HOT TOPICS

Issue # 12, 2003

Effect of Magnesium in Ductile Iron

1) Basic elemental information forms very fine, solid inclusions that become
suspended in the molten iron. The remaining Mg is
Element & Atomic Atomic Melting dissolved in the molten iron and is termed
Symbol Number Weight Point “residual” magnesium. Depending on the method
of chemical analysis, the amount of Mg measured
Magnesium (Mg) 12 24.3 1200 F may include the residual Mg and the Mg in sulfide
and oxide inclusions, which is what is measured
2) How magnesium is introduced in the iron when using an optical emission spectrometer.
Sources of magnesium include metallic magnesium,
magnesium-ferro-silicon alloys (MgFeSi), nickel-
magnesium alloys (Nimag), and Mg-filled wire.

Compacted Graphite %
Magnesium has a very low boiling point (1994 F),
which is lower than the melting point of cast iron.
At common Mg treatment temperatures (2750F) the
vapor pressure is 4 atmospheres. Therefore, the
addition of Mg to molten iron causes boiling and
produces large volumes of Mg vapor at very high
evolution rates. Because Mg is also a highly
reactive element, it combines with O in the air and
produces bright light. Consequently, there is a
violent reaction accompanying the addition of Mg
to the melt, which is dangerous and requires great
Residual Magnesium, %
care and safe foundry practices.
(a)
3) Effects on the Microstructure
Magnesium is the principal element used to produce
spheroidal, or nodular graphite in cast iron. There
is an optimum amount that must be added to
achieve a nodular or spheroidal graphite (SG)
Percent Nodular Graphite

structure. Too little Mg recovered will result in

some vermicular graphite and possibly even flake
graphite in the cast microstructure. Compacted
graphite iron is produced by intentionally adding
too little Mg to result in a fully nodular structure.
Excessive Mg additions will result in intercellular
carbides or even white iron (a carbidic iron free of
graphite). The effects of Mg on graphite shape are
shown in Figures 1a and 1b.

Excess final Mg concentrations will also lead to

other problems, including intercellular carbides, Residual Magnesium, %
dross defects, exploded graphite (see Figure 2), and
shrinkage porosity. (b)

When Mg is added to the melt, it first reacts with Figure 1 Influence of residual magnesium on the
available sulfur and oxygen in the molten iron and graphite shape in cast iron.

Rick Gundlach, Climax Research Services

 Increasing
Section Size

Figure 2 Exploded graphite in over-treated iron.

Residual Magnesium, %
4) Magnesium Requirements
Magnesium will react with oxygen and sulfur Fig. 3 Influence of section size on Mg requirement.
before it becomes available to spheroidize the
graphite phase. The Mg consumed to make oxides Fade
and sulfides will not contribute to the From the moment the Mg treatment is
spheroidization of graphite. Therefore, the amount accomplished there is a tendency for the Mg effect
of Mg consumed to make oxide and sulfide to fade, that is, for the graphite nodule shape to
inclusions will affect the calculation of the total degrade. Loss of magnesium will occur as Mg
amount of Mg that must be added. continues to react with oxygen at the surface of the
melt and to leave the melt by vaporization. As fade
Variations in charge materials and melting occurs, the nodule count decreases along with
practices, determine the amount of oxygen and nodularity. The degradation increases with time as
sulfur in the melt. In addition, Mg vaporizes to a shown in Fig. 4, and most foundries will avoid
greater or lesser extent, depending on the treatment holding the treated iron beyond 15 minutes. Some
practice. Thus the amount of Mg that must be loss of nodularity can often be restored by post
added to achieve a fully nodular structure will vary inoculation. Leaner treatment alloys with 3% Mg
with each foundry’s practice. or less are also available to restore the proper Mg
level in the iron.
Various methods have been used to specify the
amount of Mg (final Mg) needed to assure 100% In many foundries the treated metal is immediately
nodularity. Some have used Mg:S ratio, specifying inoculated as the metal is transferred to the pouring
3:1 or 4:1. Another common method is to specify a ladle. To sustain high nodularity and high nodule
minimum “excess Mg” (such as 0.020%) according count, it is commonly recommended that the ductile
to the following formula. iron be inoculated at every transfer operation.

