Simultaneous thermal and contraction / expansion curves analysis for solidification control of cast irons

Abstract

The first part of the paper summarizes the performance of two mould devices, illustrating by representative shrinkage tendency results in ductile cast iron as affected by mould rigidity (green and furan resin sand moulds) and inoculant type (FeSi-based alloys). Less rigid green sand moulds encourage the formation of contraction defects, not only because of the high initial expansion values (εdi)max, but also because of the increased solidification undercooling. A high inoculation efficiency means not only lowering the carbides formation sensitivity and increasing the nodule count, but also a prolonged graphitization through to the end of the eutectic freezing, as observed by the high population of small late forming nodules, which leads to minimizing the tendency for shrinkage. The second part of the paper illustrates an application of this equipment to commercial foundry use. It conducts thermal analysis and volume change measurements in a single ceramic cup with cast iron quality as a variable. La-bearing FeSi inoculant appears to be more effective than RE (Rare Earth) -FeSi alloy in FeSiMgCa treated irons (no RE), in terms of reducing eutectic undercooling and (εdi)max, favourable for lower sensitivity to shrinkage formation. Experiments also compared solidification patterns for white [WI], grey [GI] and ductile [DI] irons, to correlate the most important events between the cooling curves and contraction curves, to evaluate the sensitivity to shrinkage formation. All of the irons have similar values for initial expansion up to the start of eutectic freezing, but, after that, the graphite formation promotes expansion (more than 5 times for nodular graphite), resulting in a difference in maximum expansion (2 times higher for DI). The graphitic expansion has two contrary effects. Increased graphitic expansion (force) leads to a higher shrinkage sensitivity during the first part of the eutectic reaction, but also to a decrease of shrinkage at the end of solidification, due to forcing the last liquid iron to occupy the previous formed cavities. Consequently, strong graphitization process promotion at the end of solidification favours the castings' soundness.