US20240093337A1 - Non-magnesium process to produce compacted graphite iron (cgi) - Google Patents
Non-magnesium process to produce compacted graphite iron (cgi) Download PDFInfo
- Publication number
- US20240093337A1 US20240093337A1 US18/513,843 US202318513843A US2024093337A1 US 20240093337 A1 US20240093337 A1 US 20240093337A1 US 202318513843 A US202318513843 A US 202318513843A US 2024093337 A1 US2024093337 A1 US 2024093337A1
- Authority
- US
- United States
- Prior art keywords
- treatment
- magnesium
- alloy
- iron
- lanthanum
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 229910001126 Compacted graphite iron Inorganic materials 0.000 title claims abstract description 59
- 229910052749 magnesium Inorganic materials 0.000 title abstract description 51
- 239000011777 magnesium Substances 0.000 title abstract description 51
- 238000000034 method Methods 0.000 title abstract description 49
- 230000008569 process Effects 0.000 title abstract description 43
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 64
- 239000000956 alloy Substances 0.000 claims abstract description 64
- 229910052746 lanthanum Inorganic materials 0.000 claims abstract description 31
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 claims abstract description 31
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 23
- 239000010953 base metal Substances 0.000 claims abstract description 23
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 12
- 239000010703 silicon Substances 0.000 claims abstract description 12
- 229910052742 iron Inorganic materials 0.000 claims abstract description 11
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims abstract description 10
- 229910052782 aluminium Inorganic materials 0.000 claims description 10
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 10
- 239000011575 calcium Substances 0.000 claims description 10
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 9
- 229910052791 calcium Inorganic materials 0.000 claims description 9
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 abstract description 49
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 abstract description 15
- 239000002054 inoculum Substances 0.000 abstract description 15
- 239000010439 graphite Substances 0.000 abstract description 13
- 229910002804 graphite Inorganic materials 0.000 abstract description 13
- 229910052751 metal Inorganic materials 0.000 abstract description 10
- 239000002184 metal Substances 0.000 abstract description 10
- 238000004886 process control Methods 0.000 abstract description 4
- 239000002244 precipitate Substances 0.000 abstract 1
- 239000010455 vermiculite Substances 0.000 abstract 1
- 229910052902 vermiculite Inorganic materials 0.000 abstract 1
- 235000019354 vermiculite Nutrition 0.000 abstract 1
- 238000004519 manufacturing process Methods 0.000 description 23
- 229910000519 Ferrosilicon Inorganic materials 0.000 description 13
- 229910052761 rare earth metal Inorganic materials 0.000 description 13
- 150000002910 rare earth metals Chemical class 0.000 description 12
- 229910001018 Cast iron Inorganic materials 0.000 description 9
- 229910001141 Ductile iron Inorganic materials 0.000 description 7
- 238000007792 addition Methods 0.000 description 7
- 238000005266 casting Methods 0.000 description 7
- 239000000203 mixture Substances 0.000 description 7
- 230000015572 biosynthetic process Effects 0.000 description 4
- 238000006243 chemical reaction Methods 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 3
- 229910000858 La alloy Inorganic materials 0.000 description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 3
- 229910052802 copper Inorganic materials 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- 229910052718 tin Inorganic materials 0.000 description 3
- 229910052684 Cerium Inorganic materials 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 2
- 229910001060 Gray iron Inorganic materials 0.000 description 2
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 2
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- TVGGZXXPVMJCCL-UHFFFAOYSA-N [Si].[La] Chemical compound [Si].[La] TVGGZXXPVMJCCL-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 229910052787 antimony Inorganic materials 0.000 description 2
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 description 2
- 229910052788 barium Inorganic materials 0.000 description 2
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 description 2
- 229910052804 chromium Inorganic materials 0.000 description 2
- 239000011651 chromium Substances 0.000 description 2
- 239000003517 fume Substances 0.000 description 2
- 230000006698 induction Effects 0.000 description 2
