“HOT TOPICS”

Issue #1, 2013

Fading in Ductile Iron Processing

The subject of “fade” in the ductile iron process of temperature with time is an asymptotic
is the reduction of an effect that was generated function as long as the surrounding
as the result of a processing step used to environment doesn’t change. The rate of fade
produce ductile iron. Fade means that some in an asymptotic function is proportional to the
property, either mechanical or physical, of difference in temperature between the hot metal
ductile iron is not constant during the and the surrounding environment. The larger
production process but rather decreases as a the difference in metal temperature compared
function of time. The word fade in this to its environment, the higher will be the rate of
instance does not relate to a reduction of color, temperature loss.
but is does relate to the reduction of a critical
effect essential to the production of quality Although temperature loss is a necessity to
ductile iron castings. This effect could be a form a casting, controlling temperature loss is
reduction in composition of a specific element, also a necessity so that the processing steps
a reduction in a physical property such as metal required for the production of quality ductile
temperature or a change in a capability. These iron can be performed with the desired end
fade changes can result in a decrease or an effect. For example, recovery of the
increase in a microconstituent or even a magnesium added to ductile iron is better when
reduction or increase in mechanical properties. the metal temperature is “low”. However, the
In actuality, four effects critical to the metal temperature must be “high” enough to fill
production of quality ductile iron are not the mold cavity without causing metal flow
constant but fade with time. This “Hot Topic” defects. The addition of an inoculant requires
will address all four. One effect is related to dissolution time and higher metal temperature
temperature; two effects are related to the favors dissolution. “High” temperature favors
addition of a nodularizing agent; and the fourth “high” solidification rates which in turn favor
is related to the effect of inoculation. high graphite nodule count which is favorable
for generating specific microstructures. Of
Regarding the first effect, the temperature of course, “low” metal temperature in turn favors
the molten metal does not remain constant. low nodule count.
After the metal has been transferred to a
pouring ladle, the temperature of the molten
metal and for that matter, the solid metal,
decreases to room temperature as time
progresses. Fortunately for ductile iron
producers the metal temperature does decrease
Temperature

or the process would not be able to produce a

casting since solidification is required and
necessitates a loss of heat to accomplish that
feat. Temperature is an indication of the heat
content of the metal, and therefore, temperature Time
loss is a good thing as long as the rest of the
processing steps are accomplished. The decay

__________________________________________________________________________________
George F Goodrich
Magnesium content (or whatever nodularizing What researchers have found is that nodularity
agent is used) also decreases with time. This maintains a certain degree of acceptability as a
decrease is also occurs as an asymptotic function of time until the nodularizing agent
function with the rate of change being has faded to a specific level and then the
dependent on amount of exposure to oxygen nodularity fade with time becomes rapid.1
(and to a lesser extent sulfur). Magnesium is a These researchers determined that the point at
very reactive element and will readily oxidize which nodularity fade changes from gradual to
(or “sulfurize). Agitating the liquid metal, for “rapid” was associated with a critical level of
example, increases exposure to the atmosphere magnesium in the metal. Usually this critical
at the metal surface and thereby increases the level was in the vicinity, of 0.025% but it
rate of magnesium loss due to oxidation. depended on the foundry and the process. This
Covering the molten iron bath with a slag that critical magnesium level could be significantly
is stable with respect to the magnesium content less for those processes that use rare earths in
(forsterite for example) will reduce the rate of addition to magnesium.
magnesium loss. Slag covering isn’t always
practical because magnesium will react with
the oxygen in slags (and even with the oxygen
in the refractory of the furnace linings). The Some critical Mg level
high chemical activity of magnesium makes the dependent on process
decay of the magnesium content difficult to % Magnesium & environment
control and impossible to avoid. Because of its
high affinity for oxygen magnesium will react
with the oxygen in the refractory and slags
commonly used in the ductile iron process.
The loss of silica in the furnace lining, as still
another example, can be directly related to the
magnesium content in the quantity of ductile
iron returns used in the charge make up for the
melting process.

