Ductile Iron 101

Basic Ductile Iron Training
Bob Roberts
27-Mar-2015
"The information contained herein is FORD PROPRIETARY information and may include FORD CONFIDENTIAL information as defined in Ford's
Global Information Standard II. Reproduction of this document, disclosure of the information, and use for any purpose other than the conduct of
business with Ford is expressly prohibited" Copyright © 2016 Ford Motor Company. All rights reserved.
Training Outline
• Ductile Iron Introduction

• Material Characteristics
• Ductile Iron Manufacturing
• Ductile Iron Casting Controls Checklist
• Typical Ductile Iron Failure Modes
2
Copyright © 2016 Ford Motor Company. All rights reserved.
Ductile Iron Introduction
• What is Cast Iron?
• What is Ductile Iron?
• Why Use Ductile Iron?
• Ductile Iron Properties
• How Does Ford Specify Materials?
• What is High Quality Ductile Iron?
3
What is Cast Iron?
• In simple terms, cast iron can be thought of as

steel with free graphite (carbon).
• The shape of the free graphite controls the
physical and mechanical properties.
Flake Graphite Compacted Graphite Spheroidal Graphite
4
What is Cast Iron?
• In simple terms, cast iron can be thought of as

steel with free graphite (carbon).
• The shape of the free graphite controls the
physical and mechanical properties.
• The matrix microstructure also influences the
properties.
Pearlite Ferrite
5
What is Ductile Iron?
Ductile iron is a cast iron that has
been treated while molten with
magnesium or rare earth elements
(i.e., cerium) to induce the formation
of free graphite as nodules or
spheroids, which imparts a
measurable degree of ductility.
It was “discovered” in 1943 in an Spheroidal Graphite
Flake Graphite
(Unetched Sample)
attempt to make carbidic gray iron as

a replacement for chromium to help
the war effort.
6
One Iron with Many Names . . .
• Ductile Iron is also known as Nodular or
Spheroidal Graphite (SG) iron.
• Other types of cast iron include malleable
iron, gray iron, white iron and compacted
graphite (CG) iron.
• The characteristic that distinguishes them
from each other is the form of the carbon
present. Most cast irons contain graphite.
• The term morphology is used to describe
the type and shape of the graphite.
Spheroidal Graphite
(Unetched Sample)
7
One Iron with Many Names . . .
• Ductile Iron is also known as Nodular or
Spheroidal Graphite (SG) iron.
• Other types of cast iron include malleable
iron, gray iron, white iron and compacted
graphite (CG) iron.
• The characteristic that distinguishes them
from each other is the form of the carbon
present. Most cast irons contain graphite.
• The term morphology is used to describe
the type and shape of the graphite.
• Structure can be further classified in terms Ferrite Pearlite
of percent pearlite and percent ferrite (Etched Sample)
– Amount depends on application and specification
8
Cast Iron – Graphite Morphology
9
Nodularity
• NODULARITY – percentage of
spheroidal (round) nodules
• Nodularity requirement depends
upon the application
• Higher nodularity requires more
process discipline & inspection =
higher cost
• SAE grades require 80% min.
nodularity
10
Why Use Ductile Iron?
• Cost depends upon many factors, but is

generally lower vs. steel for semi-complex to
complex geometry parts.
• The following characteristics of Ductile Iron lie
between Gray Iron & Steel:
– Density, Strength, Fatigue Life, Toughness, Modulus,
Ductility, Machinability, Thermal Conductivity,
Coefficient of Thermal Expansion & Dampening
Capacity . . .
11
Typical Ductile Iron Components
• Control arms
• Steering knuckles
• Brake calipers
• Bearing caps
• Camshafts
• Crankshafts
• Exhaust manifolds
• Brackets
• Plus……..
12
How Does Ford Specify Materials?
• Whenever possible, Ford uses