- 235000000396 iron Nutrition 0.000 description 2
- 230000000670 limiting effect Effects 0.000 description 2
- 229910052748 manganese Inorganic materials 0.000 description 2
- 239000011572 manganese Substances 0.000 description 2
- 238000012544 monitoring process Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 239000002893 slag Substances 0.000 description 2
- 229910052719 titanium Inorganic materials 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- 230000007704 transition Effects 0.000 description 2
- 229910000967 As alloy Inorganic materials 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- 229910052777 Praseodymium Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000005864 Sulphur Substances 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- SXSVTGQIXJXKJR-UHFFFAOYSA-N [Mg].[Ti] Chemical compound [Mg].[Ti] SXSVTGQIXJXKJR-UHFFFAOYSA-N 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 229910052785 arsenic Inorganic materials 0.000 description 1
- RQNWIZPPADIBDY-UHFFFAOYSA-N arsenic atom Chemical compound [As] RQNWIZPPADIBDY-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 229910052797 bismuth Inorganic materials 0.000 description 1
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000011081 inoculation Methods 0.000 description 1
- NNLJGFCRHBKPPJ-UHFFFAOYSA-N iron lanthanum Chemical compound [Fe].[La] NNLJGFCRHBKPPJ-UHFFFAOYSA-N 0.000 description 1
- -1 iron-carbon-aluminum Chemical compound 0.000 description 1
- 229910052747 lanthanoid Inorganic materials 0.000 description 1
- 150000002602 lanthanoids Chemical class 0.000 description 1
- 239000011133 lead Substances 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- 230000003472 neutralizing effect Effects 0.000 description 1
- 229910001562 pearlite Inorganic materials 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 230000003389 potentiating effect Effects 0.000 description 1
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011135 tin Substances 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Images
Classifications
-
- 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
- C21C1/08—Manufacture of cast-iron
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/08—Making cast-iron alloys
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D1/00—Treatment of fused masses in the ladle or the supply runners before casting
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C37/00—Cast-iron alloys
- C22C37/10—Cast-iron alloys containing aluminium or silicon
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/005—Ferrous alloys, e.g. steel alloys containing rare earths, i.e. Sc, Y, Lanthanides
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Refinement Of Pig-Iron, Manufacture Of Cast Iron, And Steel Manufacture Other Than In Revolving Furnaces (AREA)
Abstract
The present invention pertains to a non-magnesium process to produce Compacted Graphite Iron (CGI) by placing a treatment alloy into a treatment ladle, and then placing an inoculant over the treatment alloy in the treatment ladle and pouring a molten base metal there over. The treatment alloy comprises iron, silicon and lanthanum, wherein lanthanum is 3-30% by weight of the treatment alloy, silicon is 40-50% by weight of the treatment alloy, and the remaining is Iron. Lanthanum in the treatment alloy makes the graphite precipitate as vermiculite (compacted form) instead of flake or spheroids. With extended process window offered by this new process (0.03-0.1% residual lanthanum in the metal) required to make CGI, this new process removes the stringent process control (0.01-0.02% residual magnesium in the metal) dictated by the magnesium process of making CGI.
Description
- This patent application claims the benefit of and priority to of patent application U.S. Ser. No. 16/332,409, filed Mar. 12, 2019, which is incorporated herein by reference in its entirety, and PCT Patent Application No. PCT/IB2017/055473, filed Sep. 12, 2017, which is incorporated herein by this reference in its entirety, and Indian patent application 201641031017, filed Sep. 12, 2016, which is incorporated herein by this reference in its entirety.
- The present invention relates to a production process of compacted graphite iron (CGI) without the addition of magnesium.
- Current production of compacted graphite iron (CGI) involves addition of magnesium, a volatile, dangerous and slag generating treatment element. To contain the high reactivity of magnesium and provide ease of handling, normally it is incorporated in ferrosilicon alloy. Thus, ferrosilicon alloys containing various percentage of magnesium are used commonly in the production of ductile iron (DI) and compacted graphite iron (CGI).
