Cored Wires

Pure Magnesium & FeSiMg For Iron Foundry

Minex Metallurgical Co. Ltd.
Spheriodiser Cored Wire
PURE MAGNESIUM & FeSiMg CORED WIRE FOR IRON TREATMENT WITH IMPROVED
RECOVERY
Today majority of ductile iron castings made throughout the world are produced using ladle metallurgy practices
with FeSiMg alloys and cored wire injection. It is estimated that FeSiMg alloys are used in 65 percent of all ductile
iron produced worldwide. The supply of domestically produced FeSiMg becomes important in assessing whether this
important raw material will be available in sufficient quantities to sustain the forecasted growth.
High performing FeSiMg alloys are to be manufactured to sustain the projected growth of ductile iron. Today the
concern with automation, cost, consistency, improved recovery and reduced (fumes) environmental hazards in work
space compel more and more cast-house to adopt cored wire injection method for ladle inoculation/spheroidization
treatment.
Minex has established specialized plants to provide a consistent and quality service to the customers. Minex-
Kalmeshwar certified to Integrated Management System (viz. ISO-9001-2008, ISO-14001-EMS, OHSAS-18001) is one
of the major Pure Mg and FeSiMg cored wire production plants in the India. Minexs consistency has seen the most
quality oriented foundries in India and abroad turn to Minex as their preferred supplier. Further news and
development may be found on our website www.minexindia.com
Product Introduction

The valuable characteristics of magnesium addition to iron have been known for the purpose of nodule formation
and improving the mechanical properties. Addition of magnesium promotes transformation of graphite flakes to
nodules during solidification of iron melt due to increase in the surface tension.
Today, magnesium, pure or in a form of master alloy, is the most effective nodularizing agent used by the foundry
industry to produce quality ductile iron castings. However, the usage of magnesium for treating of liquid iron has a
number of difficulties caused by specific physical properties of magnesium. This includes low melting and boiling
temperatures (1202F/650C and 2025F/1107C respectively), low density (1.738 g/cm
3
vs. 7.0g/cm
3
of liquid cast
iron), and low solubility in liquid iron (about 0.001% wt at 650C).
As a result, the introduction of magnesium or magnesium containing alloy into liquid iron is typically accompanied by
significant flame and fume called 'pyro effect', which makes the magnesium treatment process highly violent and
unsafe. The later caused significant magnesium losses due to magnesium burning, and hence reduction of residual
magnesium content in solidified castings. Certain magnesium losses are also incurred due to magnesium reaction
with elements contained in liquid iron: first, with sulphur, and second with oxygen.
Cored wire in particular a magnesium or FeSiMg core is surrounded by a steel sheath or jacket have found wide
application in the treating of molten ferrous metal for inoculation, desulphurization and spheroidization. The pure
magnesium and FeSiMg cored wire is manufactured with special grade steel sheath so as to introduce magnesium
into the steel bath at greatest possible depth so as to make use of the increased pressure from ferrostatic head and
thus to prevent magnesium from evaporating.
Pure magnesium metal granules or FeSiMg powder is filled in high grade quality cold rolled steel strip for higher
penetration depth of magnesium & improved magnesium recovery. Cored wire is injected with aid of wire injection
system in iron melt. The Pure Magnesium and FeSiMg cored wire specifications are as follows:


FeSiMg Cored Wire Specifications
Chemical composition of Mg-FeSi powder (%)
Grade Mg Si Al (Max) Ca Re Othr (Max) Fe
FeSiMg 20 18-20 45-46 0.5 1-3 1-3 1 Bal
FeSiMg 20 (WRe) 20-25 33-38 0.8 1-3 1 max 1 Bal
FeSiMg 30 30-32 25-33 0.8 1-3 0.5 -3 1 Bal
FeSiMg 40 38-42 22-30 0.8 1-2 0.5-3 1 Bal
FeSiMg 50 50-52 25-30 0.8 1-3 1-3.5 1 Bal
FeSiMg 80 78-82 7-11 0.8 1-3 1-3 1 Bal

Powder specification Strip Specification
Grade Density
(gm/cc)
Melting
Point (C)
Boiling
Point (C)
Size (mm) Grade Diameter
(u, mm)
Thickness
(mm)
FeSiMg
4.3 4.8 910- 1225 - -1.4+0.3
EDD IS 513 9 0.5 0.40 0.03
Fe 7.8 1540 2860 -0.6+0.045
130.2 0.400.03
Si 2.4 1412 3270 -1.4+0.016

Mg 1.74 650 1090 -1.4+0.212

Wire Characteristics
Grade FeSiMg 20
FeSiMg 20
(W-Re)
FeSiMg 30 FeSiMg 40 FeSiMg 50 FeSiMg 80
Diameter
(u, mm)
9 0.5 9 0.5 9 0.5 9 0.5 9 0.5 9 0.5
Shape
Round Round Round Round Round Round
Powder Fill
(gm/mtr)
12010 11510 11010 10010 9510 7010

