Cored wire practice offers the foundry industry many advantages. It provides highly reproducible results between ladles, enables easy control of iron quality and requires only a simple exhaust system to capture pollution at the point of origin.
The variation of the temperature of the paper enclosing the steel lining of the cored wire is broadly affected by radiation (curves 7 a, 7 b and 7 c). This effect can be partially eliminated by moistening the paper or coating it with aluminum.
A nodulizer is used to transform flake graphite into spheroidal graphite in the production of ductile iron. It improves tensile strength and elongation of the cast iron while maintaining other properties.
Bansal Brothers produces nodularizer in different chemistry to suit every type of ductile iron treatment process such as open ladle, sandwich, tundish and flow through process, and even In-mould. Our chemistry has tightest variation in calcium, aluminium and rare earths metal to give maximum recovery of magnesium, consistent performance and nodule count in the castings.
In addition to the nodularizer, Bansal also offers inoculants to control microelements and oxideizable elements in molten ferro silicon. These inoculants can be added through injection at the metallurgical treatment site in liquid iron and help to achieve better reaction, shorten smelting time and control composition precisely. The injection equipment is simple and small occupation space, leading to efficient use of the inoculant. The company’s technology is eco-friendly and has negative carbon dioxide emissions.
Ferro Silicon is an essential additive in iron steelmaking as a deoxidizer. In torch steel, it can be used in the precipitation or diffusion deoxidation process to ensure that carbon does not get trapped as graphite and reduce hysteresis loss. It is also used as an inoculant to enhance nodularization of ductile cast iron and as a spheroidizing agent in spheroidal graphite iron production.
Ferro silicon can be added to the iron melt in the form of a powder or lumpy product, depending on the needs of the steel mill or foundry. It can be used in conjunction with a variety of other alloying elements, such as aluminium, calcium, barium, zirconium, strontium, and rare earths.
It is a cost-effective way to introduce these inoculants into the liquid iron in order to improve the balance of nuclei needed for eutectic solidification. This is known as the cored wire injection method, or metallurgical treatment. This method allows for greater control over the formation of nodularization and the final casting matrix structure.
Ferro silicon magnesium (FeSiMg) is used as a deoxidizer and desulphurizer for ductile iron production. It alters the growth of graphite from flakes to nodules, improving tensile strength and elongation in castings. Bansal Brothers manufactures different chemistry of FeSiMg alloy with a tightest variation in calcium, aluminium and rare earths metal to suit every ladle design, pouring temperature and casting requirement.
It can improve the alloy yield, reduce smelting cost, shorten smelting time and control composition precisely. In addition, it can purify the molten steel and partly change steel inclusion morphology and properties, improving molten steel quality and casting state. Compared with in-stream inoculants, cored wire injection has higher efficiency and lower loss rate. It is also safer and easier to handle than in-stream inoculants. Moreover, it can address sulfur contents well above 0.02% for ductile iron treatment. It is a very cost-effective and reliable solution to enhance the castability of molten steel. It is suitable for a wide range of applications such as foundry, steel casting and machine-casting.
A lining comprising a nodulizing agent in pulverulent form is placed inside an envelope that is compatible with the composition of the molten metal to be treated. It is possible to use a variety of materials to make the envelope, but the most suitable one is made of steel.
The cored wire is then introduced into the bath of magnesium melted in an electric induction furnace. The melt, which has a boiling point of 1053 deg C (for pure Mg), is heated to the melting point of magnesium and its alloys.
The temperature at the end of the melt is raised to a value which will enable the formation of graphite nuclei with the aid of the nodulising agent. This will allow the cast iron to be spheroidised and the metallurgical quality to be restored. This method is used to produce vermicular graphite cast iron in a number of foundries.
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