Archircs of Foundry,

Year 2004, Volume 4, Nr E l

Archiwurn Odlewnictwa
Rok 2004, IZmnik 4, Nr 1I
-
PAN Ratowice I'L ISSN 16.12-5308

THE SYNTHETIC NODULAR CAST IRONS

WITH METALLURGICAL SILICON CARBIDE ADDITIVE

A. VASKO', P. SKOCSOVSKY~, M. MATEIKA~

Katedra materi5lovCha iniinierstva, Strojnicka fakulta. iilinskh univerzita,
Vel'kjl diel, 010 26 Ti~ina,Slovakia

SUMMARY

The contribution deals with comparing of microstructure, meohnnicnl

properties and micromechanisms of failure of synthetic nodular cast irons
with graded amount of steel scrap in a charge. Individual meltnges were
regulated to required chemica1 composition alternatively by FeSi or S i c .
Several advantages of metallurgical silicon carbide as a consequence of
its considerably graphitizing and ferritizing influence result from the
experiments, The use of metalIurgical silicon carbide is also economically
advantageous.

Key u*orcls:rroii~dnrccrst irorl, rirernll~~rgicnl

siIicotr carbide

1. INTRODUCTION

Nowadays it is actual from an economic point of view to deal with the possibility
to substitute a part of more expensive pig iron for cheaper steel scrap in a charge of grey
cast irons. The transition from the traditional use of pig iron (claimed to be rich in
nuclei) to synthetic cast iron prepared from stee! scrap (generally believed to contain
on1y few graphitic nuclei) requires the regulation of chemical composition of melt. It is
closely linked with the introduction of metallurgical silicon carbide SiC ns a siliconizing
and curburizing additive ( S i c additive is believed to supply the synthetic pure melts
with nuclei) [I].

h13.Ala~rVaiko,PhD., aI~~~_r~usko@b~ri.r~~c~sX:
Prof: I I ? Perr
~ Ska!ovs@, DrSc.. pptr s k o c o v s ~ ~ k m rttc.
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3 hg.Miroslav Mur~jkn,PIID.,~ o n ~ ~ ~ . c ~ h . t e l e c o n t s k
 Sic additive positively influences the count of crystallization nrrclei of grlkphize
in the cast iron melt (it increases the count of nuclei), consequently the count of
graphitic nodules is increased and at the same time the susceptibility to occurrence of
carbide in the structure is decreased.
The technological foundry literature describes the addition of Sic to the cast iron
melt frequently as having a special pre-inocalnring efect. This influence is well
documented in the case of grey cast iron [23 and has also been observed to some extent
at industrial as well as at laboratory experiments in the case of nodular cast iron 131.

2. EXPERIMENTAL MATERIAL

Two series of five meltages of nodular cast iron with approximately the samc
chemical composition were made but this was achieved by different charge composition
(Tab.1). For each meltnge 30 kg of a basic charge were used where the ratio of pig iron
and steel scrap was being changed. The basic charge of the first rneltnges from both
series (i.e. meltages 1 and G ) was formed by the highest ratio of pig iron (60%)and the
Iowest ratio of steel scrap (20%).In the following meltapes, the ratio of pig iron in [he
charge was being lowered gradually and subsltituted by steel scrap. The basic charge of
the final rneltages from both series (i.e. meltages 5 and 10) was fosmcd only by steel
scmp. For the reguli~tionof chemical composition the additive of carburizer and silicon
carbide Sic90 (in meltages 1 to 5) or ferrosilicon FeSi75 (in rneltnges 6 to 10) was
added. The amount of these additives was chosen to achieve approximately the same
chemical composition of resultant rneltapes. Only 20 kg of melt were modified and
inoculated. For modification FeSiMg7 modifier was used and for inoculatien FeSi75
inoculant was used [4].
Specimens for chemical composition, experimental bars as well as experimental
bodies with a graded wall thickness were cast from a11 the rneltages.