International Standards, i.e., SAE, ASTM
to specify materials.
• For components with
unique/different/additional requirements a
Ford Engineering Material Specification
may be used.
13
SAE Ductile Iron Specifications
14
Ford Ductile Iron Crankshaft Specification
15
What is High Quality Ductile Iron?
• Consistent chemistry
• 200 nodules/mm2 minimum
• 90%+ Nodularity
• 0.5% carbides & inclusions
(max.)
• 1% porosity and/or micro
shrinkage (max.)
• Consistent matrix
microstructure
• Pearlite/ferrite within
specification (application
dependent)
16
Ductile Iron Manufacturing
• Melting process for manufacture of ductile iron is

basically same as gray iron, but with a couple additional
steps.
– Additional potential failure modes need to be considered
• The most common methods for primary melting are the
same for ductile and gray iron:
– Cupola Melting
– Induction Melting
• The most common method for holding is in an induction
furnace. Treated iron may be held in specially designed
“low oxygen” or pressure pour furnaces.
17
Ductile Iron Melt Process Steps
• Melt Base Iron

• Desulfurize/Alloy Base Iron
• Magnesium treatment
• Inoculate Iron
• Pour Iron
18
Cupola Melting of Cast Iron
19
Cupola Melting of Cast Iron
• Adds sulfur to the iron

• Additional processing required
to remove the sulfur
20
Induction Melting of Cast Iron
21
Induction Melting of Cast Iron
• High energy usage due to

electric induction
• Batch melting
• May constrain capacity
• Facilitates tighter melt

chemistry control
• Does not add sulfur
• Additional processing not
required
22
Iron Chemistry and Carbon Equivalent
CE = Carbon + 1/3 Silicon + 1/7 Mn
Carbon Equivalent Range for Ductile Iron Factors That Limit Carbon & Silicon Range
1.5 2.0 2.5 3.0 3.5

5 3.9
Eutectic Composition
Hypereutectic
CE = %C + 1/3 %Si = 4.3
Graphite
Ductile
Preferred Range Flotation
4 3.8
CE = C + 1/3Si = 4.55
Tendency
Carbon Content (%)
Carbon Content (%)

For Carbides
3 3.7
Hypoeutectic
Gray
Preferred Range
2 3.6
Low Temp
Impact
CE = C + 1/7Si = 3.9
Solubility of C in Austenite
1 3.5
CE = %C + 1/6% Si = 2.0
Excessive
Shrinkage
0 3.4
0 1 2 3 4 1.5 2.0 2.5 3.0 3.5
Silicon Content (%) Silicon Content (%)
23
Metal Chemistry: Gray vs. Ductile Iron
ELEMENT Ductile Gray
Carbon Equivalent 4.35 - 4.70% 3.85 - 4.25%
Carbon 3.50 – 3.90 3.20 – 3.50
Silicon 2.20 – 2.80 1.80 – 2.50
Manganese 0.10 – 1.00 0.50 – 1.00
Sulfur 0.015 Max. 0.15 Max
Copper 0.05 – 1.50 0.15 – 0.80
Magnesium 0.03 – 0.06 NONE
24
Magnesium Treatment
Sandwich Treatment Ladle
• 2 ton sandwich treatment

ladle filled from holding
furnace, which introduces
magnesium ferrosilicon alloy
into molten iron.
• Magnesium ferrosilicon alloy
is “sandwiched” between the
bottom of the ladle and steel
punchings used to cover the
alloy.
• Ladle height is larger than
diameter (3:1 ratio) to provide
sufficient metal head above
bottom pocket to increase Mg
recovery
25
Ductile Iron Manufacturing Process Steps
Magnesium Treatment
• Key process control is Fade Time
• The time Mg-treated iron can be held will
depend upon the subsequent processing.
• Mg fade occurs in about 12 – 15 minutes in an
environment rich in oxygen (ladle).
• It may not fade for several hours when held
under pressure or in a minimal oxygen
environment (pressure pour furnace.
26
Ductile Iron Processing
Courtesy: Gartland Foundry

