Technical Information 13

Compacted Graphite Iron

Compacted graphite irons (CG-irons) are a range of cast irons having mechanical and
physical properties intermediate between those of flake graphite and nodular graphite cast
irons. They are of interest to engineers because of their useful combination of strength,
thermal conductivity and thermal stability.

Compacted graphite irons may be produced from many different treatment methods. The
production requires controls similar to those applied in the manufacture of ductile iron
castings.
This Information Sheet summarises a successful production route for CG-iron that has
been developed by Elkem, as well as examples of structures and properties for such
materials. Treatment is based on a high rare earth containing magnesium-ferrosilicon alloy
designed specially for compacted graphite iron production. No introduction of such
elements as titanium or nitrogen is necessary with the present alloying concept.
TM
Recommended composition of treatment alloy; CompactMag :
% Si % Mg % Ca % RE % Al % Fe
44 - 48 5.0 – 6.0 1.8 – 2.3 5.0 – 6.5 max. 1.0 balance

Recommendations for Compacted Graphite Iron Production

Base Iron Composition

Base iron composition should preferentially be hypereutectic with a carbon equivalent
(CE) of about 4.3 - 4.5.
Suggested base iron composition:
%C % Si %S
3.5 – 3.8 1.5 – 1.9 0.007 – 0.012

Other elements are less important, but should not be higher than for ductile iron
production. Generally a higher level of pearlite and carbide promoting elements may be
tolerated, as long as the sulphur level is kept low and constant.

Alloy Addition
The addition rate of the alloy described above has to be adjusted according to base metal
composition, treatment process and casting requirements for each individual foundry.
Base metal sulphur level is the main factor strongly affecting the required alloy addition
rate. Experiences with the base iron composition given above have shown best results for
addition rates between:

0.30 – 0.45 wt% addition of alloy specified above.

The addition method may be an ordinary ladle treatment process as for ductile iron
production (sandwich or tundish ladle).

Elkem ASA, Foundry Products © Copyright Elkem ASA

Postal address Office address Telephone Web Revision
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Technical Information 13 2

Inoculant Sandwich Cover

It is recommended to add a moderately powerful inoculant as sandwich cover. Barium
containing ferrosilicon inoculants are found to give good results e.g. Foundrisil® inoculant.
The inoculant cover has been found to decrease the tendency to chill formation and to
give a more homogeneous graphite structure over different casting sections. In many
cases subsequent inoculation is not needed, but for chill prone sections adequate post
inoculant should also be used. Addition rate of the sandwich cover should be fixed and in
the range 0.2 to 0.3 wt%.

Microstructures
The Figures below show examples of microstructures and final iron composition obtained
for a CG-iron casting produced from a high RE-containing MgFeSi-alloy. Structures in both
thin (5 mm) and thick (35 mm) section sizes are given to show the limited section
sensitivity obtained. Homogeneous CG-structures throughout all section sizes are a
characteristic feature obtained by the high RE-containing alloy in comparison to ordinary
lower RE-containing MgFeSi-alloys.

Microstructure of compacted graphite iron produced from a high RE-containing MgFeSi-

alloy, 5 mm section size (left), 35 mm section size (right) (100X).

Final CG-Iron Composition

After treatment the final iron composition should be in the following range:
%C % Si %S % Mg % Ce
3.3 – 3.6 2.0 – 2.5 0.005 – 0.012 0.005 – 0.015 0.005 – 0.015

Fade time and treatment temperature

From laboratory and field testing, fade times up to 20 minutes were found not to have a
negative influence on the microstructure control.

Treatment temperatures in the range 1400 – 1520°C have been tested without any nega-
tive effect on the microstructure. Choice of post inoculant has to be adjusted according to
treatment temperature used.

Pearlitic grades of CGI

Pearlite promoting elements (Mn, Cu, etc) may have to be applied to produce pearlitic
grades of CGI.

For more information, see the Elkem Product Data Sheet “CompactMag”.