- Virtually all of the published reports and patents search lists magnesium as the main treatment element for production of CGI. For example few of the them are cited as follows U.S. Pat. No. 4,568,388 a “Magnesium-titanium-ferrosilicon alloys for producing compacted graphite iron in the mold and process using same”, U.S. Pat. No. 4,430,123 “Production of vermicular graphite cast iron”, U.S. Pat. No. 4,338,129 “Production of vermicular graphite cast iron”, U.S. Pat. No. 5,178,826 “Method and apparatus for the production of nodular or compacted graphite iron castings”, U.S. Pat. No. 4,501,612 “Compacted graphite cast irons in the iron-carbon-aluminum system”, U.S. Pat. No. 4,596,606 “Method of making CG iron”, U.S. Pat. No. 5,758,706 “Process control of compacted graphite iron production in pouring furnaces”, U.S. Pat. No. 5,639,420 “Method of manufacturing compacted graphite cast iron”.
- The method of CGI production using magnesium as the main treatment alloy causes fumes, flashes, violence and generates good amount of slag. Also, the process requires a very tight control of residual magnesium in the metal within a very narrow window of 0.008% Mg. CGI formation is stable only a range of 0.008% magnesium only. Below the lower limit, graphite grows as flake and above the upper limit, graphite grows as spheroids. Even small amounts of graphite flakes present in the microstructure reduce the mechanical properties. Presence of excess graphite spheroids in the microstructure reduce the casting and physical properties. Thus a close control of magnesium is a must for successful production of CGI. This control of magnesium within the stable range of 0.008% dictates very strict and tight process control requiring constant monitoring and corrective actions.
- Magnesium is being used for the production purpose of the compacted graphite Iron, but it comes with many disadvantages; in the presence of excess magnesium, the graphite nodules are formed as in case of ductile iron instead of graphite in vermicular form or in the presence of less magnesium flake form as in case of grey cast iron. Magnesium is the most commonly used alloy in spite of having limitations like: a) limited solubility in cast iron, it is only 0.04 percent, b) very low boiling point, it is only 1107° C. which makes it very quickly violent, c) requirement of close control over treatment during magnesium treatment as well as during pouring of molds after the magnesium treatment, which also means a constant monitoring of the reaction is mandatory to make sure the reaction does not over react and cause a different variety of cast iron, d) it is a potent carbide stabilizer, e) it is not effective in neutralizing tramp elements coming from steel scrap and other raw materials containing lead, zinc, titanium, arsenic, antimony and bismuth, f) extreme volatility and production of fumes giving rise to detrimental and objectionable atmosphere in foundry.
- CGI can also be produced by other methods—again with magnesium as the treatment alloy but with must addition of anti-elements like titanium, aluminum, and zirconium. These methods have their own disadvantages and are not as popular as the controlled magnesium alone process.
- An example of such can be found in the patent application U.S. Pat. No. 5,639,420 by Sanders et al, where in the most well-known method, the ladle treatment is used. According to Sanders et al, the treatment of an alloy, consisting of FeSiMgRECa, wherein RE refers to rare earth metal, Si reacts with the iron and the magnesium is added in to the alloy for the reaction purposes. The practice of using rare earth metal along with the alloy is well known, but the selection of amount of such any specific rare earth metal is the key to obtain a substantial quality of the compacted graphite iron. Few example of rare earth used as alloy components to produce compacted graphite iron can be cited by the patent application such as U.S 20090123321 A 1, in which a high-silicon ferritic CGI is being produced using alloy where in the selected rare earth metal is chromium with in a magnesium ferrosilicon alloy. In all the above process, RE refers to rare earth alloy containing cerium, and lanthanum, or cerium, lanthanum, neodymium, praseodymium with trace levels of other lanthanides.
