US3765876A - Method of making nodular iron castings - Google Patents

Method of making nodular iron castings Download PDF

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Publication number
US3765876A
US3765876A US00302762A US3765876DA US3765876A US 3765876 A US3765876 A US 3765876A US 00302762 A US00302762 A US 00302762A US 3765876D A US3765876D A US 3765876DA US 3765876 A US3765876 A US 3765876A
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percent
alloy
magnesium
bath
metal
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W Moore
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MEEHANITE WORLDWIDE Corp
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W Moore
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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

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  • ABSTRACT The method of producing a nodular cast iron casting comprising the melting of a cast iron bath of low sulphur content and near eutectic composition with a chill value of no more than eight thirty-seconds inch as measured by a standard wedge test.
  • the bath is preconditioned by adding a rare earth and an alkaline earth containing alloy in an amount sufficient to increase the chill value from 50 to 150 percent and then pouring the bath into a mold having at least one reservoir and a dam skimmer gate with the reservoir containing from one-fourth to 1 4 percent by weight of a magnesium alloy.
  • the last mentioned alloy is sufficient in amount to retain at least 0.01 percent magnesium in the metal from the bath which passes through the alloy so as to produce a casting containing nodular graphite.
  • My invention relates to nodular iron castings and more particularly to an improved method of producing nodular graphitecast iron of high as-cast ductility and superior mechanical properties.
  • Another object is to avoid the effects of structure deterioration which is common with conventionally made nodular irons.
  • Another object is to produce a nodular iron casting free from carbides in the as-cast condition and having a high nodule" count and a high as-cast ductility.
  • Another object is to provide a method where the extent of nodularization can be effectively adjusted to suit the casting section being produced and to avoid the occurrence of mixed and inferior graphite structures in the casting.
  • FIG. 1 is a drawing showing the gating system for three test bar castings, A, B and C.
  • 1, 2 and 3 are the three test bars; 4, 5 and 6 are ingates into these bars from the runner bar 7 which is connected to the dam gate 8 having the alloy 9 in its reservoir and connected to a downsprue 10.
  • These test bars were cast according to the method of this invention.
  • FIGS. 2A, 2B and 2C are a set of photomicrographs of the structures obtained in bars A, B, and C shown in FIG. 1 and cast without the benefit of Step No.2 of this invention. These are marked 2A, 2B and 2C.
  • 2A is the structure obtained in the Bar A at a point farthest from the ingate 4. Bars B and C showed similar structures at the same points farthest away from ingates 5 and 6.
  • 2B is the structure obtained in the center of Bar A in the area where the tensile bar was machined.
  • 2C is the structure obtained in Bar B in the center where the tensile bar was machined. This is essentially the same structure as found in Bar C in the center.
  • FIGS. 3A and. 38V are a set of photomicrographs taken from the bars of FIG. 1, but where Step No. 2 of the method of this invention was used.
  • 3A represents the structure taken from the center of Bar A
  • 38 is the structure taken from the center of Bar C.
  • the structure from the center of Bar B was essentially the same as that shown in 3A and 3B.
  • the conventional method of making nodular iron is to add any one or any combination of various wellknown nodularizing agents particularly cerium, magnesium and calcium alloys to molten metal in sufficient quantity to reduce the sulfur content to a low value and leave residual nodularizing elements in the composition to promote the formation of graphite or carbon in the nodular form.
  • nodular iron contains volative nodularizing agents such as magnesium which gradually volatilizes from the metal thereby decreasing the degree of nodularization. Additionally, the graphitizing effect of silicon alloys added which is part of most procedures for making nodular iron also tends to fade with time, leading to a product containing free carbides which are nonmachinable and brittle.
  • nodularizing alloys particularly those containing magnesium is accompanied by violent pyrotechnical action which is harmful from a standpoint of ecology and which because of its violence, is difficult to control quantitatively.
  • One of the methods now being used is that of incorporating the graphitizing silicon alloy or the nodularizing alloy or both directly into the mold gating system. In this way, pyrotechnics are avoided and decay of structure is avoided because additions are being made at the last possible moment, that is, during the casting operation.
  • the methodof my invention also proposes addition of at least part of the nodularizing alloy directly into the gating system of the mold but is an integrated process comprising a sequence of events and steps that will result in a consistent end product avoiding the difficulties presently associated with nodularizing in the mold.
  • My process is best described and illustrated by some tests conducted to illustrate and highlight the difficulties associated with methods now being used by those skilled in the art.
  • FIGS. 2A, 2B and 2C show the structures involved in these test bars.
  • Bar A was satisfactory in every way.
  • Bar C was unsatisfactory, although part of it had a suitable chemical analysis and
  • Bar B was unsatisfactory although the structure in one area was every bit as good as that in Bar A.
  • My invention is based on the discovery that magnesium cannot be added in a completely uniform manner in the gating system of a mold, and that the ill effects of nonuniform magnesium content can be negated by careful pre-treatment of the molten metal in the ladle prior to casting it in a mold containng magnesium alloy. This can be done in a manner that avoids pyrotechnics and fading decay during the normal useful pouring life of the metal in the mold and in a manner that insures uniformly good results in the casting.
  • the first step of the method of my invention involves melting a base iron of conventional chemistry for nodular iron and of low sulphur content.
  • This involves a carbon content ranging from 3.30 to 4.00, a silicon content from 1.0 to 3.0, a manganese content of 0.20 to 1.00, a phosphorous content of 0.02 to 0.10 and a sulphur content of 0.005 to 0.06 percent. Chemical contents outside of these limits may also be used for special purposes. Alloys for special effects such as nickel, molybdenum or copper may also be used.
  • the important feature is that the iron with. respect to carbon and sili con should be at or near eutectic in composition, having a carbon equivalent ranging from about 4.0 to 4.6 percent.
  • Step 2 where a nodulariz ation agent is added, will reduce the sulphur content to a value well below 0.02 percent, it is normal to first reduce this sulphur by other less expensive means. I prefer a sulphur content ofless than 0.025 percent and even less than 0.015 percent before Step 2 of this method is conducted.
  • the method I prefer to reduce sulphur to this value is the use of calcium carbide as a clesulphurizer and a porous plug as a means of agitation of the metal. This procedure is well-known to those skilled in the art.
  • the second step of the process of my invention is the critical one in that I have found that when successfully conducted, it pre-conditions the metal so that possible ineffective nodularization in the gating system of the mold is unlikely to occur. I have, in fact,-conditioned the metal in the ladle so that the process of nodularizetion in the mold is less critical and the end product is a more uniform nodular casting.
  • the second step of the invention consists of adding an agent containing rare earth elements mainly cerium and alkaline earth elements, mainly calcium, to the metal in the ladle so as to change the chill value of the metal to a value related to the initial chill value of the bath. What I wish to do is increase this chill value by a definite amount.
