Common Metallurgical

Defects in Ductile Iron

Compacted Graphite Exploded Graphite Chunky Graphite Spiky Graphite

Potential Causes: Potential Causes: Potential Causes: Potential Causes:

– Low residual magnesium and/or rare earth from
poor nodularisation practice, high temperatures
or long holding time.
– Excess sulphur in the base iron not balanced
by sufficient magnesium.
– Excess rare earth additions, particularly when high
purity charges are used. Normally found in thick
section castings or at higher carbon equivalents.
Note that once the rare earth addition is reduced, it may
take time to dilute the residual rare earth in return metal,
particularly in induction melted iron.
– Excess rare earth additions, particularly when high
purity charges are used. Normally found in thick
section castings or at higher carbon equivalents.
Note that once the rare earth addition is reduced, it may
take time to dilute the residual rare earth in return metal,
particularly in induction melted iron.
– Very small amounts of lead which have not been
neutralised by rare earths result in spiky graphite.
This has a catastrophic effect on mechanical
properties.
Bismuth, titanium and antimony can give similar
structures but can also be neutralised with rare
earths.

Flake Graphite
Graphite Flotation Surface Structure Nodule Alignment Carbides

Potential causes: Potential causes: Potential causes: Potential causes:

– High carbon equivalent. – Excess sulphur build-up in moulding sand. – Low carbon equivalent· – Low carbon equivalent.
– Excess pouring temperature. This causes reversion to flake as the magnesium – Under inoculation causing growth of large – Excess magnesium and/or rare earth.
– Slow cooling rate in thicker sections. in the iron reacts with the sulphur. The use of dendrites with nodules aligned between – Carbide promoting elements such as Mn, Cr, V, Mo.
– Insufficient inoculation. higher magnesium / rare earth in the nodulariser or arms of the dendrite. – Insufficient inoculation.
a cerium containing inoculant can overcome this. – High pouring temperature. – Rapid cooling rate.

Irregular Graphite Slag Inclusions Shrinkage Gas

Potential causes:
– High holding temperature.
– Long holding time which can result in "dead" irons.
– Poor inoculation or excessive fading of inoculation.
– Graphite shape may be improved by a late addition
of a powerful speciality inoculant.
Potential causes: Potential causes: Gas holes are a totally separate subject and can be
– Inadequate slag control from pouring system. – Insufficient mould strength causing dilation. influenced by melting procedures, metal handling,
– Lack of slag traps or filter. – Inadequate feed metal available. refractory conditions, mould moisture, sand permeability,
– Low pouring temperature. – Poor gating design. core resins, hot spots near cores, slag handling, metal
– Excess additions of slag forming materials. – Excess magnesium. temperature, base metal composition, mould venting,
– Turbulent mould filling. – Low carbon equivalent. Ti and Al contents amongst other sources.
– Under inoculation or over inoculation. Specialist advice should be sought in cases of gas once
the above have been investigated.

The photomicrograph given here shows dendrite arms

growing inside a hydrogen pinhole.

Elkem produces a complete range of nodularisers and inoculants for the treatment Preseed™ is a powerful preconditioning agent for all cast irons to improve consistency in
of ductile iron. MgFeSi alloys are available for applications such as sandwich treatments, melting and increase mechanical properties
tundish cover ladles and flow through systems. They are graded so as to be suited
for different ladle sizes. Products for in-the-mould processes are also available. Please refer to your local Elkem representative for further information on the range
of Elkem products for grey, compacted and ductile cast irons.
Ultraseed® inoculant is designed for pure Mg produced ductile iron, irons of low oxygen
and sulphur levels and dead iron which has been held for extended periods of time. Ultraseed® is a Registered Trademark of Elkem AS. Preseed™ is a trademark of Elkem AS.
This inoculant will give high nodule counts in ductile iron which is normally difficult to
inoculate and will help to prevent micro-shrinkage.

Elkem AS, Foundry Products Division, Hoffsveien 65 b, P.O. Box 5211 Majorstua, N-0303 Oslo, Norway, www.foundry.elkem.com