Magnesium Treatment Fluctuates!

Some reasons
Some solutions

By the TECHNICAL SERVICE of SORELMETAL

India - September 2011 SORELMETAL PM.Cabanne 1

This is often discussed during our foundry visits.
Recommendations are easy to give if the foundry has the
process under control (weigh, temperature, %, … )!
However, different parameters need to be analyzed.
Remember:
FeSiMg ~= 2000 € / T or ~= 24 € / T of liquid DI

India - September 2011 SORELMETAL PM.Cabanne 2

 General formula for quantity of FeSiMg:
-3
( Mg final + 0.76 (Si - Sf) + 10 t ) T°C 2
W FeSiMg = W ladle x
% Mg FeSiMg x R
x ( 1450 )
Where:
W FeSiMg = weight of FeSiMg in Kg W Ladle = weight of ladle in Kg
Mg final = % of Mg in liquid iron after treatment
% Mg FesiMg = % of Mg in the FeSiMg alloy
Si , Sf = initial & final Sulfur in the iron in %
t = time between treatment and beginning of pouring in mn
T = temperature of iron in °C
R = yield of the treatment

India - September 2011 SORELMETAL PM.Cabanne 3

 Effect of each parameter:
W Ladle = weight of the ladle in Kg :
Only the core wire process takes into account the weight of liquid DI in the ladle.
The other processes are influenced.
-3
( Mg final + 0.76 (Si - Sf) + 10 t ) T°C 2
A fluctuation of +/- 5% is “normal” and
automatically generates variations on the
W FeSiMg = W ladle x
% Mg FeSiMg x R
x
( 1450 )
final Mg Target Effective ∆ in %
W ladle Kg 1000 1050 5.00

A balance Mg FeSiMg % 6 6 0.00

Good hydraulic lay-out on the R % 60 60 0.00

furnace. Low speed at the end Mg final % 0.0350 0.0329 -5.96

Good design for the furnace Si % 0.01 0.01 0.00

neck and ladle Sf % 0.005 0.005 0.00

Good exhaust system t mn 5 5 0.00

Training for operators T °C 1450 1450 0.00

W FeSiMg Kg 12.17 12.17 0.00
…

India - September 2011 SORELMETAL PM.Cabanne 4

 Effect of each parameter:
W FeSiMg = weight of FeSiMg in Kg :
All the Mg treatment processes present a possible variations on the FeSiMg weight
.
-3
( Mg final + 0.76 (Si - Sf) + 10 t ) T°C 2
A fluctuation of +/- 1% is frequent
(accuracy of the balance)
W FeSiMg = W ladle x
% Mg FeSiMg x R
x ( 1450 )
Target Effective ∆ in %
W ladle Kg 1000 1000 0.00

A clean balance with calibration Mg FeSiMg % 6 6 0.00

Frequent audits of the automatic R % 60 60 0.00

distributors Mg final % 0.0350 0.0355 1.37

Capability of the balance Si % 0.01 0.01 0.00

Sf % 0.005 0.005 0.00
Training for operators
t mn 5 5 0.00
…
T °C 1450 1450 0.00
W FeSiMg Kg 12.17 12.30 1.10

India - September 2011 SORELMETAL PM.Cabanne 5

 Effect of each parameter:
Si = initial Sulfur:
The best advantage of SORELMETAL versus the others .

-3
( Mg final + 0.76 (Si - Sf) + 10 t ) T°C 2
Depending on the melting process and
charge composition Si fluctuates between
W FeSiMg = W ladle x
% Mg FeSiMg x R
x ( 1450 )
0.08 & 0.01 Target Effective ∆ in %
W ladle Kg 1000 1000 0.00

Good raw material & charge Mg FeSiMg % 6 6 0.00

composition R % 60 60 0.00
Good recarburiser and ferro- Mg final % 0.0350 0.0312 -10.86
alloys Si % 0.01 0.015 50.00
Good process control Sf % 0.005 0.005 0.00
(spectro, Lecco)
t mn 5 5 0.00
& T °C 1450 1450 0.00
W FeSiMg Kg 12.17 12.17 0.00
Sorelmetal ®

India - September 2011 SORELMETAL PM.Cabanne 6

 Effect of each parameter:
Si = initial Sulfur:
The best advantage of SORELMETAL versus the others .
TF10 Others
W ladle Kg 1000 1000
Mg FeSiMg % 6 6
R % 60 60
Mg final % 0.0350 0.0350
Si % 0.0073 0.0153 Sorelmetal ®
Sf % 0.005 0.005
t mn 5 5
T °C 1450 1450
W FeSiMg Kg 11.60 13.29

