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Effect of Inoculants on Grey Cast Iron
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Effect of Inoculants on Grey Cast Iron
1.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 171 Effect of Inoculants on Grey Cast Iron N. Shashikantha1, Venkatesha Reddy2, Raju T N3 1 ,2 Associate Prof. Department of Mechanical Engineering, Dr. Ambedkar Institute of Technology Bangalore, India 3 Assistant Prof. Department of Mechanical Engineering, Dr. Ambedkar Institute of Technology Bangalore, India ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract- Attempts have been made to study the effect of inoculation on grey cast iron melted in induction furnace. The inoculants like calcium silicide, ferrosilicon, aluminum silicon and silicon carbide have been used in the present investigation. The effect of these inoculants on the micro and macro properties of grey cast iron have been investigated. The results reveal that the calcium - silicide is a better inoculating agent than others. It has been found that when calcium silicide is used as an inoculant the cell count of base metal is improved by about 8 to 10 times. It has also been found that calcium silicide increases the tensile strength of the base metal by an extent of 40%. There has been no appreciable increased in tensile strength and eutectic cell count when silicon carbide is used as an inoculant. Keywords— Inoculant; Eutectic Cell Count; Wedge Value; Graphite Flake. INTRODUCTION The process of inoculation involves the addition of small amounts of certain materialknownasinoculanttothemolten metal either during tapping of the metal into the kiddie or during pouring it into the mould. Its main purpose is to prevent the formation of eutectic carbide, particularly in rapidly cooled thinner sections of the castings (1 -3). The inoculationchangesthegraphitestructureoftheironresultingin animprovement of physicaland mechanicalpropertiesofthe product. The effectiveness of an inoculating agent can be assessed by measuring the number of eutectic cells present in grey iron, the count indicating the number of points at which the eutectic solidification took place (2). The inoculationprocedurescurrentlyavailablecanbedividedinto twomainmethodsLadleinoculationandLateinoculation.Ladle inoculation includes all procedures in which the inoculating material is added either as the metal is being poured into the mould or within the mould itself (2). In the present investigation the term inoculation, is restricted to Ladle Inoculation i.e., addition of inoculant to the stream of molten metal falling from the induction furnace into the ladle. In the presentinvestigationanattempthas been madetooptimize the useofinoculantslikecalciumsilicide, Ferro silicon,aluminum- silicon and silicon carbide. METHODOLOGY The moulds for tensile test bar and wedge test bar were prepared by oil bonded sand. These moulds were heated for about 180 ° C for two hours in an oven beforepouring liquid metal. Three different charges were used to melt grey cast iron.The charge mixes used are as follows and arc designated as A, B and C. Charge Mix Heat A Heat B Heat C Heel 20% 25% 30% Steel scrap 15% 18% 20% Pig iron 25% 20% 10% Foundry returns 40% 37% 40% For all the above heats the standard test bars and wedges were cast using different inoculants. In addition, constitutional wedges and uninoculated test bars were obtained for all the heats The melting of grey cast iron has been carried out in mains frequency induction furnace after charging in pre-determined chargemix.Themeltwasanalyzedfortotalcarbonandaddition ofpetroleumcokewasmadetoarriveataimedvalueofcarbon. Addition of Ferro-Silicon was made to maintain the silicon content within the range of 1.6-1.8%. Melts were super- heated between 1470 °C to 1520 °C and were again analyzed for total carbon and silicon before pouring. Inthepresentworkinoculantstriedwerecalciumsilicide,Ferro silicon, aluminum silicon, silicon carbide and mixtures of calcium silicide, Ferro silicon and silicon carbide. The inoculation was carried out during tapping with the help of pneumatic inoculator. The amount of inoculant added was kept constant at 0.35% of the molten metal tapped. The tensile test bar casting was made in accordance with IS; 210-1962 and the tests were carried out in a 30T universal testing machine. 20 mm dill specimens were cut out from the tensile test bars for hardness, microstructure and eutectic cell count. The surface of each specimen was polished carefully and was made din free. After cleaning the specimen thoroughly it was etched in Stead's reagent. The specimen was quickly transferredtorunningwaterandwasfinallydippedin acetone and dried. The specimen was ready for microscopic observation. The constitutional and process wedges with different inoculants were obtained from each heat. After quenching to 600 °C, the wedges were hammeredandbroken
2.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 172 centrally. The chill depth of wedges so obtained were measured by -using a guage having varying slot depths. After thorough polishing of the surface of the specimen the unetchedsurfaceofeachspecimen wasexaminedforgraphite flake type, size and distribution. The same specimen was then etched in 2% nital for 30 seconds and was observed at higher magnification.Eutecticcellcountwasdoneinspecimens etechedwithStead'sreagent.Theareacountingmethodadopted by Dawson (4) was followed for this purpose. The number of cells per square cm was given by Hardness values of all samples were obtained by Brinnel hardness testing. RESULTS AND DISCUSSION TYPE AND SIZE OF GRAPHITE The typical micro structures of uninoculatcd and inoculated irons are shown in Figs. 1-6. It appearsfromthemicrographs that Figure 0.1 Uti-inoculated, Figure 0.2 Inoculated with unetched, heat A, 100X. SiC, Unetched, heat A, 100X. Figure 0.3 Inoculated with Fe Si, Figure 0.4 Inculated with unetched, heat A, 100X Ca si, unetched, heat A, 100X Figure 0.5 Inoculated with Fe Si- Figure 0.6 Inoculated with Ca Si(1:1), unetched, heat A, 100X SiC - Fe Si (1:1), unetched, heat A, 100X Calcium silicide has modified graphite to A-type with 4-6 flake size. It has been found that there is no existence of any other type of graphite than A-type. Ferro silicon as inoculant is also seen to produce A-type, 4-6 flake size graphite. However aluminium -silicon when used as an inoculant does not have much influence in modifying the graphitein base metal structure. Thisisalso true for silicon carbide. Silicon carbide - calcium silicide mixedinthe ratioof1:1, 2:1, 3:1 and 4:1 have modified the graphite to A-type, 5-7 flake size. However such combinations of inoculantsareunableto avoid the formation of B, D and E types of graphite. Silicon carbide - ferrosilicon mixed in the ratio of 1:1, 1:3 and 2:1 have also produced A-type, 5-7 flake size graphite. Again thesecombinations havefailedtoavoidtheformationofDand E types of graphite. EUTECTIC CELL COUNT Histogram shown in Fig. 3.7 reveals the following: Figure 0.7 Variation in cell count with inoculant.
