Technical Information 13 Compacted Graphite Iron

Compacted graphite irons (CG-irons) are a range of cast irons having mechanical and physical properties intermediate between those of flake graphite and nodular graphite cast irons. They are of interest to engineers because of their useful combination of strength, thermal conductivity and other properties. They have good founding characteristics and their production requires controls similar to those applied in the manufacture of ductile iron castings. This Information Sheet summarizes a successful production route for CG-iron that has been developed by Elkem, as well as examples of structures and properties for such materials. Treatment is based on a high rare earth containing magnesium-ferrosilicon alloy designed specially for compacted graphite iron production. No introduction of such elements as titanium or nitrogen is necessary with the present alloying concept. Recommended composition of treatment alloy : Si 44 - 48 Mg 5.0 - 6.0 Ca 1.8 - 2.3 RE 5.0 - 7.0 Al max. 1.0 Balance iron % % % % %

Recommendations for Compacted Graphite Iron Production Base Iron Composition Base iron composition should preferentially be hypereutectic with a carbon equivalent of about C.E. = 4.3 - 4.5. Impurities should be kept low. Suggested base iron composition is: C Si S P 3.7 - 3.9 % 1.5 - 2.0 % 0.005 - 0.010 % max. 0.03 %

Alloy Addition The addition rate of the alloy described above has to be adjusted according to base metal composition and treatment process for each individual foundry. Base metal sulphur level and treatment temperature are important parameter that strongly affect the required alloy addition rate. Experiences with the base iron composition given above have shown best results for addition rates between : 0.3 - 0.4 weight percent addition of alloy specified above The addition method may be an ordinary ladle treatment process as for ductile iron production (sandwich or tundish ladle).
Elkem ASA, Silicon Division
Postal address: P.O.Box 5211 Majorstua N-0303 Oslo Norway Office address: Hoffsveien 65 B Oslo Telephone: 47 22 45 01 00 Telefax 47 22 45 01 52 Revision No. 2 14.03.1997

Inoculant Addition It is recommended to add a high efficiency inoculant for production of CG-irons. Barium and Strontium containing ferrosilicon inoculants are found to give good results. Inoculant addition rate should be similar to that for ductile irons, i.e. between 0.3 and 0.8 wt percentage. The higher levels giving a fine distribution of compacted graphite throughout castings and less sensitivity to carbide (cementite) formation. Microstructures The Figures below shows examples of microstructures obtained for a CG-iron casting produced from a high RE-containing MgFeSi-alloy. Structures in both thin (5 mm) and thick (35 mm) section sizes are given to show the limited section sensitivity obtained. Homogeneous CG-structures throughout all section sizes are a characteristic feature obtained by the high RE-containing alloy in comparison to an ordinary lower RE-containing MgFeSi-alloys.

(a) (b) Figure 1: Microstructure of compacted graphite iron produced from a high RE-containing MgFeSialloy, (a) 5 mm section size, (b) 35 mm section size (100X).

CG-Iron Composition Example of final CG-iron chemical composition obtained from the given parameters: %C 3.8 % Si 2.5 % Mn 0.20 %P 0.02 %S 0.007 % Ti 0.012 % La 0.008 % Ce 0.015 % Mg 0.010

Mechanical Properties Mechanical properties of CG-iron will of course be affected by the ferrite/pearlite-ratio, but for a predominantly ferritic grade properties may be (from 25 mm diameter separately cast test bar) : Yield strength Tensile Elongation strength (MPa) (%) (MPa) 310 - 340 340 - 400 3-6

For more information, see the Elkem Product Data Sheet CompactMag.