Sphere-O-Dox G is a new inoculant which works well as ladle addition and in-stream inoculants, or as cast and sintered inserts. It has superior nucleating power compared to traditional ferrosilicon based inoculants.
This product is a dense, 75% calcium bearing 75% ferrosilicon containing a blend of sulfur and oxygen. It has the potential to reduce chill and carbide formation as well as promote graphite oxidation to improve mechanical properties.
Several tests have shown that a special ferro-silicon alloy containing strontium and having a low calcium content is highly effective as an inoculant for flake graphite iron or nodular cast iron. The inoculant can also contain a rare earth element such as cerium or mischmetal or a mixture of these elements.
The power of the inoculant was most strongly demonstrated when it was added to a melt containing nodular graphite. Plates from tap 6/1 which were inoculated with the special inoculant were very ductile while those from tap lO/ 3 were brittle.
The inoculant composition of the invention also showed superior chill removal when tested with low sulphur iron in comparison with two proprietary barium-containing inoculants, FOUNDRISIL(r) and CALBALLOY(tm). It was even more powerful at 0.01% sulphur than two commercially available barium-containing inoculants at 0.033% sulphur.
In order to provide good oxidation resistance it is necessary that the inoculant contains some calcium. Usually this is accomplished by adding a high silicon ferrosilicon alloy, which also suppresses iron carbide formation and promotes graphite formation.
In ladle inoculation experiments on a cast iron sample prepared as described in Example 3 (using 4C chill blocks) it was found that the present invention produces chill depths superior to those obtained with the commercial inoculant SUPERSEED.
A molten bath of low-calcium, aluminum-contaminated ferrosilicon is produced in the submerged arc furnace and to this strontium metal or strontium silicide and zirconium silicon or titanium silicon may be added or both.
When used in cast irons, this product reduces chill and nodule formation, resulting in improved mechanical properties. It can also be used as a ladle inoculant or in-stream inoculant.
Metallographic studies show that strontium has a different impact on the microstructure of chromium cast iron than other nucleogenic modifiers. It promotes the growth of fine Type A flake graphite, increases the number of eutectic colonies (g + M7C3) and reduces the length of hard carbides.
Compared with the 75% calcium bearing ferro silicon, it has much better inoculating effect and a significantly lower residue. It remarkably reduces the chill phenomenon and has excellent anti-recession ability.
The ferro silicon strontium inoculant has the advantage over the calcium nodulariser in that it can promote inoculation effectively and also reduce the chill phenomenon. It is especially effective in thin section gray irons with a low sulphur content.
It can be used as ladle inoculant or in-stream inoculant in liquid iron treatment. In grey irons it can increase nodule count, improve graphite morphology and mechanical properties.
It is also highly effective in ductile irons. It can decrease sulphur levels, chill and carbide formation and improve machinability. This is achieved through the addition of controlled amounts of aluminium, barium, strontium, calcium and zirconium.
SMZ is the oldest inoculant in the foundry industry. It is a 65% Si based inoculant with controlled levels of calcium, zirconium, manganese and barium. It is available in ladle and stream grades for different addition techniques.
It has excellent metallurgical properties and can be used in low sulphur grey iron and as a first stage inoculant in ductile iron. It promotes type A graphite and reduces chill in thin sections. It also improves the morphology and distribution of graphite in the casting and refines eutectic clusters for good mechanical properties.
Alinoc is a 75% ferrosilicon inoculant with enhanced levels of calcium and aluminium. It has excellent performance in reducing chill and carbide formation in both gray and ductile iron.
Sphere-O-Dox is a unique, rare earth based innoculant which combines the best of contemporary inoculation concepts. It is a powerful nucleator which can be added as a ladle addition, in-mold or with ASI’s inoculant tablets and pressed briquettes (InocuBloc).
The alloy is designed to provide a high level of chill reduction while increasing nodule count, mechanical properties and improving machinability. It contains a proprietary blend of silicon, zirconium, magnesium and barium with low levels of aluminum and calcium to minimize dross formation.
It has strong recession-proof ability making it ideal for large thin-walled castings or for long pouring times. It also has excellent graphitization promotion ability which improves the morphology and distribution of fine flake type graphite in gray iron.
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