Skip to main content
SpringerLink
Log in

Control of Surface Graphite Degeneration in Ductile Iron for Windmill Applications

  • Published:
International Journal of Metalcasting Aims and scope Submit manuscript

Abstract

The objective of this paper is to review the factors influencing the formation of degenerated graphite layers on the surfaces of ductile iron castings for chemical resin-acid moulding and coremaking systems and how to reduce this defect. In the resin mould technique the sulphur in the P-toluol sulphonic acid (PTSA), usually used as a hardener, has been identified as one factor causing graphite degeneration at the metal mould interface. Less than 0.15% S in the mould (or even less than 0.07% S) can reduce the surface layer depth. Oxygen may also have an effect, especially for sulphur containing systems with turbulent flows in the mould, water-bearing no-bake binder systems, Mg-Silica reactions, or dross formation conditions. Despite the lower level of nitrogen in the iron melt after magnesium treatment (less than 90 ppm), nitrogen bearing resins have a profound effect on the frequency and severity of surface pinholes, but a limited influence on surface graphite degeneration. The specific characteristics and optimum conditions for the manufacture of heavy sectioned ductile iron windmill castings were reviewed. The paper concludes on the optimum iron chemistry, melting procedure, Mg-alloys and specific inoculants systems, as well as the practical solutions to limit graphite degeneration to ensure castings with the highest integrity.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. “Ductile Iron Techniques—Suggestions for Ductile Iron Production,” Montreal, Canada: Rio Tinto Iron & Titanium, Inc. (1971).

  2. Karsay, S.I., “Ductile Iron Production (I) -The State of the Art,” Revised in part by QIT Technical Staff, QIT, Montreal, Canada (1992).

  3. “Common Metallurgical Defects in Ductile Iron Chart,” Elkem Foundry Products Division, Oslo, Norway (2004).

  4. Goodrich, G.M., “Cast Iron Microstructure Anomalies and Their Causes,” AFS Transactions, vol. 105, pp. 669–683 (1997).

    Google Scholar 

  5. Mullins, J.D., “Chunk Graphite Defects in Ductile Iron, Sorelmetal-Suggestions for Ductile Iron Production” (Data Sheet No. 93), Rio Tinto Iron & Titanium, Inc., Montreal, Canada (2006).

    Google Scholar 

  6. Pan, E.N. and Chen, C.Y., “Effects of Bi and Sb on Graphite Structure of Heavy-Section Ductile Cast Iron,” AFS Transactions, vol. 104, pp. 845–858 (1996).

    Google Scholar 

  7. Fallon, M.J., “Experiences in the Manufacture of Ductile Irons,” The Foundrymen, vol. 88, issue 9, pp. 308–318 (1995).

    Google Scholar 

  8. Baier, J. and Koppen, M., “Manual of Casting Defects. Incidence and Avoidance of Defects Attributable to Moulding Sands,” Marl, Germany: IKO-Erbsloh, pp. 32–35 (1994).

    Google Scholar 

  9. Golovan, N.A., Dudni, K.J.A., Dubrov, V.V., “Formation of Flake Graphite Near the Surface of Nodular Cast Iron Casting,” Russian Casting Production Journal, issue 7, pp. 35–36 (1977).

  10. Watmough, T. and Malatesta, M.J., “Strengthening of Ductile Iron for Crankshaft Applications,” AFS Transactions, vol. 92, pp. 83–99 (1984).

    Google Scholar 

  11. Yamamura, H., Sekiguchi, M., Inoue, K., “Influence of Defects on the Fatigue Life of Ductile Cast Iron with As-Cast Surfaces,” Proc. of 1998 K. Millis World Symposium on Ductile Cast Iron, Hilton Head Island, SC, USA, pp. 433–453 (1998).

  12. Lawerenz, M., “Shot Peening of Ductile Iron,” Modern Casting, issue 2, pp. 51–53 (1990).

  13. Xiaogan, H., “Nodular Iron Surface Deterioration Due to PTSA in Resin,” AFS Transactions, vol. 100, pp. 9–15 (1992).

    Google Scholar 

  14. Marti, F. and Karsay, S.I., “Localized Flake Graphite Structure as a Result of a Reaction between Molten Ductile Iron and Some Components of the Mould,” AFS Transactions, vol. 87, pp. 221–226 (1979).

    Google Scholar 

  15. Bauer, W., “Research on the Surface Graphite Generation in the Ductile Iron Casting in PTSA-Furan Resin Moulds,” Giesserei-Praxis, issue 11, pp. 175–183 (1982).

