Technical Information 24

Partition of Slag Phases in the Treatment and Pouring of Ductile Iron

One problem encountered in automatic pouring systems incorporating a stopper rod is the
build up of slag in the pouring unit, especially on and around the stopper rod, that leads to:
• Costly cleaning and maintenance of the holding unit.
• The stopper rod not seating properly and metal dripping from the launder.
• Inconsistent pouring rates which can interfere with consistent inoculation from
dispensing units.
• Slag entering the mould.

An investigation has been carried out into the composition of slag phases contained in a
tundish ladle/unheated automatic pouring unit system. Different slag phases have been
found to precipitate in various parts of the system and these are shown schematically
below.

Slag constituents:
Magnesium
Calcium
Sulphide
Iron
Aluminium

Figure 1: Partition of slag phases in the sandwich treatment ladle (surface, wall and pocket)
and in the autopour (inlet, surface, bottom, stopper and nozzle).

Ductile iron slag phases can be categorised into five principle types:
1. Magnesium containing slags: MgO (Periclase), MgO•Al2O3 (Spinel), 2MgO•SiO2
(Forsterite) and MgO•SiO2 (Enstatite).
These phases tend to be distributed throughout the system, both treatment vessel
and pouring unit. The very hard aluminium containing spinel is found to be
concentrated around the stopper rod and pouring nozzle.
2. Calcium containing slags: complex oxides, sulphides and aluminates.
Calcium phases can be found in most locations in the system, but are
predominantly concentrated around the stopper rod.
3. Sulphide phases; magnesium and calcium sulphides.
Sulphide phases tend to be concentrated around the stopper rod, but can be found
in small quantities elsewhere in the system. Proper control of sulphur in the base
metal and good deslagging practise minimises the harmful effects of this phase.
4. Iron containing slags: Fe,Al (Hercynite), Fe,Mg (Ringwoodite and Magnesoferrite).
These are mostly found in the upper parts of the pouring unit and may be regarded
as oxidation products generated by contact between the iron and atmosphere.
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Technical Information 24 2

5. Aluminium phases: Al,Si (Mullite), Al,Mg (Sapphrinite)

As with other harmful aluminium containing slags, these tend to be concentrated
around the stopper rod.

In general terms, aluminium and calcium phases have the most tendency to concentrate
on the stopper rod. It is possible to alter the slag phase composition and hold the more
harmful phases back in the treatment ladle.

Barium

This is done with the addition of barium, either as an integral part of the MgFeSi alloy or,
more commonly, as part of a ferroalloy sandwich cover (e.g. by the use of a barium
containing inoculant in the cover material).

The competition between barium, calcium and magnesium to combine with the aluminium
phases seems to be dominated by barium. Barium phases tend to settle in the treatment
ladle and only a minimum of slag is transferred into the pouring unit, as shown schemati-
cally below.

Slag constituents:
Barium

Figure 2: Distribution of barium containing slag phases.

The effect of barium additions is that the stopper rod and the insides of the pouring unit
remain cleaner and will have a longer working life. As the barium containing slags settle
mainly in the treatment ladle, it appears that more slag is being generated. This is not
necessarily true as the reaction slags are being accumulated in the ladle rather than being
transferred into the pouring unit. Ladles will therefore require better skimming and cleaning
of linings, however most foundries will find this a better, cleaner and cheaper option than
replacing stopper rods and cleaning out pouring units.

Without doubt, the best way of minimising harmful calcium and aluminium bearing slags
from contaminating the pouring unit is to prevent the introduction of such elements into the
iron. As this is not possible in many cases, the best alternative is to make a deliberate
addition of a barium-containing alloy to the treatment ladle to control the slag partition and
minimise slag fouling the pouring units.