Coil Specification (Flipping Coil Horizontal & Vertical)
Details
9 mm u 9 mm u 9 mm u 9 mm u 9 mm u 9 mm u
Coil Identification
20% Alloy 20% W-
Re Alloy
30% Alloy 40%
Alloy
50%
Alloy
20%
Alloy
F1-05 F2-05 F3-05 F4-05 F6-05 F7-05
Powder
Weight
(MT)
0.500 0.500 0.500 0.500 0.500 0.500
All coils are color coded and fixed
with a detailed sticker clearly
displaying details such as coil no.,
powder content, strip weight,
gross weight density & length. A
fluorescent sticker displays the
name of the product in bold
letters on the outer diameter of
the coil.
Handling
No metal sling, chain or rod is to
be used across the ID of the coil
for handling as it may damage
the coil. Use only polyester,
synthetic slings, fork lift/tractor
to handle the coil. The pallet is an
integral part of the coil and it is
to be removed till the coil is
consumed.
Shelf Life
Follow the shelf life period
specified by MINEX
Strip Weight
(MT)
0.505 0.420 0.595 0.640 0.695 0.850
Net Weight
(MT)
1.005 0.920 1.095 1.140 1.195 1.350
Length
(Mtrs)
4166 4385 4545 5000 5555 7142
Internal
Diameter
(mm)
650 650 650 650 650 650
External
Diameter
(mm)
1000 1050 1050 1050 1080 1200
Height (mm) 630 630 630 630 630 630

Pure Magnesium Cored Wire Specifications
Chemical composition of pure Magnesium powder (%)
Grade Mg Other (Max)
Mg 100 98 2.0

Powder specification Strip Specification
Grade Density
(gm/cc)
Melting
Point (C)
Boiling
Point (C)
Size (mm) Grade Diameter
(u, mm)
Thickness (mm)
Mg 1.74 650 1090 -1.4+0.212 EDD IS
513
90.5 0.9 0.03
Wire Characteristics
Grade Diameter
(u, mm)
Shape Powder Fill (gm/mt)
Ca 9 0.5 Round 60 10
Coil Specification (Flipping Coil Horizontal & Vertical)
Details 9 mm u Coil Identification
F8-04
Powder Weight
(MT)
0.400
All coils are color coded and fixed with a detailed sticker clearly displaying
details such as coil no., powder content, strip weight, gross weight
density & length. A fluorescent sticker displays the name of the product
in bold letters on the outer diameter of the coil.
Handling
No metal sling, chain or rod is to be used across the ID of the coil for
handling as it may damage the coil. Use only polyester, synthetic slings,
fork lift/tractor to handle the coil. The pallet is an integral part of the coil
and it is to be removed till the coil is consumed.
Shelf Life
Follow the shelf life period specified by MINEX
Strip Weight (MT)
0.770
Net Weight (MT)
1.170
Length (Mtrs) 6153
Internal Diameter
(mm)
650
External Diameter
(mm)
1140
Height (mm) 700
a) b)
Cored Wire Injection Process
Over the last few years, cored wire has increases its
popularity of spheroidization of ductile iron and
manufacturing of compacted graphite (CG) iron.
The current concern with automation, cost,
consistency and large amount of fumes coming in
work space from iron treatment ladle makes more
and more cast shop adopt cored wire method. The
treatment effects can be equal to or higher than
other methods if it is applied adequately. Therefore
there is no surprise that cored wire is adopted
widely.
Normally the Cored Wire is a steel tube filled with
granular Magnesium or FeSiMg alloy or mixture of
these. (as shown in fig.)







Process Parameters affecting cored wire
injection
Sulphur content of the Base Metal to be
treated ( Sf )
Treatment Temperature
Wire feed rate and treatment time
Geometry of treatment ladle
Quantity of the Metal to be treated.
Composition of Mg cored wire
Desired percentage of Magnesium in the
Metal
Free board of about 300mm
Geometry of the wire guide tubes
Design of treatment station

Sulphur content of the Base Metal
Mg Cored wire injection process is very flexible
with Sulphur content, because it can treat base iron
with higher S composition as combined
desulphurization and Mg treatment of cupola iron
with S range 0.05 to 0.15% (preferably S s 0.08%)
and base iron with low S composition as Mg
treatment of electrically melted iron with S content
< 0.03% (preferably S < 0.015%)
But always keep in mind, any point of increase of
Sulphur in iron will result in high wire
consumption, more cost and more slag. And if
Sulphur is very low < 0.01% then special attention
has to be paid in inoculation of the melt.
Wire feed rate and treatment time
Wire feeding speed is very important parameter in
Mg wire injection process, as it greatly influences
the desulphurization and spheroidization of iron
melt. The optimum wire injection speed is such that
it release the Mg/FeSiMg powder into a certain
depth (near bottom of ladle) of iron melt, where Mg
changes to vapor bubbles under sufficient
ferrostatic head which raise slowly and reacts with
iron melt from bottom to head.





