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.
Solutions for Foundry Products
Reproducibility and consistency
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.
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.
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.
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.
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.
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.