When magnesium is added to ductile iron, the

% Nodularity

conditions required to cause the graphite to

come out of solution in a round or nearly round
shape are generated in the iron. Obtaining this
round or nearly round graphite shape is critical
to the attainment of the desired properties in
ductile iron. Consequently, any degradation of Time
the graphite shape causes the properties of the
resulting iron to degrade as well. The final Finally, the most “notorious” fade that occurs
magnesium required to produce acceptable in the ductile iron process is the fade of the
graphite nodularity in ductile iron is usually response to inoculation. Inoculation is the
between 0.025% and 0.05%. Lower levels may procedure used to increase nucleation of
be acceptable depending on the amount of other graphite nodules and to minimize the
elements such as rare earth additions. possibility of carbides forming during ductile
However, the degree of nodularity will change iron solidification. (Inoculation is also known
with time, but not asymptotically like for its ability to improve graphite nodularity an
temperature and magnesium. effect that also fades with time.) The

2
inoculation step is critical to the production of fade. Mold inoculation with the use of inserts
acceptable ductile iron since ductile iron is placed in the down sprue was one technique
highly susceptible to the occurrence of that was particularly successful.2 This stream
carbides. This high susceptibility to carbide technique has been further developed with the
formation has many reasons. First, the use of injection of fine inoculant in the pouring
nodularizing agent, magnesium, is a carbide stream. Although the effect of this secondary
stabilizing element. Secondly, magnesium inoculant is effective, this effect generated with
recovery when it is added to molten metal the secondary inoculation does not exceed the
increases as the temperature of the molten original effect achieved with the primary
metal is reduced. This reduced temperature inoculation step.
favors carbide formation especially in thin
sections. Thirdly, ductile iron solidifies with
the graphite in a round shape (as opposed to the
flake shape in gray iron). Compared to the
flake shape, the round graphite has the lower
surface area to volume ratio and the amount of
carbon that comes out of solution during

Inoculation Effect
solidification in a given amount of time has less
surface area on which to form. This difference
can be alleviated with a high nodule count
resulting from a good response to inoculation.
Still, the mean free path for the carbon atom to
diffuse from the liquid to the graphite nodule is
greater in ductile iron than in gray iron even
with a high nodule count. Since the time for Time
the carbon atom to diffuse to the graphite is
longer compared to the flake shape in gray iron
because the path is longer, the potential to form Because the inoculant is added during the
carbides is higher in ductile iron than in gray molten metal handling phase and dissolution of
iron. the ferrosilicon must occur, the maximum
effect of the inoculation step takes a finite
Inoculation is accomplished with the addition amount of time to develop. This finite period is
of a ferrosilicon additive containing small call an incubation period. Incubation time can
vary depending on composition of the
quantities of aluminum and or calcium (>0.5%)
inoculant, size of the inoculant, and the method
or some other proprietary elemental additive.
of inoculant addition. Since the fade effect of
The effect of the inoculation fades
the inoculant doesn’t start until the inoculant
asymptotically while the increased silicon
has “incubated”, inoculant effect fade doesn’t
composition (and other elemental addition) that
start until sometime has elapsed after the
accompanies the inoculation addition does not
inoculant was added.
change. This generation of an inoculation
effect that fades as a function of time (rather
Experience has taught the successful producer
than a decrease in composition) fosters the
of quality ductile iron that “temperature fade”
name “inoculation” as opposed to “alloying”.
is the controlling factor. That is to say, if the
During the early stages of development for a
ductile iron process is under acceptable control,
commercially acceptable ductile iron processes,
the temperature of the molten metal will
it was learned that multiple inoculation steps
decrease below a desired designated level for
proved successful in combating the effect of
the casting being poured before any of the other

3
effects fade to an unacceptable level. Fade is
always an issue in the successful production of
ductile iron castings. However, the time
required to generate an unacceptable effect is
not normally reached with a process that is in
control. One technique commonly employed is
to pig out (pour into pig molds) any metal
remaining at the end of a designated time after
the inoculation step. This “time” period
usually corresponds with the time that the
molten metal reaches a temperature that is no
longer acceptable to successfully pour a
casting. This time will vary depending on the
foundry, and the castings that are being poured.
Many foundries use time after inoculation as a
means to prevent pouring unacceptable
castings. Usually this acceptable period of time
to pour is determined with a time study of the
process. A typical time is usually in the 8 to 12
minute range before the metal is pigged, but
again, this is very process dependent and must
be determined for every foundry condition.

References

1. Unpublished work conducted at General Motors

Research Laboratories in the late 1960’s by the
author on the subject of factors affecting magnesium
content and nodularity for extended hold time of
magnesium treated ductile iron.

2. The Influence of Mold Inoculation with Ferrosilicon

Inserts on Hardness Control in Alloy Gray Iron
Castings. E.D. Ryntz, Jr. and H.L. Arnson.
Transactions of the American Foundrymen’s
Society, Vol. 85, p. 211-216, 1975.