Master Alloy FeSiMg a prcis

Steel
Alloy of Fe & C C = 0.2% to 2.1%

Element abundant in earths crust

Iron

Cast Alloy of Fe, C & Iron Si

C = 1.7 to 4.3% Si = 0.5 to 3%

Iron-Iron Carbide diagram

H K+ L Austenite
Temp C 910 C

Liquid
L + Fe3C

Steel
E+K

K + Fe3C

Cast Iron

723 C

E
0%

E+ Fe3C 0.8% ~2% Carbon wt % ~3%

Cast Iron
Ternary alloy of Fe + C + Si Lower Melting point than Steel Better castability Low cost material use of sand casting Forms used Pipes / Machines / cylinder heads / cylinder blocks / gear boxes

Blast Furnace

Cast Iron Types Gray White Malleable Ductile

1. Gray Cast Iron

C 2.5 4% Si 1 3% Carbon Graphite

Low ductility low elongation 0.6% High Thermal Conductivity / Damping Capacity Gray Iron forms With slow cooling (viz. heavy castings) High Silicon & Carbon

2. White Cast Iron

C Si Carbon Cementite

1.8 3.6% 0.5 2%

Very High Hardness Abrasion Resistance Brittle White Cast Iron Fracture surface is white Can be Heat treated

3. Malleable Cast Iron

C 2 2.6% Si Carbon

1.1 1.6% Graphite

Shock Resistance Ductility & Machinability Malleable Cast Iron Heat treated White Cast iron Thinner Castings Railway Components

4. Ductile Cast Iron

C 3 4% Si Carbon 1.8 2.8% Graphite Nodules

Popular name : SG Iron High Strength >gray cast iron Ductility 6 to 20% Casting of intrinsic shapes Ductile Cast Iron Machinability better than steel Crankshafts / disc brake callipers steering knuckles / Pipe and

Steel Production world wide (2009)

Billion Tons

250 +

50 - 250

10 - 50

2.5 - 10

< 2.5

Present Market Potential & Minex Presence

64000MT/Year

30000MT/Year

14000MT/Year

Spheroidal Graphite Iron

S. G. Iron is ductile than forms of Cast Iron.

SG Cast Iron Iron Flakes to Nodules formation addition of nodularizing elements like Mg/Ce
Iron Ductile C 3 4% Si 1.8 2.8 % Mn 0.2 0.9% S 0.03 % max P 0.1% max Carbon form Nodules

Applications of S G Iron

Various forms of Mg addition

Pure Magnesium Nickel Magnesium alloy Fe-Mg briquettes. Magnesium-Ferro Silicon alloy

FeSiMg Production routes

FeSi melting & Mg ingot Plunging FeSi & Mg melting in Induction Furnace Carbo-thermic reduction of SiO2 using EAF and Treatment of Si Melt with Fe & Mg Magnesio-thermic reduction of Quartz and Mill scale Not followed

FeSiMg Microscopic Structure

Nodularizing Mechanism
Nodularizing is a simultaneous desulphurizing & deoxidizing Mg + S= MgS --------- Desulphurization Mg + O = MgO ------- Deoxidation Mg + Si + 3O = MgSiO3 2Mg + Si + 4O = Mg2SiO4 After this the growth of graphite proceed as nodules
Orthorhombic Irregular shape

Spheroidal

Graphite

Increased under cooling

As the solidification velocity increases with time the graphite flakes are converted to spheroids

After Mg Treatment

Various forms of Mg addition

Pure MG addition: Addition of Mg produce violent reaction, and addition is made above the boiling (1103C) temperature. The obtained recovery is very low (20-50%). FeSiMg addition: Addition of FeSiMg with the presence of Si, Ca & Ce gives less violent reaction. Si increase the Mg solubility. Recovery in this addition 60-90%.

Inoculation
Silicon is graphite stabilizer in Cast Irons Provide nucleation sites for the carbon to precipitate as graphite rather than Fe3C Increases No. of nodules leading to finer structure of Cast Iron

Role of Alloying Elements- FeSiMg alloy

Mg
12

Magnesium allows to precipitate graphite in the form of nodules

RE
58

Rare earth reduces the negative effects of trace elements like Ar/Bi/Ti/Pb, forms intermetallic, also reduce sulphur

Role of Alloying Elements- FeSiMg alloy

Ca
20

Reduces the reactivity of Mg and thus minimizing the fumes emission Initiate the modification process by reacting with S and O forming sulfide and silicate phase Aluminium in reduces undercooling and shrinkage tendency Base aluminum is low, a small amount of aluminum improves inoculation

Al
13

FeSiMg Alloy Treatment Methods

Sandwich Cover Process

Plunger Process

Tundish Cover Process

Inmould Process

Cored Wire Treatment Process

Treatment ladle (covered)

FeSiMg / Mg wire

Sources & Effect of impurities

Elements Lead Effects Can reduce tensile Strength, Promotes pearlite Sources paints, freecutting steels, nonferrous alloys, Max Limit % 0.002

Antimony

Degenerate Graphite nodules, white metal, solder, some spheroids accumulations torn some pig irons into small pieces. Promotes carbides and undesirable Bismuth containing graphite forms that reduce molds and core tensile properties coatings Promotes undercooled graphite. Combines with nitrogen to neutralize its effects Promotes hydrogen pinhole defects, Neutralizes nitrogen Some pig irons, steel scrap,

0.005

Bismuth

0.002

Titanium

0.05

Aluminum

ferrous alloys, inoculants, scrap

0.6

Projects Carried By R&D

Redesign the ladle lining with insulation and high Al2O3 refractory and SiC refractory Trials for refining FeSi-50% Trial for reduction of slag sticking to F/C wall in imported FeSi Melting process Effect of cooling rate on FeSiMg alloy

Problems faced during production & process

Melting Alloying Castin g Sizing

Slag Sticking to lining FeSi refining Mg losses Skull formation Spillage losses Mould erosion Slag entrapped mtr Excessive undersize Capsule size generation