Technical Information 22

Late Metal Stream Inoculation

With increasing demands from end-users for higher quality castings and increasing
numbers of foundries investing in highly mechanised moulding and pouring lines, the
requirements for effective inoculation are becoming more difficult to meet.

Non-uniform inoculation from conventional ladle treatments can arise, caused by

variations in metal temperature, human error in addition and the accepted deterioration of
inoculating effect with time (fade). Further, particular difficulties can arise in some pouring
units where satisfactory addition of inoculant is not possible.

Automatic high production moulding lines linked to either a heated or unheated stopper
rod controlled pouring unit have proved to be both highly economic and efficient,
particularly in the repetition section of the industry where high volumes of castings of
consistent metal quality are required.

A method of inoculating this iron between the stopper rod and the downsprue is therefore
essential. The system must be automatic, linked to activation of the stopper rod (or in
some cases activated by light emitted by the metal flow) and be highly reliable. Several
types of inoculating unit are available commercially at variable quality and cost. Whilst
Elkem does not supply such machinery, it is strongly recommended that a system with
adequate safety systems be installed to eliminate the possible requirement for 100%
inspection of castings. Specialist advice on the selection of inoculating units and
recommendations on installation can be obtained through local Elkem representatives.

With high investment in moulding lines, pouring units and inoculating systems, it is logical
to control accurately the quality of the inoculant. This must have:
• Good consistent flowability to ensure that particles of inoculant reach the metal
stream, even at low flow rates through a small orifice in the injection unit.
• A clean cut on the bottom sieve fraction to avoid excessive fines. Undersize
material can contain oxides and the heat from the metal stream tends to blow fine
material into the atmosphere. Variations in the undersize fraction can also lead to
inconsistency in flow rate and possible blockage of the dispensing unit.
• No oversize particles which can block the injection unit.
• Good solubility in the iron to give maximum inoculation effect without leaving hard,
unmachinable inoculant particles which have not dissolved, even at low casting
temperatures.
• Less tendency to give slag inclusions in the iron.

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Technical Information 22 2

With conventional ladle inoculation, the effects of the inoculant begin to fade instanta-
neously and it has been shown that the number of sites available for nucleation deterio-
rates.

Coarsening behaviour of nuclei particles in cast iron during holding.

From this, it can be seen that some 5x105 sites per cubic millimetre of metal are available
immediately after addition of the inoculant, fading to 1x105 after about 10 minutes. With
late metal stream inoculation, fade is virtually eliminated and the addition rate to provide
satisfactory inoculation (chill removal, graphite morphology) is dramatically reduced. See
also Elkem Technical Information Sheet No. 6 on “Fading of Inoculation” for more details.

Typical addition rates:

Cast Iron Ladle Inoculation Late Stream Inoculation
Grey Iron 0.1-0.3% 0.03-0.2%, typical 0.1%
Ductile Iron 0.3-0.6% 0.06-0.3%, typical 0.2%

Elkem provides a complete range of materials suitable for late stream inoculation and
reference should be made to the Data Sheets for Superseed® 50/75, Superseed® Extra,
Zircinoc®, Foundrisil®, Reseed® and Vaxon® 75. These materials are available world-wide
in a 0.2-0.7 mm grading for maximum flowability and solution into the iron. See also Elkem
Technical Information Sheet No. 15 and 16 on “Selection of Inoculants” for more details.
In certain applications a wider grading is acceptable and details are available on request.

The main advantages of late metal stream inoculation are:

• Reduced addition rates compared to ladle inoculation provide an economic benefit.
• Reduced addition rates mean lower calcium and aluminium additions thus leading
to less tendency towards slag and pinholes.
• Avoiding the promotion of high eutectic cell counts that may lead to shrinkage
porosity, again because of the lower addition rates of inoculant.
• Operator error is eliminated.
• Only the metal entering the mould is inoculated, thus avoiding wasteful treatment of
ladle “heels”.