  • the first is that calcium and cerium will not increase the chill value until they have first effectively neutralized the sulphur content.
  • the sulphur content has been neutralized, calcium and cerium begin to produce metastable carbides in the melt thereby increasing the chill value.
  • a very effective control tool in pre-conditioning the metal for subsequent nodularization in the mold becomes available. This is an essential feature of the process of my invention.
  • the original chill value of the bath as measured on a standard test wedge such asare with a one-half inch back and a 28 wedge angle is preferred at no more than eight thirty-seconds.
  • higher chill values may lead to the production of stable carbides rather than metastable carbides when Step 2 is conducted by adding cerium and calcium. Stable carbides would adversely affect the structure in the final castings.
  • the only way to be sure that metastable carbides are present is to start with a metal of high graphitizing value that is a low chill value and then cause this chill value to increase because of the cerium and calcium added. l actually prefer a base metal chill value of one thirty-second to four thirty-seconds inch although a value as high as eight thirty-seconds inch would still be acceptable.
  • Calcium and cerium are added to the bath in Step 2 until the chill value increases by at least 50 percent but preferably by not more than 150 percent.
  • the increased value would be three thirty-seconds to five thirtyseconds.
  • a bath of initial chill value of four thirty-seconds inch would be changed to a chill value of eight thirtyscconds inch of higher by a successful Step 2 treatment ofthis invention.
  • a typical mixture used for Step 2 of this invention would consist of 80 percent calcium silicide and percent rare earth (cerium) fluoride.
  • An amount that would increase the chill value as desired would range from one-eighth to 1 1/8 percent and more usually about three-fourths percent depending on the sulphur content of the bath.
  • Other combinations of calcium and cerium are also effective, but this is a matter of local preference and economics.
  • the important feature of Step 2 of this invention is to introduce sufficient calcium and cerium into the melt to give a measurable increase in the chill value of the metal. When this has been done, the metal has been suitably pre-conditioned for final Step 3, which consists of complete nodularization in the gating system of the mold.
  • Another rare earth which may be used is neodymium and another alkaline earth material is barium.
  • Step 3 of this invention consists of casting the metal of Step 2 in a mold which contains a magnesium-silicon alloy in a suitably designed gating system.
  • the metal flows over the alloy and dissolves it on its way to that part of the mold constituting the casting itself.
  • the dissolved alloy results in the production ofa fully nodular structure characterized by a large number of small perfectly formed nodules in a largely ferritic matrix and with the complete absence of hard brittle carbides.
  • Step 3 I prefer to use a dam gate arrangement well known to those skilled in the art, although other skimmer devices can also be used.
  • This dam gate consists of a metal reservoir and a skimmer core which keeps all dirt and products of reaction from entering the mold cavity.
  • the relative size of the reservoir is important in terms of the volume occupied by the magnesiumsilicon alloy. I prefer to size this reservoir so that the weight or volume of alloy used will occupy no less than 25 percent but no more than 50 percent of the volume of the reservoir. This ensures the best condition for uniform solution of this alloy during the pouring time of the casting.
  • the rate of flow of metal is governed by the choke under the skimmer core and is according to normally acceptable foundry practice where the pouring rate is equal approximately to one to one and one/- fourth times the square root of the weight of metal poured.
  • the alloy used may be any alloy containing magnesium and silicon and its preferred size is about one-fourth to one-eighth mesh because this size will dissolve reasonably uniformly.
  • the magnesium-silicon alloy may be replaced with a magnesium-nickel alloy.
  • the amount of alloy added is dependent primarily on the duration of the pouring time of the mold but will generally be so that total retained magnesium in the final metal casting is at least 0.01 percent based upon the weight of metal and usually is not more than 0.10 percent. This means that more than this be available initially and I prefer that the magnesium initially available be from 0.04 percent to 0.20 percent based upon the weight of metal.
  • the total amount of silicon or nickel available initially should be from 0.10 percent to 1.0 percent. l have found that these amounts of magnesium and silicon while not too critical, give the best results under most conditions.
  • I may use more than one reservoir dam gate in the gating system where the metal is poured relatively slowly and where the casting is complex and is gated at several different points.
  • This selection of the exact gating system would relate basically to casting geometry as is well known to those skilled in the art.
  • a multiple of dam gates may tend to give more uniform solution of the alloy which is always desirable but which has been rendered less critical by the pre-conditioning of the metal accomplished in Step 2 of the method of this invention. Without such preconditioning the solution rate and uniformity would become so critical that inferior castings could result.
  • the criticality of Step 3 has been reduced to the point where it is possible to make commercially acceptable castings.
  • This metal was desulphurized using 1 percent calcium carbide and agitation supplied with a porous plug and nitrogen gas. The sulphur content was reduced to 0.01 percent and the chill value of the bath was measured and found to be three thirty-seconds inch on a wedge having a one-half inch back and a 28 angle.
  • the bath was then treated with an addition of fiveeighths percent of a mixture containing 80 percent 'calcium silicide and 20 percent rare earth fluorides.
  • the sulphur content was further reduced to 0.005 percent and the chill value was increased to seven thirtyseconds inches.
  • This pre-conditioned metal was cast into the mold where one-half percent by weight of oneeighth inch mesh, percent magnesium, 40 percent silicon alloy had been placed in the dam gate reservoir.
  • the resultant test bar castings were numbered A, B and C as was the case in the experiment described in FIG. 1, and they were then tested to give the following results in Table 3.
  • nondular cast iron castings comprising melting a cast iron bath of low sulphur content and near eutectic composition with a chill value of no more than eight thirty-seconds inch as measured by a standard wedge test, pre-conditioning said bath by adding a rare earth and an alkaline earth containing alloy in an amount sufficient to increase the chill value from 50 to percent and then pouring said bathinto a mold having at least one reservoir and dam skimmer gate with said reservoir containing from one-fourth to l 7 percent by weight based upon the weight of cast iron of a magnesium alloy, said last mentioned alloy being sufficient in amount to retain at least 0.01 percent magnesium based upon the weight of cast iron in the metal from said bath passing through said alloy so as to produce a casting containing nodular graphite.
  • said cast iron bath has a carbon content from 3.30 to 4.00 percent, a silicon-content from 1.0 to 3.0 percent, a manganese content from 0.20 to 1.00 percent, and a phosphorous content from 0.02 to 0.10 percent, said cast iron in said bath or after said pre-conditioning step having a sulphur content from 0.005 to 0.06 percent.
  • cerium is cerium fluoride and said calcium is calcium silicide.
  • magnesium alloy is magnesium silicon alloy or magnesium nickel alloy.
US00302762A 1972-11-01 1972-11-01 Method of making nodular iron castings Expired - Lifetime US3765876A (en)

