• Improved yield
  
  • Reduced consumption of treatment material because of low fines
  • Large percent of returns usable
  • Less pigging during base iron changeovers
  • Lower temperature loss during treatment
• Reduced defects
  
  • Eliminate hard spots caused by undissolved inoculant
  • Slag defects reduced
  • Low silicon products reduces production of silica rich slag, slag build-up on ladle walls and slag carried through to the casting
  • Reduced sources of Al that cause H2 pinholing
• Increased productivity
  
  • Reduce casting rejects that fail to meet hardness or strength specifications
  • Products faciliate process control, charge material utilization, management of metallurgical problems, sulfur issues and pigging due to Mg fade
• Improved quality
  
  • Uniform microstructures, lack of carbides and micro-shrinkage provide enhanced physical properties and casting quality
  • Proper silicon and process control required to produce ductile iron

Iron Metal Treatment

Foseco’s iron metal treatments are carefully formulated and processed to provide the best possible metal treatment value to iron foundries.

Inoculation Alloys

INOCULIN alloy is a finely graded, dust-free inoculation alloy with a low melting point developed for application in metal stream inoculation. It is equally suitable for the inoculation of both gray and ductile cast irons.

• Sized specifically for use with Foseco’s MSI in-stream inoculation systems
• Much less friable than standard FeSi or other premium alloy inoculants, producing significantly less wear and feed variance in MSI units
• Low melting point ensures quick dissolution in iron. (Liquidus of 2156°F vs. 2228°F for FeSi)
• Accurate feed rate
• Results in consistent microstructures which are particularly critical in small or thin section castings
• Results in consistent mechanical properties
• Cost savings through reduced inoculant usage and fewer rejected castings

Low Silicon Magnesium Additions For Ductile Iron

NODULANT material is a low silicon magnesium addition (i.e., nodularizer) for ladle treatment of ductile iron. It can be used in overpour, sandwich or plunging processes by itself or in conjunction with MgFeSi

• Contains very little silicon so it allows more flexibility in melting control. It is possible to treat iron with a base silicon in excess of 2.0% with NODULANT nodularizer and still provide adequate post-inoculation. Extended furnace lining life can be expected with higher melt out silicon.
• More flexibility in the control of the post-inoculating addition. Better quality ductile iron can be produced consistently since this helps to overcome problems of fade.
• More flexibility of magnesium and sulfur control since the product allows for independent additions of Mg and Si.
• Contains almost no silicon, providing a very clean reaction leading to less scrap and ladles that are more easily maintained.
• Although NODULANT nodularizers contain magnesium in pure form, the reaction violence is modified by the high Ca content so that it compares favorably with MgFeSi.
• In overpour or sandwich treatment applications reaction efficiency is similar to that of MgFeSi.
• NODULANT products introduce NO aluminum into the treatment process.

Related Case Studies:

 Iron and Steel

• 4 & 6 Cylinder Head (Germany) Case Study (51.52 KB)
• Feeding System Facts Newsletter 2 (215.78 KB)  
• Roof Node for Berlin Olympic Stadium Case Study (78.15 KB)

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