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DROSS IN DUCTILE IRON

by
Hans Roedter, Sorelmetal Technical Services

WHAT IS “DROSS”? magnesium with other elements. Dross also

Dross is a reaction product which is formed from occurs in the form of long stringers instead of
Mg treatment and during subsequent reoxidation concentrated “slag like” areas. When it occurs in
of Mg rejected from the molten metal before it this string like form it acts like cracks or flake
solidifies. It is therefore just another word for a graphite in the structure and so fatigue strength
specific type of slag (reaction product). and impact strength of the material are lowered
considerably.
The reaction binds magnesium with sulphur,
oxygen and silicon and forms continuously.
This “dross” is light weight and so it will generally
be found in the upper surfaces and under cores,
but it can be entrained throughout the metal as
well, especially with colder pouring tempera-
tures.
It is very difficult to completely avoid the reaction
of magnesium with these other elements, since
we need magnesium to form nodules. We are
always confronted with the problem of dross in
the production of Ductile Iron.

WHAT IS PROMOTING “DROSS” AND WHAT CAN BE

DONE TO KEEP THE “DROSS” OUT OF THE CASTING?
Since “dross” is always connected with
magnesium, it is necessary to keep the
magnesium level as low as possible. Good
inoculation practice with some late inoculation in
conjunction with sufficient magnesium will
When looking at “dross” in the microscope you produce nice round small nodules. See
will almost always find flake graphite in Suggestion Sheet 76.
association with the dross. The reason for this is
insufficient magnesium due to the reaction of
If the CE (Carbon Equivalent) is high there is “SMOOTH METAL FLOW IS NECESSARY FOR CLEAN
more danger to promote “dross”. The use of CASTINGS”
stronger inoculation materials and some late The cleanness of a melt is directly related to the
inoculation will usually require a smaller overall charge materials and melting practice. If you
addition allowing for lower silicon content and a use rusty, oxidized charge materials, such as
lower CE. Most inoculants are supporting the can occur in thin steel scrap, there is the danger
formation of “dross”. So this is another reason to to get more slag and a high amount of
keep the addition amount as small as possible. undissolved oxides in the melt. Today, more
melting is done in medium frequency furnaces
All reactions change with changes in tapping and
where you have less stirring/movement during
pouring temperatures. The amount of dross
the melting operation than in main frequency
formed is significantly increased at lower
furnaces and you will then find more of these
temperatures. Heavy - sectioned castings
products in the melt.
normally are cast at low temperature to reduce
primary shrinkage. This therefore increases the The Mg treatment and type of treatment alloy
possibility to find more dross, since Si can has a great influence on the formation and
oxidize on the surface of the iron specifically at quantity of dross. It is suggested to use a
these lower temperatures and reacts with Mg. In treatment process where you have a high Mg
general then it is advisable to cast Ductile Iron yield. As the total amount of magnesium is
castings “hot”. The use of a safety riser (on reduced you will get also less dross. Since the
riserless castings) can compensate for the “dross” is a small and low-density product, which
additional primary shrinkage seen. is “swimming” in the melt, it needs a long time to
rise up to the surface. To bring the “dross”
“Dross” is also formed because of turbulence in
quickly out of the melt you have to coagulate the
the treatment, pouring from the treatment ladle
“dross” by having high turbulence in treatment
to the pouring ladle and during filling of the
(higher Mg content alloys) or to use materials to
mould. The filling of the mould is best done so
coagulate the reaction products in the melt which
that the iron is entering the mould from the
will help to clean the iron.
bottom side. Since there is a high temperature
loss during filling of the mould, you should use For additional information about reducing dross
enough or larger ingates to fill the mould quickly in your castings consult Rio Tinto’s publications
with the minimum amount of turbulence. One on Ductile Iron Production and Gating & Risering
possible cause is from having too small a System Design.
downsprue for a given choke area.
The gating system is the place where the melt
can “pull” oxygen through the moulding sand
which will form “dross”. Therefore the gating
system should be always a pressurized filling
system. Dross can even form in the runner
system on the way to the mould cavities.
Therefore it is good to place filters at a location
just before the iron is entering the mould cavity.
The choke should be directly at the gates or the
filter. Sometimes it is necessary to use ceramic
inserts or tile to form the gating and filling
system. Lap type defects and “elephant skin”
surface defects are extreme examples of
magnesium silicate dross formed at low pouring
temperatures.

REV – March 2006