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CA (1) CA979221A (da)
DD (1) DD108771A5 (da)
DE (1) DE2342277A1 (da)
DK (1) DK131004B (da)
FI (1) FI54867C (da)
FR (1) FR2204690B1 (da)
GB (1) GB1437372A (da)
IT (1) IT993721B (da)
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Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3870512A (en) * 1973-03-05 1975-03-11 Deere & Co Method of producing spheroidal graphite cast iron
US4227924A (en) * 1978-05-18 1980-10-14 Microalloying International, Inc. Process for the production of vermicular cast iron
US4245691A (en) * 1977-12-02 1981-01-20 Ford Motor Company In situ furnace metal desulfurization/nodularization by high purity magnesium
US4806157A (en) * 1983-06-23 1989-02-21 Subramanian Sundaresa V Process for producing compacted graphite iron castings
US4989662A (en) * 1990-02-27 1991-02-05 General Motors Corporation Differential pressure, countergravity casting of a melt with a fugative alloyant
US5038846A (en) * 1990-02-27 1991-08-13 General Motors Corporation Differential pressure, countergravity casting with alloyant reaction chamber
US5178826A (en) * 1991-06-01 1993-01-12 Foseco International Limited Method and apparatus for the production of nodular or compacted graphite iron castings
US5249619A (en) * 1991-10-30 1993-10-05 Mack Trucks, Inc. Brake element and a preparation process therefor
US20090183848A1 (en) * 2005-12-20 2009-07-23 Novacast Technologies Ab Process for Production of Compacted Graphite Iron
WO2011015005A1 (zh) * 2009-08-07 2011-02-10 Yang Jinde 一种球墨铸铁行星架的铸造方法
CN102492891A (zh) * 2011-12-23 2012-06-13 天津市万路科技有限公司 蠕化剂的生产及其应用

