stream in the casting ladle is 0.07 to 0.15%.
  • the parts with very special characteristics are passed through the heat treatment (ferritization) furnace to improve their strength and elongation values. Furthermore, the subsequent heat treatment gives a very special characteristic to the parts produced in metal chill-mold in terms of the absorption of noises caused by friction or contact with other parts (vibrations due to friction).
  • a variant of the invention provides a process which allows obtaining in parallel nodular gray cast iron and flake graphite cast iron in metal chill-mold, for which a metal and non-metal load is initially fed to a melting furnace.
  • the material of the melting furnace is transferred from the melting due to friction).
  • a variant of the invention provides a process which allows obtaining in parallel nodular gray cast iron and flake graphite cast iron in metal chill-mold, for which a metal and non-metal load is initially fed to a melting furnace.
  • the material of the melting furnace is transferred from the melting furnace both to a first maintenance furnace (for the flake graphite cast iron) and to a second maintenance furnace (for the nodular cast iron) by means of a transfer ladle.
  • FeP and FeMn are added in the transfer ladle and the material is poured into the first maintenance furnace.
  • the material is poured from the first maintenance furnace and from the second maintenance furnace to at least one distribution ladle; in which, in the event of producing nodular cast iron a nodulizing agent and an inoculant are added in the distribution ladle. And for the case of flake graphite cast iron no component is added.
  • the material is fed from the distribution ladle to at least one casting ladle, in which in the event of producing nodular cast iron an additional amount of inoculant is added in the casting ladle. For the case of flake graphite cast iron no component is added.
  • the material from the casting ladle is poured into at least one metal mold.
  • the equivalent carbon content in the melting furnace is 4.4 to 4.60, for the purpose of allowing producing both types of cast irons.
  • the melting furnace can be the same but it is more operative to use one of the melting furnaces for the flow of materials of the flake graphite gray cast iron and a second maintenance furnace for the flow of materials of the nodular gray cast iron.
  • the present invention provides a process for making nodular cast iron using a prior art installation which is traditionally intended for flake graphite cast iron, which is described below.
  • FIG. 1 shows a traditional casting installation 10 formed by a melting furnace 20 in which a casting load introduced by a feeding belt 11 is melted.
  • this installation 10 there is also a transfer ladle 30 which receives the material from the melting furnace 20.
  • Another part of this installation is a maintenance furnace 40 which is fed by the transfer ladle 30.
  • a distribution ladle 50 receives the material from the maintenance furnace 40 and feeds it to at least one casting ladle 60; from which the molten material is drained towards at least one metal mold 70 assembled in a carousel 80.
  • the parts are demolded and transported by means of a conveyor belt 12 and a classification belt 13 towards a heat treatment furnace 90 and from the latter to the different phases of the process of classification, unitary control and finishing.
  • the returns are recovered at the outlet 95.
  • the (metal and non-metal) casting load is fed to the melting furnace 20, when the metal is molten and an equivalent carbon content "Ce" of 4.40 to 4.60 has been achieved, the molten material is transferred to the maintenance furnace 40 by means of the transfer ladle 30, and there the composition and the temperature of the molten material are adjusted in the event that there is any deviation.
  • the casting load comprises as metal materials: pig iron, first quality scraps, internal returns, graphite, FeSi, FeP and FeMn, achieving a composition of:
  • the maintenance furnace 40 when the molten material reaches the maintenance furnace 40 its composition is the same as that present in the melting furnace 20, with some small adjustments if there is a deviation. Likewise, the same composition as the one of the maintenance furnace 40 is in the distribution ladle 50 and casting ladle 60.
  • a casting load is fed by means of a conveyor belt 11 to a melting furnace 20; this casting load is then transferred to a maintenance furnace 40 by means of a transfer ladle 30.
  • the molten material is poured from the maintenance furnace 40 into a distribution ladle 50, adding thereto a nodulizing agent and an inoculant.
  • the distribution ladle 50 is marked in Figure 2 by means of a circle with a dotted line to indicate that that is where the nodulizing agent and the inoculant are added, establishing a great difference with the prior art.
  • the distribution ladle 50 feeds the molten material to at least one casting ladle 60, in which an additional amount of inoculant is added; and, finally, the molten material is cast from the casting ladle 60 into metal molds 70 assembled in a carousel. Again, a circle with a dotted line is used to indicate that an additional amount of inoculant is added in the casting ladle 60.
  • the equivalent carbon content in the melting furnace 20 is 4.7 to 4.90 to be able to obtain the nodular cast iron in the installation 10.
  • the casting load used for this process comprises: pig iron, first quality scraps, internal returns, graphite, FeSi and FeMn.
  • this molten material is completely adjusted in terms of composition and temperature.
  • the molten material When the molten material has a correct composition and temperature, it is treated with the nodulizing agent and the inoculant in the distribution ladle 50.
  • the nodulizing agent used is preferably Fe-Si-Mg and is added in a percentage of 7 to 10% with respect to the molten material to be treated.
  • the inoculant which is added together with the nodulizing agent is to reduce the power of formation and precipitation of metal carbides (cementite) due to the quick solidification of the metal in the chill-mold and to increase the power of nucleation (nodularization) at the time of the treatment.
  • the inoculant used is preferably of the Germalloy type with a composition of 71.50% Si; 0.88% Ca and 3.78% Al and is added in a percentage of 0.15 to 0.22 with respect to the molten material to be treated.