%Mg = 0.020 + ¾ (%S)

100
The minimum excess Mg is determined empirically
based on the foundries experiences.
Nodularity

The amount of Mg required to obtain a fully

nodular structure varies with solidification rate. 50

Light sections require less residual Mg. For

example, thin-walled castings may be made 100%
nodular at 0.022% Mg. Mg concentration in heavy
section ductile iron (sections above 2 inches) 0
generally exceeds 0.040%. A schematic diagram
Time
illustrating the effects of section size is shown in
Fig. 3. Fig. 4 Mg spheroidization effect fades with time.
5) Magnesium Treatment Methods 6) Effects on the Mechanical Properties
Various methods have been devised for introducing The highest strength and elongation are achieved
magnesium to the molten iron. The oldest is the with a fully nodular structure. When nodularity
“pour-over” method, which consists of placing falls off, due to insufficient Mg, the tensile strength
MgFeSi in the bottom of a ladle and pouring the and tensile elongation also decreases. Yield strength
molten metal on top of the alloy. The “sandwich” does not immediately fall off.
method, an improvement over the pour-over
method, consists of covering the alloy with ferro- Excess Mg levels can lead to intercellular carbides,
silicon and/or steel punchings. For both methods, which also cause a reduction in tensile elongation.
the ladle has a pocket in the bottom, for Excess Mg can also promote remote area shrinkage,
accommodating the alloy, and a high aspect ratio and such shrinkage porosity may affect the
(typically 3:1) to improve the Mg recovery. performance of the casting.

The “pour-over” and “sandwich” methods give poor 7) Effects on Castability

Mg recoveries, generally 30 – 50%. This condition A fully nodular structure generally requires more
causes two major problems; the Mg recovery is not feeding and risering than an under-treated melt. As
consistent and predictable and the amount of Si stated above, over treating with Mg can lead to
added can be excessive. remote area shrinkage porosity.

The “tundish cover ladle (covered ladle)” is a 8) Environmental considerations

significant improvement over the pour over method. There are no known environmental or health
The tundish cover ladle employs a similar ladle concerns associated with magnesium as metallic
design but it is enclosed with a lid that contains a Mg or as a dissolved component in cast iron. Mg is
pouring basin. Using the tundish cover ladle, Mg prone to ignite when present as finely divided
recoveries are much higher (50-70%) and more particles, and care should be taken in handling and
consistent because the vessel is closed, minimizing storage. MgFeSi is a stable substance and does not
exposure to oxygen in the air. create the same problems as metallic magnesium.

The Mg recoveries in the above three methods are 9) Effects on melting and chill
dependent on the treatment temperature, alloy Melting losses are high because of the high
sizing, Mg content of the alloy, and the volatility of magnesium. Special processes are
concentrations of other elements in the alloy, employed to limit volatility during Mg treatment.
particularly Ca. Higher Mg contents favor intercellular carbides
and, at high concentrations, a propensity for chill.
The Fischer converter process uses metallic
magnesium to introduce Mg to the melt. This 10) Considerations in various ductile iron grades
process is extremely violent and utilizes a low-cost The optimum magnesium concentration does not
Mg source. Similarly, Mg-filled wire can use vary with ductile iron grades. For ferritic grades, a
metallic Mg as the source. lower Mg residual is advantageous.

In-mold treatment offers another way to introduce 11) Effect of section thickness
Mg to the molten iron. In this method, a reaction The optimum magnesium level varies with section
chamber is molded into the mold runner system. size and solidification rate. The minimum Mg
MgFeSi is placed in the chamber before closing the requirements increase with section size.
mold and each casting is treated individually. The
size of the alloy is carefully controlled to attain 12) Counteracting detrimental effects
uniform dissolution and treatment of the metal in Over-treated iron is not generally a problem with
the mold. Mg recoveries are also high with in-mold the manufacture of ductile iron. However, excess
treatment and Mg fade is not an issue. Mg levels can be reduced by dilution with untreated
iron or by the addition of sulfur to the melt.
The Flotret process is similar to in-mold treatment
in that the metal is poured through a box containing 13) References
a reaction chamber. The box is placed over a ladle
and the metal flowing into the ladle is uniformly Ductile Iron Handbook, American Foundry Society,
treated and boasts high Mg recoveries. Des Plaines, IL , 1992.