- Torbjorn Skaland in the patent application US20040042925 for the purpose of nodularizing treatment of ductile iron used a ladle treatment method for nodularizing of a magnesium ferrosilicon alloy for which he uses lanthanum as the rare earth metal in the range of 0.3% to 5% by weight as an inoculant. Dremann and Fugiel in the patent application U.S. Pat. No. 4,568,388 A, for the purpose of producing compacted graphite iron by using magnesium titanium ferrosilicon alloy, for which he uses 0.5% of calcium and 0-2% of aluminum and the rest is balanced iron as an additive to the alloy.
- The objective of the present invention is to provide a compacted graphite iron (CGI) production process which is a non-magnesium process.
- The present invention pertains to a non-magnesium process to produce compacted graphite iron by placing a treatment alloy into a treatment ladle, and then placing an inoculant in the treatment ladle and pouring a molten base metal there over. The treatment alloy comprises iron, silicon and lanthanum, wherein lanthanum is 3-30% by weight of the treatment alloy, silicon is 40-50% by weight of the treatment alloy, and the remaining is iron.
- According to another embodiment of the invention the non-magnesium process to produce compacted graphite iron involves a treatment alloy containing ferro silicon lanthanum alloy with lanthanum in the range of 3-10% by weight of the treatment alloy.
- According to a further embodiment of the non-magnesium process to produce compacted graphite iron, the treatment alloy further comprises at least one of calcium and aluminum or in combination thereof, and calcium and aluminum are in range of 0.5-3% each by weight in the treatment alloy.
- According to a preferred embodiment of the non-magnesium process to produce compacted graphite iron, the treatment alloy is 0.4-2% by weight of the base metal, and the inoculant is 0.1-0.5% by weight of the base metal.
- According to yet another embodiment of the non-magnesium process to produce compacted graphite iron, the treatment alloy is treated with a base metal which comprises 3-5% carbon by weight, 2-5% silicon by weight and less than 0.016% sulfur by weight of base metal.
- According to an alternate embodiment of the non-magnesium process to produce compacted graphite iron, the base metal further comprises at least one or combination of manganese, copper, tin, antimony, molybdenum, vanadium, chromium and other pearlite promoting alloying elements.
- As per yet another embodiment of the non-magnesium process to produce compacted graphite iron, at least one of manganese is in range of 0.15-0.8% by weight of the base metal, copper is in range of 0.1-0.8% by weight of the base metal, or tin is in range of 0.01-0.1% by weight of the base metal, or a combination thereof.
- According to a preferred embodiment of the non-magnesium process to produce compacted graphite iron the inoculant is a ferrosilicon composition, and the ferrosilicon composition comprises at least calcium, aluminum, barium or lanthanum, or a combination thereof.
- According to another embodiment of the non-magnesium process to produce compacted graphite iron, addition of the inoculants is done by placing it on top of the treatment alloy within the treatment ladle, or during transfer from treatment ladle to pouring ladle, or in instream during pouring the casting ladle or as blocks or inserts into the mold during casting the mold, or as blocks or inserts in the sprue during casting into the mold.
- According to a further embodiment of the non-magnesium process to produce compacted graphite iron, it is an open pour ladle process wherein the treatment ladle is kept open during the entire treatment process.
- According to an alternate embodiment of the non-magnesium process to produce compacted graphite iron wherein producing compacted graphite Iron with this treatment process has a wide stable process window with residual lanthanum in the metal in the range of 0.03-0.1%.
- According to a preferred embodiment of the non-magnesium process to produce compacted graphite iron, the treatment alloy can be added in the form of lumps, or powder as in cored wires or inserts in in-mold process of producing compacted graphite iron.