27
Ductile Iron Processing
Courtesy: Gartland Foundry

28
Inoculation
Inoculants are added to create nucleation sites that
promote spheroidal (nodular) graphite formation
29
Inoculation
Inoculants are added to create nucleation sites that
promote spheroidal (nodular) graphite formation
Inoculants may be added:

• In-stream as pouring ladles or molds fill
• In-the-mold (inmold)
• Both in-stream and inmold
Potential failure modes of poor inoculation

• “Poorly inoculated” iron may have carbides and other
“undesirables” present in microstructure, which
adversely affect machinability.
• “Over-Inoculated” iron may contribute to shrinkage.
30
In-stream Inoculation
• DISA mold line stopper
rod box showing
stopper rod in closed
position
• Inoculant gravity
feeder system shown
by arrows
31
Unpoured molds
Instream Inoculation Poured molds
DISA Green Sand Mold Line direction of travel
32
In-stream
inoculation
33
Non-Destructive Testing Methods
• Ring test – hit casting with hammer and listen for “ring”
• Acoustic resonance
– scientific version of ring test
• Ultrasound – measure sound wave velocity in part
34
Ductile Iron
Casting Controls Checklist
W-CMS
Worldwide Casting Manufacturing Standard
35
Ductile Iron Casting Controls Checklist
• The Casting Manufacturing Controls Checklist is

contained in Ford’s Worldwide Casting
Manufacturing Standard, W-CMS
• W-CMS is a global standard for minimum
manufacturing requirements of metal cast
components and provides generic control plan
expectations for casting processes by material
type.
• Lessons learned globally have been captured in
the W-CMS standard.
36
Ductile Iron Casting W-CMS
Char.
Class.
(min Test / Inspection Recommended Suggested Best Evidence or Gap
Area Item Characteristic level) Frequencies (Minimum) Control Method Measuring System Practice G/Y/R identified
Raw material
Lot/Document control Verify supplied sample

Restricted substance Radioactivity testing
compliance (WSS- Certification and/or Monitor steel for possible
1.1 Metallics certification each material lot M99P9999-A1) Spectrometer Boron contamination
Key point:
SiC may be a possible
1
1.2 Alloys/Inoculants certification each material lot Approval process Certification
source for Boron
contamination
develop approved
1.3 Non-metallic certification each material lot Approval process Certification
1.4
1.5
Sand raw material (Core and Molding)
Mold and Core Sand additives certification
each material lot
each material lot
Approval process
Approval process
Certification
Certification
supplier process
1.6 Inventory control (handling and storage) each material lot Store appropriately Visual FIFO
1.7 Non-metallics (fluxes) each material lot Approval process Certification
Manufacturing aides
1.8 (screens/filters/ceramics) each material lot Approval process Certification
Melting / Holding Operation: Induction (Batch) / Cupola (Continuous)
1) Final Carbon
Equivalent ranges (4.3-
Pre-Control:
4.6%) depending on
CE, C, Si, S, Mn, P,
spectrometer section thickness
Metal Chemistry (Major Elements)
2.1 (per SS #2297/2323) HIC
each heat lot /
Every hour
Cu, Cr, Sn,
(C & S Leco
Determinators)
2) Round robin verification
study
Key point:
Boron amounts higher
Fixed Limits:
than 0.0012% can result
in softer materials and
Chemistry control
Al, Mg, Ti, V, Mo, Ni lower UTS
each heat lot /

Pb, Ce, B, La*, Te*
spectrometer
Te, W, La are dependent
upon product/process
each heat
2.2 Metal Chemistry (Other Elements) Every hour needs
each heat lot / Daily verification
2.3 Metal Temperature Every hour Pre-control Immersion pyrometer w/calibrated unit
2.4 Metallics charge makeup (weight) each charge Recipe Weigh scale Auto compensation
2 each heat lot / Detailed thermal analysis

