ElFiCast Cored wire for iron foundries

Technical overview of Cored Wire for Ductile Iron treatment

11th International foundrymen conference Croatia, Opatija, April 28 29, 2011

Opatija, April 28th 29th, 2011

Ductile iron cored wire process O. BAHUON

Brief history of Cored Wire process

The cored wire was introduced in the 1980s, first in the steel industry, as a simple and economical way to introduce any element of addition or treatment in deep ladles of liquid metal. The advantage of this method was quickly understood and applications for the treatment of ductile iron was developed. Several types of applications exist today in the elaboration of ductile iron, cored wire can be used for desulfurization, for the treatment of spheroidization, for inoculation in ladle or even just before pouring, and some others applications linked to specific requirements.
Opatija, April 28th 29th, 2011 Ductile iron cored wire process O. BAHUON

Focus on the Nodularization of the ductile iron graphite

Difficulties => Introduce the magnesium (boiling temperature at 1090 C) in liquid iron at 1450 C => Limited sobubility of magnesium in the liquid iron
Opatija, April 28th 29th, 2011 Ductile iron cored wire process O. BAHUON

Advantages of Cored Wire process

Metallurgical Cost Health & Safety Storage Lower Dispersion
High Consistency No Risk of Human Error Automation High Productivity Safe Use of Hazardous material Clean & Easy Handling Material Identified Injection parameters adjusted after the filling of the ladle

Reduction of Mg Targeted high metal quality

Opatija, April 28th 29th, 2011 Ductile iron cored wire process O. BAHUON

Savings using Cored Wire

Unknow parameters (weigth)

Aim Using Lumps

SAVINGS

Aim Using CW % min Scattering Cored Wire addition

Opatija, April 28th 29th, 2011

Ductile iron cored wire process O. BAHUON

Components of the Cored Wire treatment process

1) Consumable => wire + addition process 2) Equipment => Ladle + feedings equipment 3) Liquid Iron

To highlight the benefits of Cored Wire process we need to apply the best practices on these components
Opatija, April 28th 29th, 2011 Ductile iron cored wire process O. BAHUON

What do we need for to produce 1 an effective and efficient cored wire ? Choice and control of raw materials Chemistry, sizing, flowability, ISO certified suppliers Homogeneous and consistent powder metric weight weighting and blending in-situ Automatic control of each individual powder feeding & weighting system Mixing just before filling the wire Speed control of the profiling line Prevention of lock seam opening hazards Optimized final packaging Full traceability
Ductile iron cored wire process O. BAHUON

Opatija, April 28th 29th, 2011

Keys success to produce a consistent cored wire

The homogeneity of the composition of the encapsulated powder is guarantied by in-situ weighting and late blending of the single components Avoid to use pre-mix batches

Homogeneity of encapsulated powder (blends)

Consistent filling rate

The consistency of the weight of encapsulated powder (grams of powder per meter of wire) all along the wire is obtained by using a permanent servo-controlled weighting system during filling Avoid to fill the wire at constant volume

Opatija, April 28th 29th, 2011

Ductile iron cored wire process O. BAHUON

Feeding equipment

- Memory of coiling - Flattening between feeder rolls - high distance between guide tube and ladle - low penetration into the liquid bath (twisting) - Release of Mg on the top of the ladle => poor efficiency non-steady yields Ferrostatic Pressure

Feeding equipment

Cored Wire Injection Practices

Opatija, April 28th 29th, 2011

Ductile iron cored wire process O. BAHUON

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Straight and vertical injection

Straighten the wire to avoid residual constraint Specific feeding equipment with adapted rolls Guiding tube perpendicular to the bath (vertical) Shorter distance between guiding tube and bath No effect of ferrostatic pressure Deeper penetration of wire into the melt Deeper release of the product and longer reaction time with the molten metal High and steady yields
Deep penetration

Opatija, April 28th 29th, 2011

Ductile iron cored wire process O. BAHUON

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Wire straightening

Non-straightened wire
Opatija, April 28th 29th, 2011

Straightened wire
Ductile iron cored wire process O. BAHUON

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Geometry of the treatment ladle

A ratio of H/D = 2 minimum is recommended in order to have the highest metallo-static charge to oppose the magnesium vapor pressure. Also the height of the free board above the liquid surface in the ladle before treatment, must be compatible with the violence of the reaction. H/D is the critical factor for the yield of magnesium, with the same cored wire we can see a double consumption of wire with bad ratio
Opatija, April 28th 29th, 2011 Ductile iron cored wire process O. BAHUON

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Wire diameter link to the ladle

Determinated by Mg content in the powder, requested addition of Mg, and speed of injection. Economy is also a factor, typically higher diameter lead to low price. The goal is to find a wire whose ratio is: weight of powder/weight of wire is as high as possible.

Opatija, April 28th 29th, 2011

Ductile iron cored wire process O. BAHUON

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Temperature of liquid iron

This is the most important factor since temperature dictates the vapor pressure of Magnesium (8 bars at 1400 17 bars C, at 1500 C) Consequently the speed of the Mg vaporization increases. In addition, the instantaneous flow rate of Mg is affected by the injection speed (for a given Mg % in the powder) A greater Mg flow rate associated with liquid iron temperature above 1500 result in poor yields due to a formati on of bigger C bubbles of Mg vapor. And dont forget that solubility of Mg in cast iron decreases with temperature.
Opatija, April 28th 29th, 2011 Ductile iron cored wire process O. BAHUON

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Factors to be considered when treating cast iron

Liquid iron treatment temperature Magnesium rate (for Mg treatment) Liquid iron weight Liquid iron characteristics (oxidation, % S)

Today we can achieve up to 60 % magnesium recovery with a pure magnesium patented cored wire and consistent process

Opatija, April 28th 29th, 2011

Ductile iron cored wire process O. BAHUON

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PAPMAG Technology
External steel sheath Insulation Internal steel sheath

Insulation which delays the heat transfer, thus protects the Magnesium (~1 second) deeper penetration of Mg into the liquid steel. reduces the heat from thermal

radiation. optimizes the wire guiding

Powder

Dramatic Improvement in Mg Recovery Very Steady Results Highly Predictable Results

Deep penetration

Pioneer, Leader, AFFIVAL is your innovative and sustainable partner.

Thank you for your attention

Opatija, April 28th 29th, 2011

Ductile iron cored wire process O. BAHUON

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Wire Feeding in Foundry

Opatija, April 28th 29th, 2011

Ductile iron cored wire process O. BAHUON

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Wire Feeder for foundries

Speed injection range: 0 to 120 m/min Very accurate and steady injection speed (cm/min) Very accurate length of wire fed (mm) Light equipment easy to locate (ladle, mould ) Customizable equipment for any customer requirement

Opatija, April 28th 29th, 2011

Ductile iron cored wire process O. BAHUON

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Treatment booth for foundry

Opatija, April 28th 29th, 2011

Ductile iron cored wire process O. BAHUON

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Treatment Booth

Wire feeder Entry guides Exit guide tubes Movable ladle cover Sliding Door De-dusting system compatible (not provided) Possible full automation All treatment
Nodularization Inoculation
Opatija, April 28th 29th, 2011 Ductile iron cored wire process O. BAHUON

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Treatment booth for foundry

Opatija, April 28th 29th, 2011

Ductile iron cored wire process O. BAHUON

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