  16. Morita, S. and Inoyama, N., “Behavior of Nitrogen in Cast Iron,” AFS Cast Metals Res. Journal, vol. 5, issue 3, p. 109 (1969).

    Google Scholar 

  17. Tinebra, J.P. and Wilson, S.J., “No-Bake Chemical Binder Systems: Their Effect on Microstructural and Physical Properties of Ductile Iron,” AFS Transactions, vol. 101, pp. 169–174 (1993).

    Google Scholar 

  18. Farquhar, J.D., “Nitrogen in Ductile Iron-A Literature Review,” AFS Transactions, vol. 87, pp. 433–438 (1979).

    Google Scholar 

  19. Robinson, M., “Nitrogen Levels in Ductile Iron: AFS Committee 12-H Report,” AFS Transactions, vol. 87, pp. 503–508 (1979).

    Google Scholar 

  20. Strong, G.R., “A Literature Survey on Nitrogen on Malleable Iron,” AFS Transactions, vol. 85, pp. 29–36 (1977).

    Google Scholar 

  21. Information on: http://www.vestas.com (last accessed 11-15-12)

  22. Information on: http://www.windpower.org (last accessed 11-15-12)

  23. Forrest, R.D., “Sorelmetal for GGG 40.3 (High Impact Ductile Iron) As-Cast Production? The Answer is Blowing in the Wind,” Sorelmetal Technical Services (Data Sheet No. 90) Rio Tinto Iron & Titanium, Inc. (2006).

  24. Information on: http://www.elkem.com/foundry/ (last accessed 11-15-12)

  25. Riposan, I., Chisamera, M., Stan, S., “Influencing Factors on As-Cast and Heat Treated 400-18 Grade Characteristics,” China Foundry, vol. 4, issue 4, pp. 300–303 (2007).

    Google Scholar 

  26. Thielman, T., “Zur Wirkung van Spurenelementen in Gusseisen mit Kugelgraphit,” Giesssereitechnik, issue 1, pp. 16–24 (1970).

  27. Margerie, J.C., “The Notion of Heredity in Cast Iron Metallurgy,” The Metallurgy of Cast Iron, Saphorin: Georgi Publishing Co., pp. 545–558 (1975).

    Google Scholar 

  28. Mullins, J.D., “Basic Ductile Iron Alloying. Sorelmetal-Suggestions for Ductile Iron Production,” (Data Sheet No. 85, Rev-March 2006) Rio Tinto Iron & Titanium, Inc., Montreal, Canada (2006).

    Google Scholar 

  29. Riposan, I., “Einfluss von metallischen Materialen und Behandlung Stochnologie auf das Geffuge des Gusseiesens mit Kugelgraphit,” Giessereitechnik, issue 1, pp. 13–17 (1989).

  30. Adam, N., Riposan, I. and Chisamera, M., “Ferritic Ductile Iron Production in Coreless Induction Furnace by the Use of High Mn Returns and Steel Scrap,” Revista de Turnatorie (Romanian Foundry Journal), issue 3–4, pp. 17–20 (2003).

  31. Riposan, I., Chisamera, M., Stan, S. and Adam, N., “Influencing Factors on the High Purity Pig Iron-Steel Scrap Optimum Ratio in Ductile Iron Production,” Ductile Iron Society (DIS) Annual Meeting, June 23–26, 2004, Montreal, Canada; Ductile Iron News Journal, issue 2 (2004), http://www.ductile.org/magazine/2004_2/factors-influencing.htm (last accessed 11-15-12).

  32. Riposan, I., Chisamera, M., Stan, S., Constantin, V., Adam, N. And Barstow, M., “Beneficial Remnant Effect of High Purity Pig Iron in Industrial Production of Ductile Iron,” AFS Transactions, vol. 114, pp. 657–666 (2006).

    Google Scholar 

  33. “Preseed™ Preconditioner” Elkem Foundry Products Division, http://www.elkem.com/en/Foundry/Products/Preconditioner/ (last accessed 11-15-12).

Download references

Author information

Authors and Affiliations

  1. Politehnica University of Bucharest, București, Romania

    I. Riposan, M. Chisamera & S. Stan

Authors
  1. I. Riposan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. M. Chisamera
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. S. Stan
    View author publications

    You can also search for this author in PubMed Google Scholar

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Riposan, I., Chisamera, M. & Stan, S. Control of Surface Graphite Degeneration in Ductile Iron for Windmill Applications. Inter Metalcast 7, 9–20 (2013). https://doi.org/10.1007/BF03355540

Download citation

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/BF03355540

Keywords

Search

Navigation