- 3.38 € /
Cost of Mg treatment € 23.20 26.58
Liquid Ton

India - September 2011 SORELMETAL PM.Cabanne 7

Effect of each parameter:
Sf = final Sulfur:
Final sulfur is more a result of the Mg treatment rather other influencing
parameters.
However, depending on the quality of the FeSiMg (Ce & Ca presence &
value), its % can fluctuate.
The higher the initial sulfur is, the higher the final sulfur will be, the
higher the risk to obtain dross in the casting.
We recommend looking for a final Sulfur: < 0.005% for heavy parts, or
between 0.005 – 0.015 for “usual” castings

Many foundries have decided to switch a “normal” PI for our UHPI

to minimize the dross defect: heavy castings or big thickness,
castings submitted to impact & fatigue, …

India - September 2011 SORELMETAL PM.Cabanne 8

 Effect of each parameter:
Mg final = final Mg before pouring:
The final Magnesium before pouring depends on:

the casting thickness

the level of S, Zn and free oxygen in the iron (quality of charge

material, melting process)

the time between the first mold and last one (in
that case the time t will include this period – next slide)
-3
( Mg final + 0.76 (Si - Sf) + 10 t ) T°C 2
W FeSiMg = W ladle x
% Mg FeSiMg x R
x ( 1450 )
India - September 2011 SORELMETAL PM.Cabanne 9
 Effect of each parameter:
Mg final = final Mg before pouring:
The final Magnesium before pouring depends on the level of S, Zn and free oxygen
in the iron (quality of charge material, melting process):
% Mg final(spectro)= MgS + MgO + MgZnO3 + MgX + Mg free
Only the free Mg promotes the nodularization, and a very small part of MgS and
MgO will create some nucleis !
Many defects (like poor graphite shape) come from too low free Mg.
Thus we ought to look at the PI ratio, like our HPI, to minimize the presence
of free O, S and Zn from steel scraps!

However, a high Magnesium creates or promotes defects as well:

carbides, dross, micro-shrinkage !!!!!

India - September 2011 SORELMETAL PM.Cabanne 10

 Effect of each parameter:
%Mg FeSiMg = % of Mg in FeSiMg:

Often, this ratio is overlook. But a FeSiMg

5-7 presents a natural variation close to 0.5
(+ 0.25%): -3
( Mg final + 0.76 (Si - Sf) + 10 t ) T°C 2
different lots, grain size segregation, grain size, origin, W FeSiMg = W ladle x
% Mg FeSiMg x R
x ( 1450 )
…
Target Effective ∆ in %
W ladle Kg 1000 1000 0.00

A good supplier Mg FeSiMg % 6 5.8 -3.33

Frequent audits of the melting R % 60 60 0.00

platform Mg final % 0.0350 0.0335 -4.17

Capability on the product Si % 0.01 0.01 0.00

Sf % 0.005 0.005 0.00
Training for operators
t mn 5 5 0.00
…
T °C 1450 1450 0.00
W FeSiMg Kg 12.17 12.17 0.00

India - September 2011 SORELMETAL PM.Cabanne 11

 Effect of each parameter:
‘t = time between end of treatment and beginning of pouring
Only a fluctuation of 2 mn between treatment and pouring decreases the level of
Mg by 0.002. Causes are mainly due to transport and slag removing.
Excesses of slag comes from the quality of the melting -3
( Mg final + 0.76 (Si - Sf) + 10 t ) T°C 2
process and more from the quality of charge material:
sand, rust, sterile, steel coating, …
W FeSiMg = W ladle x
% Mg FeSiMg x R
x ( 1450 )
Target Effective ∆ in %
W ladle Kg 1000 1000 0.00

Good maintenance and Mg FeSiMg % 6 6 0.00

transportation machine R % 60 60 0.00
Training for operators Mg final % 0.0350 0.0330 -5.71

And Si % 0.01 0.01 0.00

Sf % 0.005 0.005 0.00
GOOD RAW MATERIAL to
minimize dirt & slag t mn 5 7 40.00
T °C 1450 1450 0.00
W FeSiMg Kg 12.17 12.17 0.00

India - September 2011 SORELMETAL PM.Cabanne 12

 Effect of each parameter:
‘t = time between end of treatment and beginning of pouring or
time between Mg treatment and last mold:
For a final Mg of 0.035 %:
If total pouring period is 15 mn, the FeSiMg -3
needed is 14,94 Kg ( Mg final + 0.76 (Si - Sf) + 10 t ) T°C 2
W FeSiMg = W ladle x
% Mg FeSiMg x R
x ( 1450 )
If this time becomes only 10 mn,
mn thus the Optimized Normal in %
need decreases to 13,56 Kg
W ladle Kg 1000 1000 0.00
Mg FeSiMg % 6 6 0.00
Good maintenance and R % 60 60 0.00
transportation machine Mg final % 0.0350 0.0350 0.00
Si % 0.01 0.01 0.00
Training for operators
Sf % 0.005 0.005 0.00
Ladle with cover t mn 10 15 50.00
T °C 1450 1450 0.00
Automatic pouring line
W FeSiMg Kg 13.56 14.94 10.25
…