2.5 Thermal analysis (CE, C, Si) Every hour Pre-control Thermal arrest unit (trace) cooling curve
Measure inputs
Desulfurization (method dependent), if (Weigh Scale or flow
2.6 required each heat lot/ batch Pre-control rate)
1) Alarm / Digital display

2) All treatment ladles,
intermediate ladles, and
pouring ladle liquid or
solid metal heels are
Transfer method Work instruction removed after use or fade
2.7 (per SS #2742) each ladle includes heel removal Weigh scale time expires
2.8 Alloy additions each heat lot/ batch Recipe Weigh scale Auto feeding
Pre-inoculation additions (product
2.9 dependent) each ladle
each heat lot for (batch)/
Recipe Weigh scale Auto compensation
37
2.10 Slagging continuous (cupola) Work instruction Visual inspection
2.11
Char.
Class.
Magnesium Treatment (Tundish,
Raw Sandwich, Converter)
material
Lot/Document control Verify supplied sample

1) Sandwich Treatment
Restricted substance Radioactivity testing
ladles have a height to
compliance (WSS- Certification and/or Monitor steel for possible
diameter ratio of
1.1 Metallics certification each material lot M99P9999-A1) Spectrometer Boron contamination
1H:(2 - 3)*D
2) Pre-heated ladles (gas
SiC may be a possible
Dimensional burner)
1 source for Boron
Magnesium Treatment Ladle PM Each repair / build of verification: Fixture 3) Operator inspection of
1.2 Alloys/Inoculants certification each material lot Approval process Certification contamination
3.1 (per SS #2220) ladle Forms or mold (gig) or gage ladle each shift
1.3 Non-metallic certification each material lot Approval process Certification
1) Photo eye or vibration
1.4 Sand raw material (Core and Molding) each material lot Approval process Certification
sensors for conversion
1.5 Mold and Core Sand additives certification each material lot Approval process Certification
detection
2) Magnesium Treatment
materials are added to
Manufacturing aides
the treatment ladle as
Magnesium (Alloy) Addition (wt %) late as possible prior to
3.2 (per SS# 2742) Melting HIC
/ Holding Operation:
each treatment Induction Pre-control
(Batch) / Cupola (Continuous)
Weigh iron and alloy tapout
1) Final Carbon
Equivalent
1) Filing theranges (4.3-
treatment
Pre-Control:
4.6%) depending
ladle avoids directon
spectrometer section
pouring thickness
over the material
Cu, Cr, Sn,
Metal Chemistry (Major Elements) each heat lot / (C & S Leco 2) Round robin verification
chamber.
2.1 (per SS #2297/2323) HIC Every hour Determinators) study
2) Fill rate optimized for
Boron
magnesiumamounts higher
recovery
Target and Fill Rate: than 0.0012%
3) Preferred can result
methods are
3 Magnesium Treatment Filling Ladle design
Fixed Limits:& pouring in softer and
Tundish materials
Pure Mgand
3.3 (per SS #2220) each treatment Al, Mg, Ti,
position V, Mo, Ni Visual inspection
interaction lower UTS
Converters
Pb, Ce, B, La*, Te* Te, W, La are dependent
each heat lot / spectrometer upon
1) Alarmproduct/process
system
2) Fade time counters
2.3 Metal Temperature

