About Elkem Foundry Products

Elkem Foundry Products is the leading metal treatment solution provider to the cast iron industry and a supplier of high quality special ferrosilicons to the steel industry. Our products, supported by our experienced technical service teams, provide innovative solutions for iron foundries and steel mills worldwide. The car industry, pipe producers and engineering companies are our important customer categories. 

Elkem's Foundry Products and its Global Technical Foundry team receive awards

Elkem Foundry Products and its Global Technical Foundry team are honoured to be chosen to receive the following awards from the American Foundry Society at the 2015 Metalcasting Conference in Columbus, Ohio, USA.

Epic™

Elkem, in conjunction with Pico, has developed Epic™: a simple, robust and affordable thermal analysis system for cast irons.

Elkem Foundry Products

Products

Ferrosilicon for steel

A wide range of ferrosilicon alloys are available for alloying and deoxidation purposes in steelmaking processes. Elkem supplies ferrosilicon to the steel and steel related industry. Ferrosilicon is an important additive in the manufacture of steel products. Our main markets are the worldwide producers of alloyed, stainless and carbon steel, as well as the producers of manganese alloys.

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Iron Foundry Products

Elkem manufactures a wide range of inoculants, MgFeSi alloys and preconditioners for the production of cast irons. Alloys are available from the extensive portfolio to cover all foundry conditions and iron qualities.

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Recarburisers

Recarburisers are used in high-grade steel, grey and ductile iron castings. Elkem’s Elgraph® recarburisers has proven to give the best performance on dissolution rate, carbon recovery and with the lowest nitrogen/hydrogen content. The unique production technology, located in Norway, is the foundation for the high quality carbon additives.

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Solutions for Foundry Products

  • Scrap rate
  • Reproducibility and consistency
  • Mechanical properties
  • Shrinkage
  • Casting weight/thickness
  • Surface defects
  • Charge materials

How to reduce scrap rate


A windmill hub producer had scrap issues due to poor Charpy impact results. The problem was related to the charge materials and nucleation state of the base iron. The solution was to replace their current preconditioner with a specialist alloy, Preseed™ preconditioner. This resulted in 50-75% increase in Charpy impact results and eliminated metallurgical scrap.

Elkem’s experienced technical staff can help you resolve the issues, and find cost effective solutions.

How to improve process control

The use of thermal analysis to determine the nucleation levels in base iron is becoming more common in foundries. Taking corrective action at an early stage of the process can reduce scrap, and save time and money downstream of the furnace.

Epic™ is a portable, affordable and user-friendly thermal analysis system designed to give information and control of the process from the furnace to the mould, quickly identifying any areas that need attention before problems arise.

Elkem’s experienced technical staff can help you pin point causes of variation, and find cost effective solutions.

How to make ferritic ductile iron castings with improved strength and elongation

Lower weight and higher performance is the goal of every cast iron producer. This can now be achieved by a new range of high performance cast iron grades:  SSF - Solution Strengthened Ferritic iron.

This has increased yield strength and significantly higher elongation compared to traditional GJS 500 – 700.

Greater tolerance to trace elements also makes this iron interesting to the foundryman.

Elkem is at the forefront of this development and can provide you with proven metal treatment solutions for these new grades.

Reducing shrinkage in ductile irons

All ductile iron foundries suffer from shrinkage issues and often castings are over-engineered to compensate. ss

Optimising chemistry, temperature and sand conditions can help to reduce shrink, but good choice of MgFeSi alloys and inoculants is also crucial.

Lamet® nodulariser is proven to reduce shrinkage, and in combination with Ultraseed® Ce inoculant provides the maximum graphitisation during freezing to counter shrink in ductile iron components.

Elkem’s experienced technical staff can help you understand shrinkage mechanisms, and find cost effective solutions.

Alloys for all castings

With castings weighing from a few grams to several hundred tonnes, casting technology and processes vary greatly. Elkem has a range of alloys to provide the optimum treatment for cast iron whatever the weight and section thickness of the casting.

Elkem’s technical experts are able to advice on the right alloy package to give solutions for your casting needs.

Eliminating pinholes in cast irons

Titanium, aluminium and moisture are the common causes of hydrogen pinholes in greensand systems. Both Al and Ti lower the surface tension in the liquid iron and that allows gasses to be more easily picked up.

Elkem produces a range of MgFeSi alloys and inoculants with very low Al to help keep the aluminium content below the critical levels for pinhole generation.

Solutions to charge materials availability

Selection of good quality charge materials for melting stock makes production of quality irons easier. However, many foundries are limited to what is available. Zinc plated steel, for example, creates both environmental and metallurgical issues.

Using Preseed™ preconditioner can allow for full or partial replacement of expensive pig iron with more cost effective solutions.

Elkem is working with foundries to develop solutions for these and other charge material related issues.

Upcoming events

A.F.S. Metalcasting Congress

21. - 23. April 2015
Columbus, Ohio, USA
In April, Elkem Foundry Products will be present at the 119th A.F.S. Metalcasting Congress in Ohio, USA, at the Greater Columbus Convention Center. This congress features the latest advancements in metalcasting technology and services and has something for everyone in the supply chain: suppliers, metalcasters and casting buyers and designers. Metalcasting Congress consists of technical sessions, awards banquets, a table-top exhibition show and Cast in North America.

We look forward to welcoming you to our booth #304!
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Gifa

16. - 20. June 2015
Düsseldorf, Germany
In June, Elkem Foundry Products will of course be present again at Gifa – the leading international trade show for the foundry industry! Please visit us in Hall 13, Stand C40 to check out our extensive product portfolio and meet your local Elkem representative.

We look forward to welcoming you to our stand!
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