-
FIG. 1 Schematically illustrates the process window one has to maintain tightly while using magnesium during manufacturing CGI. Residual magnesium % required to be maintained is 0.01-0.02. -
FIG. 2 Illustrates the schematic of this invention process where metal from the furnace is tapped directly into an open treatment ladle containing treatment alloy and inoculant -
FIG. 3 Illustrates this invention process where metal from the furnace is tapped directly into an open treatment ladle containing treatment alloy and inoculant -
FIG. 4 Illustrates the wide stable process window range one has to maintain while using this treatment alloy containing lanthanum for the production of CGI. Residual lanthanum % required to be maintained is 0.03-0.1. -
FIG. 5 Illustrates typical microstructure of CGI produced by the lanthanum process (a) ferritic grade (b) pearlitic grade - Perhaps, the most stringent concern of using magnesium for the production of CGI is that its use requires close control over magnesium percentage during treating the base metal by magnesium as well as during pouring of molds after the magnesium treatment. In other words, the processing window of the magnesium strictly needs to be monitored and additions of required elements for the process are added at very specific timings, keeping the temperature and the reaction in mind.
-
FIG. 1 according to Dr Steve Dawson in his paper of process control for production of CGI, 106m AFS casting congress, USA, 2002 illustrates a graphical representation of the nodularity percentage in the cast iron versus the magnesium percentage, to determine at what point the transition from flake to CGI and CGI to ductile iron occurs, This ‘buffer’ is necessary to ensure that flake-type graphite does not form before the end-of-pouring, which may be as long as fifteen minutes after the initial magnesium addition. The total process window is shown between the line 1 and line 2, which points out for a stable formation of compacted graphite iron, further to which it would solidify as ductile Iron. The stable CGI plateau exists over a range of approximately 0.008% magnesium and is separated from grey iron by an abrupt transition. - This invention, as explained further, helps to remove such stringent controlling factor by removing the magnesium completely from the production procedure and permitting or allowing a longer stable processing window for the production of CGI having a longer/wider stable range for the treatment alloy, percentage makes the process more user friendly.
- The best and other modes for carrying out the present invention are presented in terms of the embodiments, herein depicted in
FIG. 2 The embodiments are described herein for illustrative purposes and are subject to many variations. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but are intended to cover the application or implementation without departing from the spirit or scope of the present invention. Further, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting. Any heading utilized within this description is for convenience only and has no legal or limiting effect. - The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
-
FIG. 2 illustrates schematic of process flow of manufacturing compacted graphite iron (CGI). Initially, a treatment alloy is placed into a treatment ladle, which is generally an open pour ladle and then placing an inoculant in the treatment ladle and pouring a molten base metal there over. The treatment alloy comprises of iron, silicon and lanthanum, wherein lanthanum is 3-30% by weight of the treatment alloy, silicon is 40-50% by weight of the treatment alloy, and the remaining is iron, hence forming a treatment alloy to be as FeSiLa or ferro silicon lanthanum alloy. The variations of the treatment alloy could also be such as pure lanthanum metal, iron lanthanum alloy, in-mold alloy with finer sizes of above composition of the treatment alloy. Alternatively, a cored wire with 100% lanthanum powder or FeSiLa powder of varying lanthanum percentage or above two mixed with inoculant powder. - As per the
FIG. 2 &FIG. 3 , metal is melted in an induction furnace with proper chemistry control and wherein the base metal contains 3 to 5% carbon by weight of the base metal, 1.5 to 5% silicon by weight of the base metal and less than 0.016% Sulphur by weight of the base metal. Depending on the grade of CGI, base metal may contain manganese in the range of 0.015 to 0.8% by weight of the base metal, and copper in the range of 0.1% to 0.8% by weight of the base metal or tin within the range 0.01% to 0.1% by weight of the base metal which could be also in combination thereof with other elements. - According to a preferred embodiment of the non-magnesium process to produce compacted graphite iron, the treatment alloy is 0.4-2% by weight of the composition of the base metal, and the inoculant is 0.1-0.5% by weight of the composition. Inoculation with ferro silicon inoculants is the final stage in the preparation of graphitic irons and involves the introduction of small quantities of ferro silicon inoculant containing elements such as at least calcium, aluminum, barium or lanthanum, or a combination thereof.