2.4 Metallics charge makeup (weight)
each heat lot /
Every hour
each charge
Pre-control
Recipe
Immersion pyrometer
Weigh scale
Daily verification
and alarms
w/calibrated
Auto
account for
unit time
the total reaction Key point:
(initialcompensation
metal in the
treatment ladle to last
each heat lot / Detailed thermal analysis
ladle poured)
2
2.5 Thermal analysis (CE, C, Si) Every hour Pre-control Thermal arrest unit
Measure inputs
(trace)
3) Typicalcooling
totalcurve
time is 12 minutes
reaction Mg Fade time
Desulfurization
Mag Fade time (method dependent),
(time of treatment if
to last (Weigh Scale or flow (studies should support
required
2.6 mold poured) each heat lot/ batch Pre-control rate) going beyond 12
3.4 (per SS #2269) HIC each treatment Pre-control Timer minutes)
1) Alarm
Assembly / Digital
aidesdisplay
2) All treatment
directs material ladles,
into
intermediate
treatment chamber ladles, (i.e.
and
pouring
funnel). ladle liquid or
solid metal
2) Vision heels are
system to
control additions
2.7 (per SS #2742) each ladle includes heel removal
Work instruction - Weigh scale time expires alloy
3) Automated
2.8 Alloy additions each heat lot/ batch Recipe
Add Weighed alloys Weigh scale Auto feeding
addition systems
Pre-inoculation additions (product and steel in proper 4) Use clean steel plates
dependent)
2.9 Alloys / Rare Earths / cover steel additions
3.5 (per SS #2220)
each ladle
treatment
Recipe
order and location in
the ladle
Weigh
Weighed
steel
scale
alloys and Auto compensation
or punchings
steel
as cover 38
2.10
3.6 Slagging HIC continuous
eatch ladle (cupola) Work instruction Visual inspection
2.11
Char.
Class.
Inoculation (StreamRaw / Pour Box / Ladle / In-mold)
material
7.1 Correct Inoculant Material each production run Work instruction checksheet Color code
Lot/Document control Alarm supplied
Verify system sample
7.2 Inoculation presence (in-stream)
Detection of in-mold inoculation presence
HIC each pour or batch Restricted/ substance
Pressure weight
compliance (WSS-
Pressure sensor / scale
In-stream: camera
Radioactivity
Vision system
Certification and/or Monitor
testing
steel for possible
Key point:
7 7.3 Metallics
1.1 (in-mold) certification HIC mold
each material lot Alloy detection
M99P9999-A1) presence
Spectrometer In-mold:
Boron laser
contamination
Jig fixture
1
Inoculation location / target (in-stream)
7.4 (per SS#1301) HIC each pour or batch Work instruction checksheet
Center
SiC maystream
pouring for
source basin
Boron
above
be a possible Verify, Verify,
7.5 Alloys/Inoculants
1.2 Inoculation application timing
certification each material
each mold lot Work instruction
Approval process Visual
Certification contamination
Inoculation system
7.6 Non-metallic
1.3 verification
certification
1.4 Sand raw material (Core and Molding)
each material
each shift lot
each material lot
Pre-control
Approval process
Approval process
Weigh check
Certification
Certification
Verify
1.5 Mold and Core Sand additives certification each material lot Approval process Certification
Manufacturing aides
1) Final Carbon
Pre-Control:
4.6%) depending on
Cu, Cr, Sn,
Fixed Limits: in softer materials and
each heat lot / spectrometer upon product/process
2 each heat lot / Detailed thermal analysis

Measure inputs
Desulfurization (method dependent), if (Weigh Scale or flow
2.6 required each heat lot/ batch Pre-control rate)
1) Alarm / Digital display

