Skip to main content
SpringerLink
Log in

Eutectic Cells and Nodule Count—An Index of Molten Iron Quality

  • Published:
International Journal of Metalcasting Aims and scope Submit manuscript

Abstract

The present work gives a detailed analysis into one of the most important quality parameters in cast iron, namely the eutectic cells or nodule count. The analysis is based on theoretical fundamentals of cast iron solidification. Expressions are derived and used to relate either the number of cells or the nodule count to factors of technological importance. It is found that such factors are intrinsically related to the chill tendency, pre-shrinkage expansion, shrinkage porosity, shrinkage depression and graphite type. Also, it is shown that the resultant mechanical properties of cast iron are strongly influenced by the foundry practice. In particular, it is established that the eutectic cell density or the nodule count is a quality factor reflecting the physical-chemical state of the liquid cast iron at a given cooling rate. In turn, this determines the graphite nucleation potential of cast iron which can be used to incorporate all of the technological factors associated with melt preparation.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Fraś, E., Górny, M., Lopez, H.F., “Chilling Tendency and Nodule Count in Ductile Cast Iron Part I — Theoretical Background,” AFS Transactions, vol. 114, pp. 575–594 (2006).

    Google Scholar 

  2. Fraś, E., Górny, M., Lopez, H.F., “Chilling Tendency and Nodule Count in Ductile Cast Iron Part II — Experimental Verification,” AFS Transactions, vol. 114, pp. 595–603 (2006).

    Google Scholar 

  3. Fraś, E., Górny, M., Lopez, H.F., “The Transition from Gray to White Iron during Solidification, Part I — Theoretical Background,” Metallurgical and Materials Transactions A, vol. 36A, pp. 3075–3082 (2005).

    Google Scholar 

  4. Fraś, E., Górny, M., Lopez, H.F., “Eutectic Cell Count, Chilling Tendency and Chill in Flake Graphite Iron, Part II-Experimental,” AFS Transactions, vol. 115, pp. 453–465 (2007).

    Google Scholar 

  5. Nicholas, K.E., “Inoculation and Casting Expansion,” British Cast Iron Research Association Journal, no.1, pp. 103–116 (1961).

  6. Vondrak, V., “Einfluss der Vorschwidungsausdehnung Auf die Lunkerbildung Bei Gusseisen mit Kugelgraphit,” Giesserei, no. 4, pp. 84–88 (1971).

  7. Lesoult, G., Castro, M., Lacaze, J., “Solidification of Spheroidal Graphite Cast Iron: III Microsegregation Related Effects,” Acta Materialia, vol. 47, pp. 3779–3792 (1999).

    Article  Google Scholar 

  8. Achmadabi, M.N., Niyama, E., Ohide, T., “Structural Control of 1% Mn ADI Aided by Modelling of Microsegregation,” AFS Transactions, vol. 97, pp. 269–278 (1994).

    Google Scholar 

  9. Ruff, G.F., Doshi, B.K., “Relation Between Mechanical Properties and Graphite Structure in Cast Irons, Part I-Gray Iron,” Modern Casting, pp. 50–55 (June 1980).

  10. Soufe, M., Okada, S., Sasaki, T., “High Quality Ductile Cast Iron with Improved Fatigue Strength,” AFS Transactions, vol. 86, pp. 173–182 (1978).

    Google Scholar 

  11. Ruff, G.F., Doshi, B.K., “Relation Between Mechanical Properties and Graphite Structure in Cast Irons, Part II-Ductile Iron,” Modern Casting, pp. 70–74 (June 1980).

  12. Javaid, A., Thompson, J., Davis, K.G., Sahoo, M., “Effect of Microstructure on the Mechanical Properties Thin-Wall Ductile Iron Castings,” AFS Transactions, vol. 109, pp. 1097–1114 (2001).

    Google Scholar 

  13. Rebasa, N, Dommarco, R., Sikora, J., “Wear Resistance of High Nodule Count Ductile Iron,” Wear, vol. 253, pp. 855–861 (2002).

    Article  Google Scholar 

  14. Fraś, E., Kapturkiewicz, W., Burbielko, A.A, Lopez, H.F., “Secondary Nucleation of Eutectic Grains,” AFS Transactions, vol. 104, pp. 1–4 (1996).

    Google Scholar 

  15. Stefanescu, D.M. “Science and Engineering of Casting Solidification,” Kluwer Academic/Plenum Publishers, New-York, Boston, Dordecht, London, Moscow, (2002).

    Book  Google Scholar 

  16. Ruxanda, R.E., Stefanescu, D.M., Piwonka, T.S., “Microstructure Characterization of Ductile Thin Wall Iron Castings”, AFS Transactions, vol. 110, pp. 1131–1147 (2002).

    Google Scholar 

  17. Ryś, J., Stereology of Materials, Fotobit-Publishers, Cracow (1995).

  18. Wiencek, K., Ryś, J., “The Estimation of Fe3C Particle Density in Steel by Simple Counting Measurements Made in Plane Sections,” Journal of Materials Engineering, No. 3, pp. 396–399 (1998).

