Technical Information 35

In-the-Mould Nodularising
The objective with in-the-mould nodularising processes is to pour untreated base iron into
the mould and do the nodularising treatment inside the mould, thus producing ductile iron
castings in a one-step operation. A reaction chamber containing the nodularising MgFeSi
alloy is incorporated into the runner system inside the mould. The treatment takes place
continuously while the iron flows through the reaction chamber before entering the cavity
that forms the casting.

Some important advantages and disadvantages of the in-the-mould ductile iron treatment process:
Process advantages Process disadvantages
• Reduced number of production steps. • Reduced space on the pattern.
• Low capital investment. • Reduced casting yield.
• Low variable cost. • Potential formation of dross in the
• Reduced temperature loss. mould.
• High Mg-recovery gives low addition rate of nodulariser alloy. • Consistent pouring rate required.
• No treatment fading. • Low base sulphur level needed,
max 0.015%.
• No post inoculation needed.
• Possible variation in Magnesium
• Late treatment discourages undercooling and carbide formation.
analyses in different parts of the
• Excellent interfacing with autopouring operations. casting.
• No holding of treated iron reduces slag problems in holding and • 100% quality inspection normally
pouring furnaces. required.
• Easy recovery after downtime.
• Minimal environmental impact.
• No treatment slag for disposal.

Example of typical in-the-mould magnesium treatment process layout.

Common design rules are: A = system choke, B = A+10%, C = A+12%, D = E = A+30%.

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Technical Information 35 2

Calculating size of in-the-mould reaction chamber using Alloy Solution Factor (ASF):

Pouring Rate
Chamber Area =
Alloy Solution Factor

Design of reaction chamber, common rules: Factors affecting Alloy Solution Factor:
• Inlet in drag. • % Mg in MgFeSi.
• Outlet in cope. • % RE in MgFeSi.
• Depth of chamber: • Pouring temperature.
Height needed for nodulariser + 25 mm • Sulphur level in base iron.
• Flow pattern in reaction chamber.

Typical ASF values range from 0.045 kg/cm2sec to 0.060 kg/cm2sec.

Typical addition rate of nodularising alloy range from 0.8% to 1.2%.

Reaction chamber area at different ASF values and different pouring rates.
ASF ASF Pouring rate, W / t [kg/sec]
2 2
[lb/in sec] [kg/cm sec] 2 4 6 8 10 12 14 16 18 20
1 0.070 28 57 85 114 142 171 199 228 256 284
0.95 0.067 30 60 90 120 150 180 210 240 269 299
0.9 0.063 32 63 95 126 158 190 221 253 284 316
Chamber Area [cm2]

0.85 0.060 33 67 100 134 167 201 234 268 301 335
0.8 0.056 36 71 107 142 178 213 249 284 320 356
0.75 0.053 38 76 114 152 190 228 266 303 341 379
0.7 0.049 41 81 122 163 203 244 284 325 366 406
0.65 0.046 44 88 131 175 219 263 306 350 394 438
0.6 0.042 47 95 142 190 237 284 332 379 427 474
0.55 0.039 52 103 155 207 259 310 362 414 465 517
0.5 0.035 57 114 171 228 284 341 398 455 512 569
0.45 0.032 63 126 190 253 316 379 443 506 569 632

Recommended MgFeSi alloys for in-the-mould ductile iron treatment:

LametTM nodulariser Elmag® MF-6113 nodulariser
Si 44 – 48% Si 43 – 47%
Mg 5.0 – 6.0% Mg 5.75 – 6.5%
La 0.25 – 0.4% RE 0.35 – 0.7%
Ca 0.4 – 0.6% Ca 0.35 – 0.6%
Al 0.8 – 1.2% Al 0.4 – 0.75%

Conventional MgFeSi alloys when used as in-the-mould nodularising agents can have
several disadvantages. Promotion of shrinkage porosity and formation of inclusion defects
are known problems. Recommended in-the-mould MgFeSi alloy sizing is 1 – 4 mm.

The use of LametTM nodulariser, which is very low in slag forming elements, is an effective
way of making clean ductile iron castings. By using pure lanthanum in the alloy in place of
the traditional rare earth mixture of elements, LametTM nodulariser promotes a lower
shrinkage tendency than traditional alloys used for in-the-mould applications. For further
information, please refer to the Elkem LametTM nodulariser brochure.
LametTM nodularizer is a trademark and Elmag® nodularizer is a registered trademark owned by Elkem ASA.