  • the molten material After the treatment with the nodulizing agent and the inoculant, the molten material has the following composition in the distribution ladle 50:
  • composition of the molten material in the distribution ladle 50 also contains residual Mg, Ti and Cu.
  • an inoculant is added in the casting ladle 60, which inoculant is preferably of the SMW type with the following composition 62.80% Si; 2.35% Ca; 0.97% Al; 0.81% Bi and 0.99% TR.
  • the inoculant which is added into the casting stream of the casting ladle is to reinforce the non-precipitation of cementite due to the quick solidification of the metal in the chill-mold.
  • This addition of inoculant into the casting stream is carried out in a proportion of 0.07 to 0.15% by weight of the treated load.
  • the molds 70 are assembled in a carousel 80, so that in the moment in which the parts have solidified they are demolded and passed to containers and when the parts have cooled, they are cleaned, classified, unitarily controlled and the finishing operations are carried out.
  • the process of the present invention is characterized by the way in which ferritic-perlitic nodular gray cast iron in the as-cast condition (without heat treatment) is obtained, using the same installation with which the ferritic flake graphite gray cast iron with subsequent annealing heat treatment is produced.
  • the parts are passed through the treatment (ferritization) furnace 90 to improve the strength and elongation values.
  • this type of part obtained by means of casting in metal chill-mold allows, for their structural characteristics with a subsequent treatment, acoustic absorption or non-amplification of noises just like compact graphite but with much better mechanical characteristics.
  • the process allows obtaining in parallel flake graphite and nodular cast iron, to that end reference is made to Figure 3 , which shows a casting installation 110 similar to the one described for obtaining flake graphite in a conventional manner but in which, to make it more operative and profitable, using the times better, two melting furnaces, two maintenance furnace and two carousels of metal molds are used.
  • Figure 3 shows a casting installation 110 similar to the one described for obtaining flake graphite in a conventional manner but in which, to make it more operative and profitable, using the times better, two melting furnaces, two maintenance furnace and two carousels of metal molds are used.
  • Figure 3 shows a casting installation 110 similar to the one described for obtaining flake graphite in a conventional manner but in which, to make it more operative and profitable, using the times better, two melting furnaces, two maintenance furnace and two carousels of metal molds are used.
  • the flow of materials for nodular cast iron are marked with a solid line and for flake graphite cast iron they
  • this casting installation 110 there is a melting furnace 20 for melting a casting load, a parallel melting furnace 20' for providing versatility to the process is also observed.
  • a transfer ladle 30 which receives the material of any of the melting furnaces 20 or 20'.
  • a first maintenance furnace 40 and a parallel second maintenance furnace 40' both fed by the transfer ladle 30, the objective of each of these melting furnaces will be explained below.
  • a distribution ladle 50 which receives the material from the first maintenance furnace 40 or from the parallel second maintenance furnace 40' is seen in the installation.
  • the installation 110 also has a heat treatment furnace 90.
  • a casting load is fed to the melting furnace 20 or 20'; the material from the melting furnace 20 is then transferred to a first maintenance furnace 40 (for the flake graphite cast iron) and to a second maintenance furnace 40' (for the nodular cast iron) by means of a transfer ladle 30, in which, in the event of producing flake graphite cast iron, FeP and FeMn are added in the transfer ladle 30, and poured into the maintenance furnace 40; and, in the event of producing nodular cast iron, graphite, FeSi and FeMn are added in the transfer ladle, and the material is poured into the parallel maintenance furnace 40'.
  • the transfer ladle 30 is marked with a circle to indicate that said addition is carried out therein depending on the type of cast iron to be obtained.
  • the material is subsequently poured from the first maintenance furnace 40 or from the second maintenance furnace 40' to at least one distribution ladle 50; in which in the event of producing nodular cast iron a nodulizing agent and an inoculant are added to the distribution ladle 50. For the case of flake graphite cast iron no component is added.
  • the casting load comprises: pig iron, first quality scraps, internal returns, graphite and FeSi, achieving an equivalent carbon content in the melting furnace 20 or 20' of 4.4 to 4.60.
  • one and the same load is used whether one type or another of cast iron is to be produced.
  • Fe-Si-Mg is added as nodulizing agent and the inoculant is of the germalloy type with a composition of 71.50% Si; 0.88% Ca and 3.78% Al and is added in a percentage of 0.15 to 0.22 with respect to the molten material to be treated.
  • composition of the molten material in the distribution ladle 50 for nodular cast iron is:
  • the molten material also contains residual Mg, Ti and Cu in the distribution ladle 50.
  • the composition achieved in the transfer ladle 30 with a phosphorus content of 0.30-0.35% allows increasing the castability and the manganese content neutralizes the action of the sulfur.
  • the process is the same as that shown in Figure 1 , i.e., the molten material from the maintenance furnace 40 passes to the distribution ladle 50 and from there to the casting ladle 60 to pour the molten material into the mold 70.
  • a very important aspect in the present invention relates to the metal molds used compared to the casting in any of the known types (disamatic type green sand, furan resin or chemical setting of the mold, ceramic, precoated sand etc.), since their specific properties are directly linked to their metallurgic structure and to the mode of preparation.
  • the process for obtaining nodular cast iron in the as-cast condition and in metal mold (chill-mold) has a series of advantages compared to the traditional disamatic sand process, including the following:

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)

Claims (6)

  1. Verfahren zur Herstellung von Gusseisen mit Kugelgraphit als Guss in Metall-Kokille in ein und derselben Guss-Installation, welche Gusseisen mit ferritischem Lamellengraphit herstellt, die Installation besteht aus:
    - mindestens einem Schmelzofen (20)
    - mindestens einem Instandhaltungsofen (40)
    - mindestens einer Transportpfanne (30) um die geschmolzene Masse von dem Schmelzofen (20) zum Erhaltungsofen (40) zu transferieren
    - mindestens ein Verteilergefäß (50) um die Masse des Schmelzofens zur Gießpfanne weiterzugeben
    - mindestens eine Gießpfanne (60) gespeist durch das Verteilergefäß (50)
    - mindestens ein Umlaufförderer (80) mit mindestens einer Metall-Kokille (70) in welche das Material von der Gießpfanne (60) entladen wird,
    dadurch gekennzeichnet,
    dass es folgende Schritte umfasst:
    a) Speisen eines Schmelzofens (20) mit einer Gieß-Masse; wobei der entsprechende Kohlenstoff-Gehalt im Schmelzofen 4.7 bis 4.90 beträgt;
    b) Transferieren des geschmolzenen Materials von dem Schmelzofen (20) zum Instandhaltungsofen (40) mittels der Transportpfanne (30);
    c) Gießen des Materials aus dem Instandhaltungsofen in das Verteilergefäß (50), dazu gebend ein Agglomerations-Agens und ein Impfmittel; so dass nach der Behandlung mit dem Impfmittel und dem Agglomerations-Agens das geschmolzene Material in dem Verteilergefäß (50) folgende Zusammensetzung hat:
    3,60-3,80% C;
    2,80-3,00% Si;
    0,65-0,75% Mn;
    0,008-0,013% S und
    0,10-0,15% P;
    d) Speisen der mindestens einen Gießpfanne (60) mit dem Material aus dem Verteilergefäß (50) wobei eine zusätzliche Menge des Impfmittels der Gießpfanne (60) zugeführt wird;
    e) Gießen des Materials aus der Gießpfanne (60) in die mindestens eine Metall-Kokille (70) durch Schwerkraft; und
    f) Kühlen und Entformen des Teils sobald es erstarrt ist.
  2. Verfahren zur Herstellung von Gusseisen mit Kugelgraphit in Metall-Kokille gemäß Anspruch 1,
    dadurch gekennzeichnet,
    dass die Gieß-Masse umfasst:
    Roheisen, Überreste erster Qualität, interner Rücklauf, Graphit, FeSi und FeMn.
  3. Verfahren zur Herstellung von Gusseisen mit Kugelgraphit in Metall-Kokille gemäß der Ansprüche 1 oder 2,
    dadurch gekennzeichnet,
    dass das Agglomerations-Agens Fe-Si-Mg ist und in einem Prozentsatz von 7 bis 10% zugefügt wird in Abhängigkeit des Gewichts des geschmolzenen Materials, das behandelt wird.
  4. Verfahren zur Herstellung von Gusseisen mit Kugelgraphit in Metall-Kokille gemäß einem der Ansprüche 1 bis 3,
    dadurch gekennzeichnet,
    dass das Impfmittel welches in das Verteilergefäß (50) gegeben wird vom Germalloy-Typ ist mit einer Zusammensetzung von 71,50% Si; 0,88% Ca und 3,78% Al und zugegeben wird mit einem Prozentsatz von 0,15 bis 0,22 in Bezug auf das geschmolzene Material, das behandelt wird.
  5. Verfahren zur Herstellung von Gusseisen mit Kugelgraphit in Metall-Kokille gemäß einem der Ansprüche 1 bis 4,
    dadurch gekennzeichnet,
    dass das Impfmittel welches in den Gießstrom in der Gießpfanne (60) gegeben wird vom SMW-Typ ist, mit folgender Zusammensetzung 62,80% Si; 2,35% Ca; 0,97% Al; 0,81% Bi und 0,99% TR und in einer Menge von 0,07 bis 0,15% des Gewichts der Masse zugegeben wird.
  6. Verfahren zur Herstellung von Gusseisen mit Kugelgraphit in einer Metall-Kokille gemäß einem der Ansprüche 1 bis 5,
    dadurch gekennzeichnet,
    dass das produzierte Stück einem Behandlungsofen (90) zugeführt wird um die Stärke und Längung zu verbessern.
EP10382002.3A 2010-01-05 2010-01-05 Verfahren zur Herstellung von Gusseisen mit Kugelgraphit Not-in-force EP2341154B1 (de)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP10382002.3A EP2341154B1 (de) 2010-01-05 2010-01-05 Verfahren zur Herstellung von Gusseisen mit Kugelgraphit
ES10382002.3T ES2537435T3 (es) 2010-01-05 2010-01-05 Procedimiento de fabricación de fundición nodular