- The process according to the
FIG. 2 &FIG. 3 involves a treatment alloy consisting of a single rare earth element added as a ferrosilicon alloy. The rare earth metal in the treatment alloy is only lanthanum and could vary from 3 to 30%. The typical composition of the alloy could be silicon (Si) of 40 to 50%, and lanthanum (La) from 3 to 30%, the rest could be iron (Fe) along with few recommended additives like calcium (Ca) and aluminum (Al) of 1% each or more as per the quantity required to produce the CGI. In another embodiment, the treatment alloy may have calcium and aluminum in the range 0.5% to 3% each by weight of the treatment alloy. - The beneficial effects of lanthanum is in reducing chill and carbide formation in any cast iron indicating that the role of lanthanum in rare earth additions used to produce compacted graphite cast iron (CG cast Iron) is important. Mostly it's been seen that rare earth metals are added into the formation of such alloys but in mixture of two or more rare earth metal but it is the focus of this invention to bring out the advantageous of using only lanthanum as a single rare earth metal.
- In another embodiment, the inoculant is added during the transfer of metal from the furnace to treatment ladle, or from the treatment ladle to the pouring ladle or in stream during pouring of the ladle into molds or as blocks or inserts into the mold during pouring into the mold cavity, or as blocks or as inserts in the mold during casting into the mold. The treatment ladle could be kept open the whole time of the process. Once the treatment ladle consisting of the treatment alloy and the inoculant is ready, the base metal form the induction furnace is poured into the treatment ladle directly, which then results in compacted graphite iron.
-
FIG. 4 is an extension to theFIG. 1 and is enabled to show the best range that one can limit to as the wide stable process one has to maintain while using this treatment alloy containing lanthanum for the production of CGI.FIG. 5 is an exemplary image of the results occurred by using this process of using only lanthanum. The images inFIG. 5 are typical microstructure of CGI produced in two grades (a) ferritic grade and (b) pearlitic grade. - Once the treatment process is finished, the metal is then poured into a variations of holdings that could be just another ladle for the convenience or pouring directly into casting molds.
- The above-mentioned descriptions represent merely the exemplary embodiment of the present disclosure, without any intention to limit the scope of the present disclosure thereto. Various equivalent changes, alterations or modifications based on the claims of present disclosure are all consequently viewed as being embraced by the scope of the present disclosure.
Claims (3)
13. A treatment alloy for treating a base metal to produce compacted graphite iron, the treatment alloy comprises iron, silicon and lanthanum, wherein the lanthanum is 3-30% by weight of the treatment alloy, and silicon is 40-50% by weight of the treatment alloy and the rest is Iron.
14. The treatment alloy according to claim 13 , wherein said lanthanum is in range of 3-10% by weight of the treatment alloy.