The release of Mg powder near the bottom can over
come the weakness of Mg as low density, high
vapor pressure, low boiling point, active chemical
property etc; and leads to higher Mg recovery. Too
high or too low speed will reduce the effect of
treatment, additonally the temperature drops are
below 80C.
At too low speed the wire is melted near the surface
of the melt and Mg is lost near surface (as shown in
fig. 3.b). And at too high speed there are two
reasons for lower yield of magnesium;
(a) the wire does not melt at the bottom and comes
out near surface of melt. Hence release of Mg much
above the level of bottom of the melt or (b) at
higher speed the rate of release of Mg near bottom
is very high. It leads to high vapor pressure of Mg
bubbles which rise at high speed (as shown in fig.
3.a). If the feeding speed and treatment
temperature are not well controlled, the treatment
effect will deteriorate seriously and sometimes
explosion will happen dangerously in treatment
ladle if the feeding speed is too high.

Fig. 2: The effect of different wire feeding speed on (a)
Mg Yield (b) desulphure rate (c) drop in temp.
Condition: intial S-0.028%, feeding speed-15m/min,
liquid wt-500 Kgs, H/D of ladle 2:1
Fig. 1: a) Tubes filled with Mg/FeSiMg b) packed coil
of cored wire









Desired percentage of Magnesium in the Metal
and Treatment cost
The following formula shows the basic calculation
method for wire length and Mg recovery. Initially
certain assumptions has to be met, the effect of
temperature is being ignored in order to calculate
the wire requirement for new applications:
Empirical Formula:
) / ( (%) Re
% %) 76 . 0 (
) ( ) (
mtr gm Wire Mg c Mg
melt in Mg S
kg Iron mt Length Wire

+ A
=

Where
AS = Opening Sulphur Final Sulphur
Mg % = Residual Mg content
Mg Rec. = Recovery of Magnesium, for all practical

For example:
Calculating quantity of cored wire to be injected
and cost of treatment as practiced at one of the
renowned SG iron foundry in India is as follows:
The existing parameters are:
Treatment Parameters Quantity /Units
Quantity of Metal treated : 1000 kgs
S (i) (Initial Sulphur) : 0.02%
S(f) (Final Sulphur) : 0.007%
AS (S (i) -S(f) ) : 0.013%
Mg (f) : 0.04
Cored Wire : Mg 20 with 20% Mg
Wire Density : 120 +/-10 gms/Mtr
Treatment : 1400 1450C

With practical consideration it is found that Mg
recovery is more than 45%.

) 1000 (
24 45
04 . 0 ) 013 . 0 76 . 0 (
) 1000 ( ) (

+
= mt Length Wire

Length of Wire (mtr) = 46 mtr (i.e. 5.5 Kgs of Powder)

Cost of Treatment /MT of LM = 5.5 kgs x Rs.180/-
= Rs.990/- /MT of LM

Although the cost comparison with other process as
sandwich or other, is very difficult, because type/
grades of alloy, cost of alloy are used and recovery
of Mg etc. Suppose using FeSiMg 7% Mg alloy is
used to treat above metal and the Mg recovery is
45-50% the alloy consumed can be calculated using
the following empirical formula, for all parameters
given above as change in sulphur AS, final Mg in
melt Mgf
R
t S
Mg
Mg
W W
FeSiMg
f
ladle FeSiMg

+ A +
=

%
3
10 %) ( 76 . 0


= 1000 x (0.04 + 0.76(0.013)) / (7x 0.45)
= 15.8 Kgs
If assumed price of FeSiMg of Mg 7% is more than
Rs. 90/-. Thus the price of treatment will be
15.8 x 90 = Rs. 1422 /- . Thus the Mg treatment of
iron with cored wire injection is cheaper than
sandwich process.
This is one of the examples, but the cost of
treatment varies from foundry to foundry because
it depends on various parameters. Cost of one
foundry cannot be applied to another foundry, it
has to be well experimented.
Advantages
Various advantages of cored wire injection process
are summarized below according to above
discussion.
Improved Metallurgical results achieved by
precise addition of Mg Cored Wire resulting
in close control of the residual Mg in the iron.
Very flexible with any composition of iron,
especially with Sulphur which is very
difficult to treat with other process
Lower loss than alloy process.
Better efficiency.
Reliable and consistent process.
Ease of operations.
Less slag formation and ladle buildup
Less slag inclusions in the castings.
Favorable cost of treatment.
Desulphurization and Spheroidization can be
done simultaneously.
Reduced labor requirements.
Less capital investment and treatment cost.
Harmless to the environment as emission
can be controlled and drawn off easily.
Process supports futuristic alloy like CG Iron
production.
Scope for Total Automation
Fig. 3: The effect of different wire feeding speed
(a) Too High Speed (b) Too low speed (c) Normal speed

a) b) c)