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Application Number Priority Date Filing Date Title
EP10382002.3A EP2341154B1 (de) 2010-01-05 2010-01-05 Verfahren zur Herstellung von Gusseisen mit Kugelgraphit

Publications (2)

Publication Number Publication Date
EP2341154A1 EP2341154A1 (de) 2011-07-06
EP2341154B1 true EP2341154B1 (de) 2015-02-25

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107190119A (zh) * 2017-05-17 2017-09-22 安徽巨泰机械制造有限公司 一种高强度高韧性球墨铸铁的铸造工艺

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102489690A (zh) * 2011-12-16 2012-06-13 十堰市泰祥实业有限公司 铸态非合金化生产qt500-7汽车发动机主轴承盖方法
CN109338026A (zh) * 2018-11-15 2019-02-15 四川海科机械制造有限公司 高温球墨铸铁的制造工艺

Citations (2)

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Publication number Priority date Publication date Assignee Title
GB1527054A (en) * 1977-05-11 1978-10-04 British Cast Iron Res Ass Producing nodular graphite iron
JPS61119351A (ja) * 1984-11-13 1986-06-06 Toyota Motor Corp 微細球状黒鉛を有する鋳鉄材料の製造方法

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2855336A (en) 1957-02-04 1958-10-07 Thomas W Curry Nodular iron process of manufacture
FR2375326A1 (fr) 1976-12-23 1978-07-21 Pont A Mousson Procede d'elaboration de fonte de base pour le moulage en fonderie
SE502227C2 (sv) * 1993-12-30 1995-09-18 Sintercast Ab Förfarande för kontinuerligt tillhandahållande av förbehandlat smält järn för gjutning av föremål av kompaktgrafitjärn

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1527054A (en) * 1977-05-11 1978-10-04 British Cast Iron Res Ass Producing nodular graphite iron
JPS61119351A (ja) * 1984-11-13 1986-06-06 Toyota Motor Corp 微細球状黒鉛を有する鋳鉄材料の製造方法

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107190119A (zh) * 2017-05-17 2017-09-22 安徽巨泰机械制造有限公司 一种高强度高韧性球墨铸铁的铸造工艺

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EP2341154A1 (de) 2011-07-06

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