Families Citing this family (11)

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US4094279A (en) * 1976-05-07 1978-06-13 Johnson Products Div. Of Sealed Power Corporation Ductile iron roller tappet body and method for making same
JPS5810966B2 (ja) * 1978-02-06 1983-02-28 川崎重工業株式会社 ダクタイル鋳鉄の製造法
JPS5823443B2 (ja) * 1978-08-07 1983-05-16 川崎重工業株式会社 ダクタイル鋳鉄の製造法
JPH0651410B2 (ja) * 1983-02-25 1994-07-06 セイコーエプソン株式会社 サーマルプリンタ
JPS6089390A (ja) * 1983-10-24 1985-05-20 Nec Corp 印字装置
CH660376A5 (de) * 1984-07-26 1987-04-15 Fischer Ag Georg Verfahren zur herstellung von gusseisen mit kugelgraphit.
JPH01168479A (ja) * 1987-12-25 1989-07-03 H Ee L:Kk スタンパ
GB0614705D0 (en) * 2006-07-25 2006-09-06 Foseco Int Improved meethod of producing ductile iron
US8056604B2 (en) * 2009-09-04 2011-11-15 Ask Chemicals L.P. Process for preparing a test casting and test casting prepared by the process
CN102688993B (zh) * 2012-06-19 2015-02-25 西峡县众德汽车部件有限公司 Sb元素在高强度球墨铸铁瓦盖中的应用
JP6823512B2 (ja) 2017-03-16 2021-02-03 本田技研工業株式会社 経路決定装置、車両制御装置、経路決定方法、およびプログラム

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US2144200A (en) * 1936-06-27 1939-01-17 Heraeus Vacuumschmelze Ag Method of manufacturing siliconiron alloys
US2542655A (en) * 1949-09-17 1951-02-20 Int Nickel Co Gray cast iron
US2792300A (en) * 1954-04-14 1957-05-14 John A Livingston Process for the production of nodular iron
US2816829A (en) * 1955-11-07 1957-12-17 Ford Motor Co Nodular iron manufacture
US2841488A (en) * 1952-02-06 1958-07-01 Int Nickel Co Nodular cast iron and process of making same
US2980530A (en) * 1958-12-11 1961-04-18 Dayton Malleable Iron Co Method of producing nodular iron
US3001869A (en) * 1959-08-07 1961-09-26 Ford Motor Co Nodular iron manufacture
US3177071A (en) * 1961-09-25 1965-04-06 Knapsack Ag Process for the manufacture of ironsilicon magnesium prealloys
US3498361A (en) * 1965-07-19 1970-03-03 Clifford Hall In-mould inoculation of cast iron
US3703922A (en) * 1968-07-17 1972-11-28 Materials & Methods Ltd Process for the manufacture of nodular cast iron

