Ductile Iron Casting Manufacturing From Induction Furnace

January 2, 2019January 2, 2019 EIRI Team

Ductile iron casting refers to a process in which magnesium/Cerium (as an alloy of magnesium / Cerium) is added to cast iron. There is a tremendous demand. While most varieties of cast iron are comparatively brittle, ductile iron castings are much more ductile due to the inclusion of nodular graphite. Solidified castings of ductile iron contain nearly perfect spheres of graphite.

Ductile iron possesses the processing advantages of grey iron, such as low melting point, good fluidity, castability and machinability, and engineering advantages of steel, including high strength, ductility and wear resistance. Achieving the desired quality consistently at low cost in a production foundry is, however, still a challenge. Addition of small amount of cerium or magnesium to molten cast iron changes the shape of graphite from laminar to spheroidal, giving rise to spheroidal graphite iron or ductile iron. The rapid growth in industrial applications of ductile iron (DI) is driven by its versatility and high performance at low cost. It offers a good combination of tensile strength and ductility. This allows designers to select ductile iron for a wide range of applications. Ductile iron also offers cost savings compared to steel and malleable iron castings through higher yield and thereby lower melting energy. Formation of graphite during solidification leads to lower volumetric shrinkage in ductile iron (compared to steel), necessitating smaller and fewer feeders to prevent the formation of shrinkage defects. Further cost advances can be achieved by eliminating heat treatment of as-cast DI parts.

Ductile Iron Casting possesses greater tensile strength, mach inability than ordinary cast iron and also has a considerable measure of ductility, resistance to impact comparable to that of steel and low cost involved that justifies it as the metal of future. Due to economic reforms based upon principle of liberalization, globalization, privatization and changes at international economy including the emergence of WTO global and domestic challenges, the demand for components of S.G. Iron particularly in automobile sector is likely to increase manifold not only for domestic consumption but also for export purpose. Since small-scale sector accounts for 40% of gross value of output in the manufacturing sector and 35% of total exports from the country, this industry has great scope.

Project Profile for Ductile Iron Casting:

Capacity: 20 Ton/Month
Land Area 10000 Sq. mtr.
Land and Building : Rs. 7 Cr.
Plant and Machinery: Rs. 5.15 Cr.
Rate of Return : 44%