Tabeln 1 Sklad wsadu wytopirw eksperymentalnych

Table IChargc cornposition of cxpcri~ncntalme1tagcs
 3. EXPERIMENTAL RESULTS
3.1 Metallographic analysis

The metallographic analysis of specimens was made by the light metallographic

microscope Neophot 32. The microstructure was evaluated by STN 42 0461 and by
methods of quantitative rnetallography [53.
From microstructural point of view all the meltages are ferrite-pearlitic nodular
cast irons with different content of ferrite and pearlite in a matrix, different size of
graphite and count of graphitic nodules per mm2. Graphite occurs only in a perfectly-
nodular and imperfectly-nodular shape in all the specimens. The microstructure of
specimens from the experimental bars of chosen meltages is documented in Fig. 1

a) wytap 1 I meltage I b) wylop 3 / mcltage 3 C) wytop 5 I ~ncltage 5

d) ~vytop6 J mcl/agc 6 e) w y ~ o p8 / rncltage 8 f) wytop EO / n i c l t ; ~ ~I c0

Rys. 1. Mikroslruktura wybranych wytop6w z prdbek ckspcrymentalnych. traw. 1%Nital, pow. 100x
Fig. I . Microstructure of chosen meltages from experimental bars, etched 1 %Nit& m a p , lOOx

The results of evaluation of microstructure by STN 42 046 1 and by methods of

quantitative rnetallography (content of ferrite and count of graphitic nodules per mm2)
are presented in Table 2 (61.
The changes of microstructure in dependence on a wall thickness of cast
(i.e. cooling rate) are presented in the work [7].
 3.2 Mechanical properties
The results of mechanical tests (static tensile test, impact bending test and
hardness test), that is tensile strength R,, impact toughness KC0 and hardness HB are
given in Table 2. Their course depends especially an the character of matrix (content of
ferrite and pearlite) and also on the size and count of graphitic nodules,
The mechanical properties in the rneltages with Sic additive (i.e. rneltages 1 to
5 ) are generally better than in the meltages with FeSi additive (i.e. meltages 6 to 101,
especially in the meltages with higher amount of steel scrap in the charge.

Tabcla 2 Mikrostruktura i wl~lSciwoScimechaniczne wybranych wytop6w

Table 2 Microstructure and mechanical properties o f chosen meltagcs
Microstructure by Quantitative
Mechanical properties
Number STN 42 0461 rnetallagraphy
of content count of rensilc impact Brincll
I meltage graphite matrix of graphitic strength toughness hardness
felriie nodules R,,, KC0 HB
(s) (mm-') (MPa) (JC~I-?)
I 6O%VIi/6 + 40%V6 FeSO 61.6 104.3 6.4 2 10.0500.8
3 805hVI6 + 205TV6 - Fe94 74.0
- 199.8
- 539.0
- 30.6
- 192.3
-
5 70%1VIS/fi + 30%V6 Fe94 78.0 179.8 5 14.7 17.2 1 82.3
6 JO'%VI5/6 + 309V6 - Fc55 50.8
- 126.5
- 367.1
- -8.4 190.0
-
8 70%VI5/6 + 30%V6 FeSO - 151.0 -
65.2 - 462.6 -24.0 181.3
-
10 70'5VISJfi s- 30%V6 FcSO 56.0 157.6 462.6 19.2 183.0

3.3 M icrofrnctographic analysis

The rnicrofsactographic analysis was made by the Scanning Electron Microscope
Tesln BS 343 on fracture surfaces of specimens from experimental bars fractured by the
static tensile rest and impact bending test. Fracture surfaces of analysed specimens from
both series of rneltages are characteristic of mixed mode of fracture.
In the specimens from the meltages with low amount of steel scrap in the charge,
transcrystalline cleavage of ferrite with an inclination to intercrystalline cleavage
(Fig.2a) was observed. Fracture surfaces of the specimens from the meltages with SiC
additive are characteristic of higher ratio of transcrystalline cleavage of ferrite than
fracture surfaces of the specimens from the rneltages with FeSi additive.
In the specimens from the rneltages with high amount of steel scrap in the
charge, transcrystalline cleavage with river drawing on facets (Fig. 2b) and
transcrystalline ductile failure of ferrite with dimple morphology (Fig. 2c) was
observed. Fracture surfaces of the specimens from the rneltages with Sic additive are
characteristic of higher ratio of transcrystalline ductile failure than fracture surfaces of
the specimens from the rneltages with FeSi additive.
 Transcrystalline continuous cleavl~ge of peasli te was observed in a11 the
specimens. In the specimens from the meltages with Sic additive with higher amount of
steel scrap also trnnscrystalline ductile failure of pearlite was observed 181.
The results of microfractographic analysis correspond to the results of
met:lllographic analysis and mechanicnl tests.