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US2144200A (en) * 1936-06-27 1939-01-17 Heraeus Vacuumschmelze Ag Method of manufacturing siliconiron alloys
US2542655A (en) * 1949-09-17 1951-02-20 Int Nickel Co Gray cast iron
US2841488A (en) * 1952-02-06 1958-07-01 Int Nickel Co Nodular cast iron and process of making same
US2792300A (en) * 1954-04-14 1957-05-14 John A Livingston Process for the production of nodular iron
US2816829A (en) * 1955-11-07 1957-12-17 Ford Motor Co Nodular iron manufacture
US2980530A (en) * 1958-12-11 1961-04-18 Dayton Malleable Iron Co Method of producing nodular iron
US3001869A (en) * 1959-08-07 1961-09-26 Ford Motor Co Nodular iron manufacture
US3177071A (en) * 1961-09-25 1965-04-06 Knapsack Ag Process for the manufacture of ironsilicon magnesium prealloys
US3498361A (en) * 1965-07-19 1970-03-03 Clifford Hall In-mould inoculation of cast iron
US3703922A (en) * 1968-07-17 1972-11-28 Materials & Methods Ltd Process for the manufacture of nodular cast iron

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Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3870512A (en) * 1973-03-05 1975-03-11 Deere & Co Method of producing spheroidal graphite cast iron
US4245691A (en) * 1977-12-02 1981-01-20 Ford Motor Company In situ furnace metal desulfurization/nodularization by high purity magnesium
US4227924A (en) * 1978-05-18 1980-10-14 Microalloying International, Inc. Process for the production of vermicular cast iron
US4806157A (en) * 1983-06-23 1989-02-21 Subramanian Sundaresa V Process for producing compacted graphite iron castings
US4989662A (en) * 1990-02-27 1991-02-05 General Motors Corporation Differential pressure, countergravity casting of a melt with a fugative alloyant
US5038846A (en) * 1990-02-27 1991-08-13 General Motors Corporation Differential pressure, countergravity casting with alloyant reaction chamber
US5178826A (en) * 1991-06-01 1993-01-12 Foseco International Limited Method and apparatus for the production of nodular or compacted graphite iron castings
US5249619A (en) * 1991-10-30 1993-10-05 Mack Trucks, Inc. Brake element and a preparation process therefor
US20090183848A1 (en) * 2005-12-20 2009-07-23 Novacast Technologies Ab Process for Production of Compacted Graphite Iron
WO2011015005A1 (zh) * 2009-08-07 2011-02-10 Yang Jinde 一种球墨铸铁行星架的铸造方法
CN102492891A (zh) * 2011-12-23 2012-06-13 天津市万路科技有限公司 蠕化剂的生产及其应用
CN102492891B (zh) * 2011-12-23 2014-04-09 天津市万路科技有限公司 蠕化剂的生产及其应用

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JPS4977818A (da) 1974-07-26
BE803531A (fr) 1973-12-03
NO135017B (da) 1976-10-18
AR195739A1 (es) 1973-10-31
JPS5614055B2 (da) 1981-04-02
AU469766B2 (en) 1976-02-26
BR7306324D0 (pt) 1974-10-22
FI54867C (fi) 1979-04-10
DD108771A5 (da) 1974-10-05
DK131004C (da) 1975-10-13
FR2204690B1 (da) 1977-02-25
PL87816B1 (da) 1976-07-31
DE2342277A1 (de) 1974-05-09
FR2204690A1 (da) 1974-05-24
CA979221A (en) 1975-12-09
AU5512573A (en) 1974-11-07
DK131004B (da) 1975-05-12
SU587872A3 (ru) 1978-01-05
NO135017C (da) 1977-01-26
FI253873A (da) 1975-02-14
NL7314978A (da) 1974-05-03
GB1437372A (en) 1976-05-26
FI54867B (fi) 1978-12-29
IT993721B (it) 1975-09-30
ZA732522B (en) 1974-03-27

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