India - September 2011 SORELMETAL PM.Cabanne 13

 Effect of each parameter:
T °C = treatment temperature
The treatment temperature is the addition of:
Pouring temperature (function of casting thickness
and type of risering)
+
Loss of temperature during transfer and pouring
Worldwide reference
+ for DI foundry
Loss of temperature during the treatment information

Between 5 to 12°C
10 Kg of “cold” ferro-alloy per minute
in a ladle (1Ton – 1500°C)
decreases the temperature
by 15°C

India - September 2011 SORELMETAL PM.Cabanne 14

 Effect of each parameter:
T °C = treatment temperature
An increase of pouring temperature by 50°C
decreases the final magnesium by 0.003
-3
( Mg final + 0.76 (Si - Sf) + 10 t ) T°C 2
W FeSiMg = W ladle x
% Mg FeSiMg x R
x ( 1450 )
Target Effective ∆ in %
W ladle Kg 1000 1000 0.00

Insulating refractory + cover Mg FeSiMg % 6 6 0.00

for ladle (s) R % 60 60 0.00
Small addition in the ladle Mg final % 0.0350 0.0321 -8.20

Quick transfer (s) and short Si % 0.01 0.01 0.00

Sf % 0.005 0.005 0.00
pouring period
t mn 5 5 0.00
T °C 1450 1500 3.45
W FeSiMg Kg 12.17 12.17 0.00

India - September 2011 SORELMETAL PM.Cabanne 15

 Effect of each parameter:
R = yield of the treatment:
From the mathematical formula, we automatically get the yield, and all the past
parameters could have an influence!
-3
( Mg final + 0.76 (Si - Sf) + 10 t ) T°C 2
R = W ladle x
% Mg FeSiMg x W FeSiMg
x ( 1450 )
However, yield is a typical parameter like the previous. And, it is more a sum of
subjective items than purely a mathematical list:
quality of the spectro and spectro sample, how and where the spectro sample is taken
design, cleanliness of the ladle (body and pocket) and quality of its liner
quality and cleanliness of the steel cover
output of the furnace during the tapping
time between input of FeSiMg and beginning of the tapping
level of oxidation of liquid iron and practice of pre-conditioning
exhaust system directly attached on the ladle as with for core wire process
etc, …

India - September 2011 SORELMETAL PM.Cabanne 16

 Effect of each parameter:
R = yield of the treatment:
-3
( Mg final + 0.76 (Si - Sf) + 10 t ) T°C 2
R = W ladle x
% Mg FeSiMg x W FeSiMg
x ( 1450 )

If all the previous parameters are “under control”, we recommend to recalculate the
yield for each treatment.
In case of major deviation, the foundrymen will be alerted and will check all the
precedent list (previous slide)
For a similar design of ladle and process (melting treatment, …), the yield can move
from 60 to 40% from one foundry to another!!!
Our “job” consists of giving information to our customers or potential customers

India - September 2011 SORELMETAL PM.Cabanne 17

 Summarize:
For the same final Mg = 0.035 %: But for the same weight of FeSiMg
if we take into consideration all the if we take into consideration all the
possible fluctuations (with an “negative” fluctuations (with an
industrial level), the price of the industrial level), the final Mg will
treatment will become: become:
Target with TF10 & well Effetive or
process Others ∆ in % Target Effective ∆ in %
W ladle Kg 1000 1050 5.00 W ladle Kg 1000 1050 5.00
Mg FeSiMg % 6 5.7 -5.00
Mg FeSiMg % 6 5.7 -5.00
R % 60 57 -5.00 R % 60 57 -5.00
Mg final % 0.0350 0.0350 0.00 Mg final % 0.0350 0.0197 -43.71

Si % 0.0073 0.0153 109.59 Si % 0.0073 0.0153 109.59

t mn 5 6 20.00 Sf % 0.005 0.005 0.00

T °C 1450 1500 3.45 t mn 5 6 20.00

W FeSiMg Kg 11.60 16.89 45.62 T °C 1450 1500 3.45
W FeSiMg Kg 11.60 11.60 0.00
∆ in € per liquid
Ton
Cost of Mg
€ 23.20 33.78 10.58
treatment

India - September 2011 SORELMETAL PM.Cabanne 18

Summarize:
The final Magnesium content is one of the most important parameter
to obtain spherical graphite. Possible causes for fluctuation are
multiple.

The quality of the process, including charge materials, is the major

way to get good castings in DI.

RIO TINTO Iron & Titanium, our Agents, our literature, our Technical
Services, and our famous SORELMETAL can help foundries to
maintain magnesium treatment under control.

India - September 2011 SORELMETAL PM.Cabanne 19

India - September 2011 SORELMETAL PM.Cabanne 20
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