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In this work, heat balance is incorporated in developing expressions of general validity for the solidification of hypo-eutectic flake graphite cast iron, as well as eutectic and slightly hyper-eutectic nodular iron. These expressions incorporate the active nucleation and growth processes that occur in flake and nodular graphite. The derived analytical equations describe the eutectic cell N and nodule count N n as a function of the solidification parameters and melt chemistry. From this analysis, eutectic cell or nodule counts can be predicted based on experimental data related to cooling rates and chemical composition. In particular, it has been found that the quality of the liquid cast iron is closely tied to its intrinsic nucleation properties (N S and b coefficients in the nucleation equation, N nuc =N s exp(-b/∇T m )), or directly to the graphite nuclei density, N nuc . Moreover, the outcome of the present work is used in providing a rational for the effect of technological factors such as the material mold ability to absorb heat, the casting modulus, pouring temperature, chemistry, inoculation practice, holding temperatures and times on the resultant cell count or nodule count in cast iron.

Eutectic Cell and Nodule Count in Cast Iron: Part I. Theoretical Background