intermediate ladles, and
solid metal heels are
2.7 (per SS #2742) each ladle includes heel removal Weigh scale time expires
2.8 Alloy additions each heat lot/ batch Recipe Weigh scale Auto feeding
39
2.11
Char.
Class.
Product Testing and Inspections
Raw material
Automatic impression
10.1 Surface Hardness subgroup sample/lot Pre-control
Lot/Document control Brinell measurement
Verify supplied sample
per Material Spec, ES, or Restricted substance Radioactivity testing
10.2 Mechanical Property (from part if possible) Print Tensile tesing
compliance (WSS- UTS-YS-Elongation
Certification and/or Monitor steel for possible
1.1 Metallics certification each material lot M99P9999-A1) Spectrometer Resonance
Boron Inspection or
contamination
10.3 Surface Integrity per Print/ES or PV plan Acceptance Criteria NDT (Magnetic Particle)
UT
10.4 Internal Integrity per Print/ES or PV plan Acceptance Criteria NDT (Xray) or DT NDTmay
SiC whenbepossible
a possible
1 source for Boron
1.2 Alloys/Inoculants certification each material lot Approval process Certification 1) Ultrasonic Velocity
contamination
1.3 Non-metallic certification each material lot Approval process Certification Testing or Resonance
1.4 Sand raw material (Core and Molding) each material lot Approval process Certification Testing
1.5 Mold and Core Sand additives certification each material lot Approval process Certification 2) Test equipment
1.6 Inventory control (handling and storage) each material lot Store appropriately Visual includes appropriate
FIFO
1.7 Non-metallics (fluxes) each material lot Approval process Certification tester calibration
Manufacturing aides (minimum weekly) and
1.8 (screens/filters/ceramics) each material lot Approval process Certification verification (each shift).
3) Each part's nodularity
test has a positive
1) Final Carbon
indication (marking) of
Pre-Control: acceptance and an error
4.6%) depending on
Nodularity testing Safety parts (Inverted CE, C, Si, S, Mn, P, Correlation to proof when a reject is
10.5 (per SS #2220 / 2297 / 2323) Delta): 100% Cu, Cr, Sn,
Non-destructive testing %nodularity identified
Per Part Print:
10 Special
Characteristics/Pass
Through
Fixed Limits: in softer materials and
Characteristics.
Consider key
1st Piece and Last Piece pattern/core features At PPAP: Full layout
each heat lot / spectrometer upon product/process
SC/PTC/ Each cavity / each prone to damage or Dimensional gage or with point cloud scanning
10.6 Dimensional HIC production run wear. CMM (Laser or light)
Air decay or
air-under-water or Leak Test Robustness
2
10.7 Leak testing (if specified) per Print/ES or PV plan Acceptance Criteria
per Material Spec, ES, or
each heat lot /
mass airflow Standard GTS-1.4.1
Detailed thermal analysis
Key point:
10.8.1 Microstructure: %Nodularity HIC Print Pre-control Visual comparator 80% Nodularity minimum
Measure inputs
10.8.2
Desulfurization (method dependent), if
Microstructure: Nodule count (nod/mm2)
2.6 required HIC
Print heat lot/ batch
each minimum level
Pre-control
(Weigh Scale or flow
Visual comparator
rate) 200 nod/mm2 minimum
Validate and set
10.8.3 Microstructure: Pearlite Print
micro analysis Visual comparator 1) Alarm / Digital display
appropriate
10.8.4 Microstructure: Ferrite Print micro analysis Visual comparator intermediate ladles, and
Surface
solid chillheels
metal - Maximum
are
sample size and
Transfer method Work instruction 4%
removed after use or fade
2.7 (per SS #2742)
10.8.5 Microstructure:
2.8 Alloy additions Carbides
per Material
each
each
ladle Spec, ES, or includes heel removal Weigh scale
Print heat lot/ batch maximum level
Recipe Visual comparator
Weigh scale
Matrix
time
Maximum
Auto
carbides -
expires
1%
feeding
frequency
40
2.11
Typical Ductile Iron Failure Modes
• Wrong microstructure
– Flake Graphite
– Low Nodularity
– Carbides
– Exploded Graphite
• Shrinkage
• Non-metallic inclusions (sand/slag)
41
Potential Failure Modes and Avoidance Practice
Flake Graphite
Flake Graphite:
• Results in lower ductility from
inadequate formation of nodules
due to Mg fade (loss), too high
sulfur content, extended exposure
to oxygen, or untreated base iron.
The negative effect is 50%
reduction in material strength.
Avoidance Practices:
• Effective ladle tracking system
• Control the time between Mg
treatment and last pour
(Magnesium Fade Time).
– Usually, this time period is controlled to
less than 12 minutes time between Microstructure of flake graphite
treatment to pouring with automated (not spheroids)
alarms & interlocks to prevent pouring
out-of-spec fade time
• Hold treated iron in a low oxygen
pressure pour furnace 42
Low Nodularity
Compacted Graphite:
• Primarily due to sulfur
contamination or inadequate
inoculant, compacted graphite
can results in lower ductility
from inadequate formation of
nodules.
• Hold treated iron in a low
oxygen pressure pour furnace
• Control the time between Mg
treatment and last pour
(Magnesium Fade Time).
• Monitor Sulfur content of metal
and Sand. Microstructure of Compacted
• Control weight of inoculant Graphite (not spheroids)
additions.
43
Carbides
Carbide Formation:
• Carbides are brittle constituents that forms when
iron solidifies below the iron carbide eutectic point
(2050F) due to excessively fast cooling rates.
• Chill carbides can occur at part features such as
sharp corners, thin walls or fins.
• Other contributors include carbide promoter
chemistry elements (Cr, V, Mo and other trace
elements), low Silicon content or lack of
inoculation.
• Establish startup controls to confirm the following Microstructure of Carbides in ductile
KPIVs prior to release of first parts poured: iron
– Sand temperature is high enough to prevent
chill carbides.
– Ladles are hot enough to prevent
unexpectedly rapid Mg fade rates
– Verification of inoculant addition
44
Exploded Graphite
Exploded Graphite:
• Results from excessive Mg and/or
rare earth elements (Ce, La, Nd).
• Normally found in the thicker
sections where the cooling rate is
slowest, but could be at the surface
if sand is contaminated.
• Control Mg treatment weight
additions, paying special attention to
the morphology of the 1st part
poured (using high magnification).
Exploded graphite
Image from
www.solidmetals.net 45
Low Nodule Count
Nodule Count Density:

• Normally found in the thicker
sections where the cooling rate is
slowest, but could be at the
surface if sand is contaminated.
• Control of nodulizing agent Nodule Count Density
(inoculant) additions. While most Image from

inoculants act almost instantly, www.solidmetals.net
they do lose their nodulizing

affect over time. Therefore, it is
important to add the inoculant as
late as possible in the process.
• In-stream inoculation must be
carefully monitored for weight
addition and aim of injector
nozzle.
46
Insufficient Inoculation
In-Stream Inoculant:
• Inoculation target – center of
metal stream above mold to
assure Ferro silicate power is
mixing with metal stream.
• Manual check point for
operation, time period no
longer than casting line
length. Metal Stream Inoculant Feed Tube
• Backpressure sensor for
material presence.
47
Questions?
48

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Ductile Iron 101

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Basic Ductile Iron Training

• Ductile Iron Introduction

• In simple terms, cast iron can be thought of as

Flake Graphite Compacted Graphite Spheroidal Graphite

• In simple terms, cast iron can be thought of as

Flake Graphite Compacted Graphite Spheroidal Graphite

attempt to make carbidic gray iron as

– Amount depends on application and specification

Flake Graphite Compacted Graphite Spheroidal Graphite

• Cost depends upon many factors, but is

• Whenever possible, Ford uses

• Melting process for manufacture of ductile iron is

• Melt Base Iron

• Adds sulfur to the iron

• High energy usage due to

• Facilitates tighter melt

1.5 2.0 2.5 3.0 3.5

Carbon Content (%)

• 2 ton sandwich treatment

Courtesy: Gartland Foundry

Courtesy: Gartland Foundry

Inoculants may be added:

Potential failure modes of poor inoculation

DISA Green Sand Mold Line direction of travel

• Ultrasound – measure sound wave velocity in part

• The Casting Manufacturing Controls Checklist is

Lot/Document control Verify supplied sample

each heat lot /

2 each heat lot / Detailed thermal analysis

1) Alarm / Digital display

Lot/Document control Verify supplied sample

2.3 Metal Temperature

2 each heat lot / Detailed thermal analysis

1) Alarm / Digital display

Nodule Count Density:

(inoculant) additions. While most Image from

they do lose their nodulizing

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