Surface Graphite Degeneration in Ductile Iron Castings for Resin Molds

The objective of this paper is to review the factors influencing the formation of degenerated graphite layers on the surfaces of ductile iron castings for chemical resins-acid molding and core-making systems and how to reduce this defect. In the resin mold technique the sulphur in the P-toluol sulphonic acid (PTSA), usually used as the hardener, has been identified as one factor causing graphite degeneration at the metal-mold interface. Less than 0.15% S in the mold (or even less than 0.07% S) can reduce the surface layer depth. Oxygen may also have an effect, especially for sulphur containing systems with turbulent flows in the mold, water-bearing no-bake binder systems, Mg-Silica reactions, or dross formation conditions. Despite the lower level of nitrogen in the iron melt after magnesium treatment (less than 90 ppm), nitrogen bearing resins have a profound effect on the frequency and severity of surface pinholes, but a limited influence on surface graphite degeneration.