15. The treatment alloy according to claim 13 , wherein the treatment alloy further comprises at least one of calcium and aluminum or in combination thereof, wherein calcium and aluminum is in range of 0.5-3% by weight of the treatment alloy.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US18/513,843 US20240093337A1 (en) | 2016-09-12 | 2023-11-20 | Non-magnesium process to produce compacted graphite iron (cgi) |
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IN201641031017 | 2016-09-12 | ||
IN201641031017 | 2016-09-12 | ||
PCT/IB2017/055473 WO2018047134A1 (en) | 2016-09-12 | 2017-09-12 | A non-magnesium process to produce compacted graphite iron (cgi) |
US201916332409A | 2019-03-12 | 2019-03-12 | |
US18/513,843 US20240093337A1 (en) | 2016-09-12 | 2023-11-20 | Non-magnesium process to produce compacted graphite iron (cgi) |
Related Parent Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/332,409 Division US11859270B2 (en) | 2016-09-12 | 2017-09-12 | Non-magnesium process to produce compacted graphite iron (CGI) |
PCT/IB2017/055473 Division WO2018047134A1 (en) | 2016-09-12 | 2017-09-12 | A non-magnesium process to produce compacted graphite iron (cgi) |
Publications (1)
Publication Number | Publication Date |
---|---|
US20240093337A1 true US20240093337A1 (en) | 2024-03-21 |
Family
ID=61561952
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/332,409 Active 2039-09-30 US11859270B2 (en) | 2016-09-12 | 2017-09-12 | Non-magnesium process to produce compacted graphite iron (CGI) |
US18/513,843 Pending US20240093337A1 (en) | 2016-09-12 | 2023-11-20 | Non-magnesium process to produce compacted graphite iron (cgi) |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/332,409 Active 2039-09-30 US11859270B2 (en) | 2016-09-12 | 2017-09-12 | Non-magnesium process to produce compacted graphite iron (CGI) |
Country Status (5)
Country | Link |
---|---|
US (2) | US11859270B2 (en) |
EP (1) | EP3510394B1 (en) |
ES (1) | ES2901405T3 (en) |
SI (1) | SI3510394T1 (en) |
WO (1) | WO2018047134A1 (en) |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN113500171B (en) * | 2021-06-16 | 2022-07-01 | 西安理工大学 | Preparation method of iron-based continuous casting profile based on graphite nodule ultrafine grinding |
CN113600804A (en) * | 2021-08-04 | 2021-11-05 | 泛凯斯特汽车零部件(江苏)有限公司 | Lightweight production process of brake for automobile |
CN114653902B (en) * | 2022-04-19 | 2024-03-22 | 江苏亚峰合金材料有限公司 | Environment-friendly casting inoculant containing rare earth elements |
Family Cites Families (17)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1223694A (en) * | 1967-12-07 | 1971-03-03 | Foseco Int | Inoculation of grey cast iron |
BR8008987A (en) | 1979-12-19 | 1981-10-20 | Foseco Int | PRODUCTION OF VERMICULAR GRAPHITE CAST IRON |
JPS5693808A (en) | 1979-12-19 | 1981-07-29 | Foseco Int | Molten metal treating agent and production of vermicular graphite cast iron |
US4806157A (en) * | 1983-06-23 | 1989-02-21 | Subramanian Sundaresa V | Process for producing compacted graphite iron castings |
US4501612A (en) | 1983-10-27 | 1985-02-26 | The University Of Alabama | Compacted graphite cast irons in the iron-carbon-aluminum system |
US4596606A (en) | 1984-09-04 | 1986-06-24 | Ford Motor Company | Method of making CG iron |
US4568388A (en) | 1985-02-11 | 1986-02-04 | Foote Mineral Company | Magnesium-titanium-ferrosilicon alloys for producing compacted graphite iron in the mold and process using same |
SE9001894L (en) | 1990-05-28 | 1991-12-02 | Volvo Ab | PROCEDURES FOR PREPARING THE IRON |
GB9111804D0 (en) | 1991-06-01 | 1991-07-24 | Foseco Int | Method and apparatus for the production of nodular or compacted graphite iron castings |