3.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 173 a) Calcium silicide has improved the cell count of the base metal by 8-10 times. b) Ferro silicon also has improved the cellcount of thebase metal by 5-6 times. c) Ferro silicon and calcium silicide in the ratio of 1:1 have improved the cell count of the base metal to the extent of 6-8 times. d) Aluminum silicon has improved the cell count of base metal to an extent of 3-4 times. e) The mixtures of silicon carbide and Ferro-silicon in various proportions are also found to improve the cell count of the base metal by 3-5 times. f) The mixtures of silicon carbide and calcium silicide in various proportions are also FOUND TO IMPROVE the cell count of the base metal to an extent of 7-8 times g) Silicon carbide has failed to increase the eutectic cell count of the base metal. ULTIMATE TENSILE STRENGTH It is observed from Fig. 3.8 that Figure 0.8 Variation in ultimate tensile strength with inoculant. I. Greycastironinoculatedwithcalciumsilicidehasgota tensile strength about 40% greater than that inoculated with silicon carbide and base metal. II. Grey cast iron inoculated with Ferro-silicon has got a tensile strength about 25-30% greater than that inoculated with silicon carbide. III. Grey cast iron inoculated with aluminum silicon has got a tensile strength about 15% greater than that inoculated with silicon carbide. IV. grey cast iron inoculated with silicon carbide exhibits a very low ultimate tensile strength V. Grey cast iron inoculated with mixture of ferrosilicon-calcium silicide in the ratio 1:1hasgota tensile strength about 35% greater than that inoculated with silicon carbide. VI. grey cast iron inoculated with mixture of silicon carbide, calcium silicide, and silicon carbide- ferrosilicon in different ratios have got a tensile strength about 15 - 35% greater than that inoculated with silicon carbide. WEDGE VALUE Figure 3.9 indicates that a) Calcium silicide and ferrosilicon have aided in bringing down the chill depth to almost nil b) Addition of aluminum silicon, the mixture of silicon carbide-calcium silicide and the mixture of silicon carbide-ferrosilicon have aided in decreasing the chill depth c) Silicon carbide has not appreciably changed the wedge depth of base metal. Figure 0.9 variation of chill depth with inoculant HARDNESS Therehasnotbeenmuchvariationinthehardnessvalueofgreycast ironinoculatedwithcalcium silicide, Ferro silicon, mixture of Ferro silicon-calcium silicideintheratio1:1aluminumsilicon and mixture of silicon carbide-Ferro silicon and of silicon carbide-calcium silicide (Fig 3.10). Figure 0.10 variation in Brinell hardness number with inoculant
4.
International Research Journal
of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 04 Issue: 09 | Sep -2017 www.irjet.net p-ISSN: 2395-0072 © 2017, IRJET | Impact Factor value: 5.181 | ISO 9001:2008 Certified Journal | Page 174 CONCLUSIONS 1. The present investigation has revealedthatcalcium silicide is a better potential inoculant when compared to other inoculants tried. 2. Both ferrosilicon and mixture of CaSi & FeSi (1:1) act as good inoculants. 3. AISi also acts as an inoculant but does not modify the graphite structure. 4. Silicon carbide is not a potential inoculant of grey cast iron. REFERENCES 1. David P. Kanicki, Associate Editor - "Cast iron inoculation : understanding the basics', Modern Casting, August 1979. 2. Dawson J.V. Foundry Trade Journal, April 25 (1985) 3. Venku Reddy, Assistant General Manager, Foundry Division, H.M.T. I & LI, Bangalore "Addition of inoculation technique of cast iron". 4. Dawson J.V. and W. Oldfield, Eutectic cell count - An index of metal quality, B.C.1.R.A. Research Department Reports No. 536.
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