Analysis and simulation of non-metallic inclusions in spheroidal graphite iron

Non-metallic inclusions in spheroidal cast iron (SGI) reduce fatigue strength and yield strength. This type of inclusion usually accumulates at grain boundaries. Papers addressing this topic show the overall impact of both the fraction of so-called white (carbides) and black (non-metallic) inclusions on mechanical properties. In the present work we focus on the origin and the formation conditions of black Mg-bearing inclusions, further distinguishing between Si-bearing and non-Si-bearing Mg inclusions. The formation was simulated applying thermodynamic approaches. Moreover, appropriate experiments have been carried out and a large number of particles have been studied applying innovative feature analysis with regard to shape, size, and composition. Magnesium silicates are predicted at elevated oxygen concentrations, whereas at low levels of oxygen sulphides and carbides appear at a late stage of solidification. Experiments with three consecutive flow obstacles show that the amount of magnesium silicates decrease after each of the three obstacles, whereas the fraction of non-Si-bearing inclusions remains approximately constant. The size of inclusions divides in halves over the flow path and the number of particles increases accordingly. We point out that based on feature analysis Mg-O-C bearing inclusion show disadvantageous form factors for which reason this kind of inclusions may be extremely harmful in terms of crack initiation. All results obtained indicate that magnesium silicates are entrapped on mould filling, whereas Mg-(O, C, S, P, N) bearing particles are precipitates at late stages of solidification. Consequently, the only avoidance strategy is setting up optimum retained magnesium content. (paper)