SE502227C2 (en) | 1993-12-30 | 1995-09-18 | Sintercast Ab | Process for the continuous provision of pretreated molten iron for casting compact graphite iron articles |
FR2839082B1 (en) * | 2002-04-29 | 2004-06-04 | Pechiney Electrometallurgie | ANTI MICRORETASSURE INOCULATING ALLOY FOR TREATMENT OF MOLD SHAPES |
NO20024185D0 (en) | 2002-09-03 | 2002-09-03 | Elkem Materials | Process for making ductile iron |
NO20045611D0 (en) | 2004-12-23 | 2004-12-23 | Elkem Materials | Modifying agents for cast iron |
SE529445C2 (en) * | 2005-12-20 | 2007-08-14 | Novacast Technologies Ab | Process for making compact graphite iron |
KR101013843B1 (en) | 2007-11-09 | 2011-02-14 | 현대자동차주식회사 | High Strength and High Oxidation Resist Hi Silicon Ferritic CGI Cast Iron |
CN102787198A (en) * | 2012-08-29 | 2012-11-21 | 福建省建阳市杜氏铸造有限公司 | Vermicular cast iron and manufacturing method of vermicular cast iron |
NO347571B1 (en) * | 2016-06-30 | 2024-01-15 | Elkem Materials | Cast Iron Inoculant and Method for Production of Cast Iron Inoculant |
-
2017
- 2017-09-12 US US16/332,409 patent/US11859270B2/en active Active
- 2017-09-12 EP EP17848260.0A patent/EP3510394B1/en active Active
- 2017-09-12 SI SI201731035T patent/SI3510394T1/en unknown
- 2017-09-12 WO PCT/IB2017/055473 patent/WO2018047134A1/en active Application Filing
- 2017-09-12 ES ES17848260T patent/ES2901405T3/en active Active
-
2023
- 2023-11-20 US US18/513,843 patent/US20240093337A1/en active Pending
Also Published As
Publication number | Publication date |
---|---|
US11859270B2 (en) | 2024-01-02 |
ES2901405T3 (en) | 2022-03-22 |
SI3510394T1 (en) | 2022-02-28 |
EP3510394A1 (en) | 2019-07-17 |
WO2018047134A1 (en) | 2018-03-15 |
EP3510394B1 (en) | 2021-10-20 |
EP3510394A4 (en) | 2020-03-18 |
US20210087658A1 (en) | 2021-03-25 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US20240093337A1 (en) | Non-magnesium process to produce compacted graphite iron (cgi) | |
CA3017325C (en) | Gray cast iron inoculant | |
KR910001484B1 (en) | Gray cast iron inoculant | |
WO2006068487A1 (en) | Modifying agents for cast iron | |
CN110819753B (en) | Smelting process for eliminating broken graphite of thick and large ductile iron piece | |
Borse et al. | Review on grey cast iron inoculation | |
CN104561409B (en) | A kind of production method of hypoeutectic foundry iron | |
US2867555A (en) | Nodular cast iron and process of manufacture thereof | |
RU2590772C1 (en) | Method for production of aluminium cast iron | |
JP6888275B2 (en) | Manufacturing method of sulfur-added steel | |
JP2007119818A (en) | METHOD FOR PRODUCING CHROMIUM-CONTAINING MOLTEN STEEL CONTAINING Ti | |
RU2704678C1 (en) | Method of cast iron modifying and modifier for implementation of method | |
RU2529148C1 (en) | Addition alloy to produce casts from grey cast iron | |
Patel et al. | Effect of Ca and Ba Containing Ferrosilicon Inoculants on Microstructure and Tensile Properties of IS-210, and IS-1862 Cast Irons | |
RU2402617C2 (en) | Procedure for crumbling graphite inclusions in high strength iron | |
RU2019569C1 (en) | Process for manufacturing castings of white iron | |
RU2007465C1 (en) | Process of production of high-chrome white wear-resistant cast irons | |
RU2181775C1 (en) | Method for making cast iron with different type of graphite | |
RU2375461C2 (en) | Method of cast iron receiving with globular graphite | |
SU127671A1 (en) | The method of obtaining iron for casting grinding balls | |
SU692680A1 (en) | Method of casting metal-rolling rolls | |
RU2499838C1 (en) | Steel making method | |
RU2270257C2 (en) | Method of production of the steel used for production of steel cord, superfine springs and cable ropes | |
Guo | Influence of some metallurgical parameters on stream treated ductile iron | |
JP2005059011A (en) | Method for manufacturing cast slab of white cast iron |