  19. Osher, J., Quantitative Gefuengenanalysie, DVG, Leipzig-Stuttgard (1994).

  20. Zukov, A.A., Sneznoy, R.J., Girsovich, N.G., “Soviet Research Work on the Liquid State of Cast Iron,” International Cast Metals Journal, vol. 1, pp. 11–19 (1976).

    Google Scholar 

  21. Podrzucki, C., Cast Iron, STOP-Publishers, Cracow (1991).

  22. Steeb S., Maier, U., “Structure of Molten Fe-C Alloys by Means of X-Ray and Neutron Wide-Angle Diffraction as Well as Sound Velocity Measurements,” The Metallurgy of Cast Iron, Editors, B. Lux, I. Minkoff, F. Mollard, Georgi Publishing Company, St Saphorin, Switzerland, pp. 1–11 (1975).

    Google Scholar 

  23. Fraś, E., Wiencek, K., Górny, M., Lopez, H., “Graphite Nodule and Eutectic Cell Count in Cast Iron, Theoretical Model Based on Weibull Statistics and Experimental Verification,” Metallurgical and Materials Transactions A, vol. 38A, pp. 385–395 (2007).

    Google Scholar 

  24. Lesoult, G., Castro, M., Lacaze, J., “Solidification of Spheroidal Graphite Cast Irons-I, Physical Modelling,” Acta Materialia, vol. 46, pp. 983–995 (1998).

    Article  Google Scholar 

  25. Juretzko, F.R., Dix, L.P., Ruxanda, R., Stefanescu, D.M., “Precondition of Ductile Iron Melts for Light Weight Casting: Effect on Mechanical Properties and Microstructure,” AFS Transactions, vol. 112, pp. 773–785 (2004).

    Google Scholar 

  26. Fraś, E., Górny, M., Lopez, H.F., “Eutectic Cell and Module Count in Cast Iron, Part I Theoretical Background,” International Steel and Iron Japan Institute, vol. 47, no. 2, pp. 259–268 (2007).

    Article  Google Scholar 

  27. Merchant, H.D., Torriello, L.J, Wallace, J.F., “Inoculation Influence on Gray Cast Iron Structure at Various Carbon Equivalences,” Modern Casting, vol. 39, no. 5, pp. 109–116, (1961).

    Google Scholar 

  28. Merchant, H.D., “Solidification of Cast Iron,” Recent Research on Cast Iron, Gordon and Breach Science Publishers, New York, pp. 1–100, (1968).

    Google Scholar 

  29. Gilbert, G.N.J., “The Effect of Phosphorous on the Mechanical Properties of Flake Graphite Cast Iron,” 1959, British Cast Iron Research Association Journal of Research and Development, vol. 7, no. 12, pp. 692–724 (1959).

    Google Scholar 

  30. Morrogh, H., “The Solidification of Cast Iron and the Interpretation of Results Obtained from Chilled Test Pieces,” British Foundryman, vol. 53, No. 5, pp. 221–242 (1960).

    Google Scholar 

  31. Oldfield, W., “The Solidification of Hypo-eutectic Grey Cast Iron,” British Cast Iron Research Association Journal, January, Report 532, pp. 177–192 (1960).

  32. Fraś, E., “Analiza Modyfikatorów Grafityzujących,” Przeglad Odlewnictwa, no. 10, pp. 314–320 (1973).

  33. Hummer, R., “Some Aspects of Inoculation of Flake and Nodular-Graphite Cast Iron,” The Metallurgy of Cast Iron, Georgi Publishing Company, St. Shaporin, Switzerland, pp. 147–159 (1975).

    Google Scholar 

  34. Mullins, J., “Nodule Count-Why and How,” http://www.ductile.org./magazine/2003-2/nodule-count.htm.

  35. Onsoien, M.,I., Skaland, T., Grong, O., “Mechanisms of Graphite Formation In Ductile Cast Iron Containing Cerium and Lanthanum,” International Journal of Cast Metals Research, vol. 11, pp. 319–324 (1999).

    Google Scholar 

  36. Hughes, I.C., Davson, J.V., “Strontium-Containing Ferro-Silicon Inoculant,” Foundry Trade Journal, vol. 125, pp. 313–321 (1968).

    Google Scholar 

  37. Dopp, R., Prinz, K., Reffercheid, E., Schurmann, E., Shulze, T., “Contribution to the Influence on Magnesium Treatment, the Inoculation and the Wall Thickness on the Formation of Spherulites in Ductile Iron,” 60th World Foundry Congress, Hague, pp. 432–438 (1993).

  38. Fraś, E., Serrano, J.T, Bustos, A., “Fundiciones de hierro-estructuras, propiedades fabricacion,” ILAFA, Santiago/Chile, (1990).

    Google Scholar 

  39. Girsovich, N.G., “Solidification and Properties of Cast Iron,” Maszgis-Publishers, Moscow (1966).

    Google Scholar 

  40. Fraś, E., Lopez, H., Podrzucki, C., “The Influence of Oxygen on the Inoculation Process of Cast Iron,” International Journal of Cast Metals Research, vol. 13, pp. 107–121 (2000).