Rys. 2. Mikromccliani7.my przclombw

of' Ihilurc. SEM
Fig. 2. Micro~ncchnnis~ns

3. CONCLUSION

T h e substitution o f n part of pig iron for steel scrap in the chnrge of nodular cast
iron has a considerable economic contribution. For the regulation of chemical
composition of melt it i s advantageous to use rnetallurgic:~lSic additive which has been
used in this work as nn alteranative additive instead of FeSi in meltages with n different
ratio of pig iron and steel scrap in the charge.
The charge cornposilion (i,e. ratio of pig iron and steel scrap) for nodular cast
iron and the choice of additive lbr the regulation of chemical composition of melt (Sic
or FeSi) influence economic casts of charging raw materials (i.e. resultant price of
casts) and they both also influence the microstructure and mechanical properties of casts
and consequently micsomechanisms of failure,
Increasing amount of steel scrap in the charge decreases total costs of charging
raw materials and in consequence of the increasing of SiC or FeSi additive the
rnicrostl-uctute is changed (the content of ferrite in the matrix is increased, the count of
graphitic nodules per unit area is increased and the occurrence of undesirable cementite
is eliminated) and consequently the mechanical properties are improved. This positive
intluence is more significirntly shown in the meltages with SiC additive.
Mode of failure of structural components depends especially on the content of
fcrrite in matrix and its purity, which has rr connection with the charge composition.
F;iilure of ferrite was made from intel-cry~itzlllinecleavage over transcrystall ine cleavage
with rives drawing on facets to transcrystalline ductile failure with dimple morphology
where higher rntie of this micromechanism of failure (transcrystalline ductile failure)
has a connection with higher content of ferrite in the matrix. Failure of peatlite was
made especially by transcrystalline continuous cleavage with river drawing on facets.

ACKNOWLEDGEMENTS

This work has been supported by Scientific Grant Agency of Ministry of

Education of Slovak Republic and Slovak Academy of Sciences, grant No. 110027103
Noll-co~lver~tionnlnzethodsfor studying srnrcrltre of cast mnteriais.

LITERATURE
Schubert, W.B. - Ta, A.T. - Knhr, G. - Benecke, T,- Lux, B.: It~fluenceof SiC
ndclitiorts or! [Ire rrlicrostrrlctlrre of grny cast iro11. SpeciaI print from The physical
metallurgy of cast iron, Stockholm, 1984.
Benecke. T.- Ta, A. T. - Kahr, G. - Schubert, W. D. - Lux, B.: Dissolrtrioll
bel~nviorlrmwE pt-e-irzoculntiorr eflccr of SiC f r l grey cnsf irorl ~ ~ e l tTranslated
s.
from Giesserei 74, 1987, No. 10, p. 30 1-306.
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v d~rctileirott. Reprinted from Materials research society
slrrirrknge p o r ~ s i t ~of
conference proceedings, Physical Metallurgy of Cast Iron, 1990.
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,q.'-(ifironr [Dizcrtatna prhca]. iilina, SjF PU 2002. 95 s.
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1. vyd. Trentin, Fompex 1 994.4 1 s.
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rlndrrlnr cost iron. In: Transcorn 2003, Section 5 , iilina, 2003, s. 79-82.
Vagko, A. - SkoCovsk~,P.: Tire itlfllrer~ceof wbnl/rlrickrzess Q J tlie ~ stncctrrr-Pof
sytrheric ~todtdnr.cnsf irwt. In: 1 l lth international scientific conference Science,
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VaSko. A. : Mikros'rnrktrirn n spSso6y porw?ovntlin syt~retick~clrliotitr s
gzrl'bfkol;$s?7grafiiom, MatetiilovC intinierstvo, rot. 10,2003, E . 3, s. 179- 1 82.
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 SYNTETYCZNE ZELIWO SFEROIDALNE Z DODATKIEM
METALURGICZNEGO WEGLIKA KRZEMU

W artykule prtedstawiono pordwnanie mikrostruktury, w!aSciwoSci mechanicznych

i przelom6w rodzajbw Zeliwa sferoidalnego z okreSlonp iloScEq stalowego wsadu.
Poszczeg6lnych wytopy poddane zosta-ly analizie skladu chernicznego, ze zwrdceniem
stczeg6lnej uwagi na zawartoSC FeSi oraz Sic. Z przeprowadzonyc h badan wyni ka, 3,e
w i ~ c e j zalet posiada metalurgiczny wqglik krzernu, w skutek jego wyratnie
grafityzujqcego i fenytyzujqcego dzialnnia. Stosowanie metallzrgicznego wegl ika
krzzemu korzystne jest r6wniei z ekonomicznego punktu widzenia.

Recenzowal prof. Edward Guzik