84

CONTROLLING THE CHEMISTRY AND THE

CHARGE MAKEUP BASED ON THE TYPE OF IRON
AND THE SECTION SIZE IS VERY IMPORTANT
by
James D. Mullins, Sorelmetal Technical Services

The percentage of carbon, silicon, carbon equivalent (CE) and magnesium must be correct for the casting
controlling section size. (The magnesium content, based on casting modulus was depicted in Suggestions Sheet
76). The casting section size helps to describe the cooling rate of the casting. Together chemistry and cooling rate
serve to determine the microstructure.
The type of metal to be produced whether either predominately ferritic or pearlitic will also require changes in the
contents of silicon (which also changes the CE) and manganese. Table 1 shows the changes necessary in the
chemistry for matrix type and section size, unless the customer metal specification dictates otherwise. The reader
is referred to The Sorelmetal Book of Ductile Iron, chapter 4, for further information about controlling the chemistry
in Ductile Iron.
TABLE 1 (REVISED IN 2004)
GENERAL RECOMMENDATIONS FOR CARBON AND SILICON CONTENTS FOR
DUCTILE IRON CASTINGS WITH DIFFERENT WALL THICKNESSES

Wall Thickness
Minimum

Desired Matrix As-Cast

Maximum

In
1/8

mm
3

1/4

1/2

12

25

50

75

100

In
1/8
1/4
1/2
3/4
1/4
/2
1
1.5
1/2
1
2
2.5
1
2
3
2
3
4
3
4

Predominantly
Pearlitic
mm
3
6
12
18
6
12
25
37
12
25
50
62
25
50
75
50
75
100
75
100

TC%
3.90
3.85
3.80
3.75
3.85
3.75
3.65
3.55
3.70
3.60
3.50
3.50
3.60
3.50
3.50
3.45
3.40
3.40
3.40
3.40
3.40

Si%
2.90
2.85
2.80
2.70
2.65
2.60
2.55
2.45
2.45
2.40
2.40
2.35
2.35
2.35
2.25
2.20
2.20
2.15
2.20
2..15
2.15

Predominantly
Ferritic
CE
4.87
4.80
4.73
4.65
4.73
4.62
4.50
4.32
4.52
4.40
4.30
4.28
4.38
4.28
4.25
4.18
4.13
4.12
4.13
4.13
4.12

TC%
3.90
3.85
3.80
3.75
3.85
3.75
3.65
3.60
3.70
3.60
3.50
3.45
3.55
3.45
3.45
3.40
3.40
3.35
3.35
3.35
3.35

Si%
2.95
2.95
2.90
2.85
2.85
2.75
2.70
2.65
2.60
2.55
2.50
2.50
2.50
2.50
2.40
2.35
2.35
2.25
2.35
2.25
2.25

CE
4.88
4.83
4.77
4.70
4.80
4.67
4.55
4.48
4.57
4.45
4.33
4.28
4.38
4.28
4.25
4.18
4.18
4.10
4.13
4.10
4.10

NOTE: Suggested silicon levels includes silicon added during inoculation. All castings containing 3 mm (1/8 in) sections or 6 mm (1/4 in) sections at free edges must
be given late inoculation during casting. Pearlitic castings with section thickness exceeding 12 mm (1/2 in) will require an addition of pearlite stabilizer such as cooper
or tin.

The Ductile Iron castings to be produced should be divided up into one of the two matrix types as well as by the
chemistry (related to section size) to be produced. For example, this means that the foundry may have four or more
different charges so as to obtain the correct final chemistry in the right matrix to produce heavy and light section in
two different grades. Shown in the next tables are different typical electric furnace charges that allow the foundry to
make the correct final chemistry in both ferritic and pearlitic grades, in 12 mm (0.5 inch) sections.
TABLE 2
FERRITIC DUCTILE IRON CHARGE FOR SECTION SIZE OF 12 MM (0.5 INCH)

MATERIAL

% CHG

Sorel F1
Returns
Steel Sc.
Graphite
FeSi-50

30.0
50.0
16.0
0.9
1.0

Melt total

97.9

Inocul.
5%MgFeSi

0.7
0.4

TOTALS

RECOVERY

%c

CHG

% Si

CHG

% Mn

CHG

%S

CHG

%P

CHG

1.29
1.85
0.02
0.72

0.18
2.60
0.20
46.00

0.05
1.30
0.03

0.01
0.15
0.55
-

0.00
0.08
0.09

0.013
0.010
0.020
0.040
-

0.004
0.005
0.003
0.000

0.023
0.024
0.030
-

0.007
0.012
0.005

0.80
0.95

4.30
3.70
0.10
99.50
-

3.87
0.95
0.90

100.0

0.44
1.82

46.00
46.00

0.31
0.58

0.17
-

0.012
-

0.024
-

3.87

2.71

0.17

0.012

0.024

Melt and treatment losses

-0.15

-0.08

-0.02

FINAL CHEMISTRY

3.72

2.63

0.15

0.012

0.024

TABLE 3
PEARLITIC DUCTILE IRON CHARGE FOR SECTION SIZE OF 12 MM (0.5 INCH)

MATERIAL

% CHG

Sorel F1
Returns
Steel Sc.
Graphite
FeSi-50

20.0
50.0
25.7
1.4
0.9

Melt total

98.0

Inocul.
5%MgFeSi

0.6
1.4

TOTALS

100.0

RECOVERY

%c

CHG

% Si

CHG

% Mn

CHG

%S

CHG

%P

CHG

0.86
1.85
0.03
1.11

0.18
2.45
0.20
46.00

0.01
1.23
0.05

0.01
0.27
0.60
-

0.00
0.14
0.15

0.013
0.010
0.020
0.040
-

0.003
0.005
0.005
0.001

0.023
0.024
0.030
-

0.005
0.012
0.008

0.80
0.95

4.30
3.70
0.10
99.50
-

3.85
0.95
0.90

0.39
1.68

46.00
46.00

0.26
0.58

0.29
-

0.013
-

0.024
-

3.85

2.52

0.29

0.013

0.024

Melt and treatment losses

-0.15

-0.07

-0.02

FINAL CHEMISTRY

3.70

2.45

0.27

0.013

0.024

Notes
1) To obtain the weight of any charge material or alloy, multiply the % Charge (converted to a decimal number) by the typical charge or batch weight in pounds or
kilograms.
2) The manganese content is kept intentionally low, because it promotes pearlite at lower levels (not wanted in ferritic irons) and of its tendency to segregate and
form carbides at higher levels in pearlitic irons. It is much better to alloy with copper to achieve the correct hardness level.
3) Also see Suggestion Sheets 7, 23-26, 32 and 76.
4) Silicon carbide grain can be added (usually up to 0.2%) for the reduction of iron oxide and protection of the furnace lining. It will replace some of the carbon and
silicon in the charges.
5) The recovery number shown is for the major element either C or Si in the material.
6) To determine the contribution of any charge material multiply the (% charge) times the (recovery) times the (% of element).

REV March 2006