    Google Scholar 

  41. Frost, J.M., Stefanescu, D.M., “Melt Quality Assessment of SG Iron through Computer-Aided Cooling Curve Analysis,” AFS Transactions, vol. 100, pp. 189–200 (1992).

    Google Scholar 

  42. Sweden, D.J., Wilford, C.F., “The Nucleation of Graphite from Liquid Iron: A Phenomenological Approach,” The British Foundryman, May, 118–127 (1976).

  43. Elliot, R., Cast Iron Technology, Butterworths, London (1988).

    Google Scholar 

  44. Popescu, M., Thomson, J., Zavadil, R., Sahoo, M., “Summary of AFS Research Project on Restoring Techniques for Monday Morning Iron-Phase I,” AFS Transactions, vol. 110, pp. 1047–1065 (2002).

    Google Scholar 

  45. Popescu, M., Zavadil, R., Thomson, J., Sahoo, M., “Studies to Improve Nucleation Potential of Ductile Iron When Using Carbidic Ductile Iron Returns,” AFS Transactions, vol. 115, pp. 591–608 (2007).

    Google Scholar 

  46. Fredriksson, H, Svensson, H., “Computer Simulation of the Structure Formed during Solidification of Cast Iron,” The Physical Metallurgy of Cast Iron, Editors H. Fredricsson, M. Hillert, North-Holland, New York, pp. 273–284 (1985).

    Google Scholar 

  47. Showman, R.E., Aufderheide, R.C., “A Process for Thin-Wall Sand Castings,” AFS Transactions, vol. 111, pp. 567–578 (2003).

    Google Scholar 

  48. Midea, T., Shah, J.V., “Mold Material Thermophysical Data,” AFS Transactions, vol. 110, pp. 121–136 (2002).

    Google Scholar 

  49. Fraś, E., Górny, M., Lopez, H.F., “Eutectic Cell Count, Chilling Tendency and Chill in Flake Graphite Cast Iron, Part I, Theoretical Background,” AFS Transactions, vol. 115, pp. 435–451 (2006).

    Google Scholar 

  50. Giacopini, A., Boeri, R.E., Sikora, J.A., “Carbide Dissolution in Thin Wall Ductile Iron,” Materials Science and Technology, vol. 19, pp. 1755–1760, (2003).

    Article  Google Scholar 

  51. Fraś, E., Lopez, H., “Generation of Internal Pressure during Solidification of Eutectic Cast Iron,” AFS Transactions, vol. 102, pp. 597–601 (1994).

    Google Scholar 

  52. Yang, Y., Albanian, J., “Functional Improvement of Dilatation Analysis on Thermal Analysis for SQ Iron Quality Estimation,” Physical Metallurgy of Cast Iron, Scitec Publications, pp. 433–438 (1997).

  53. Morrogh, M., “The Status of the Metallurgy of Cast Irons,” Journal of the Iron and Steel Institute, January, pp. 1–10 (1968).

  54. Stefanescu, D.M., Qui, H.Q., Chen, C.H., “Effects of Selected Metal and Mold Variables on Dispersed Shrinkage in SG Cast Iron,” AFS Transactions, vol. 103, pp. 189–197 (1995).

    Google Scholar 

  55. Fraś, E., Solidification of Metals, Warsaw, WNT (2003).

    Google Scholar 

  56. Fullman, R.I., “Measurement of Particle Sizes Opaque Bodies,” Transactions of Metallurgical Society of AIME, vol. 197, pp. 447–452 (1953).

    Google Scholar 

  57. Hellal, F., Lacaze, J., Hazotte, G., “Initial Stage of Isothermal Decomposition of Austenite to Ferrite and Graphite in Spheroidal Graphite Cast Iron,” Materials Science and Technology, vol. 15, no. 7, pp. 773–777 (1999).

    Article  Google Scholar 

  58. Fraś, E., Górny, M., “Structure of Thin Wall Austempered Ductile Iron (TWADI),” Science and Processing of Cast Iron, VIII, Tsinghua University Press, Beijing, pp. 157–162 (2006).

    Google Scholar 

  59. Bauer, W., Nechtelbergen, E., “New Investigations on the Relationship between Wall Thickness and Strength of Unalloyed Cast Iron with Flake Graphite,” AFS Transactions, vol. 99, pp. 125–131 (1991).

    Google Scholar 

  60. Cooper, G., Roebuck, A., Gayati, H., Elliot, R., “The Influence of Nodule Count on the Austempering Kinetics of a Mn-Cu Ductile Iron,” International Journal of Cast Metals Research, no.11, pp. 227–235 (1999).

Download references

Author information

Authors and Affiliations

  1. University of Science and Technology, Cracow, Poland

    E. Fraś

  2. University of Wisconsin-Milwaukee, Milwaukee, WI, USA

    H. López

Authors
  1. E. Fraś
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. H. López
    View author publications

    You can also search for this author in PubMed Google Scholar

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Fraś, E., López, H. Eutectic Cells and Nodule Count—An Index of Molten Iron Quality. Inter Metalcast 4, 35–61 (2010). https://doi.org/10.1007/BF03355497

Download citation

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/BF03355497

Keywords

Search

Navigation