#consistentmgrecovery

In modern foundry operations, producing high-quality ductile iron is essential for meeting the performance demands of industries such as automotive, construction, machinery, and infrastructure. One of the most critical steps in achieving superior ductile iron properties is effective spheroidization.

Spheroidizing is the process of converting graphite flakes into spherical (nodular) shapes using magnesium or magnesium-based alloys. When done correctly, this process improves strength, ductility, fatigue resistance, and impact performance.

Modern foundries rely on proven Spheroidizing Methods For Ductile Iron to achieve uniform graphite structure, high mechanical strength, and reliable casting performance across different industrial applications.

Understanding Spheroidization in Ductile Iron

Ductile iron, also known as nodular iron, differs from grey iron mainly in its graphite structure. While grey iron contains flake-shaped graphite, ductile iron features spherical graphite nodules.

Why Spheroidization Matters

Proper spheroidization provides:

Higher tensile strength

Better elongation

Improved toughness

Reduced brittleness

Longer service life

Poor spheroidization, on the other hand, can lead to irregular graphite shapes, weak mechanical properties, and product rejection.

Role of Magnesium in Spheroidization

Magnesium is the primary element responsible for graphite spheroidization. Proper treatment practices, controlled temperature, and high-quality alloys help foundries achieve Consistent Mg Recovery, which directly improves nodularity and reduces material wastage.

How Magnesium Works

When added to molten iron, magnesium:

Reacts with sulfur and oxygen

Modifies graphite growth

Promotes spherical graphite formation

However, magnesium is highly reactive and volatile, which makes its handling and application critical.

Typical Magnesium Range

Residual magnesium: 0.03% to 0.06%

Depends on casting size and application

Maintaining proper residual magnesium levels is essential for stable results.

Selecting the Right Spheroidizing Alloy

Choosing the correct magnesium-bearing alloy is the foundation of successful treatment.

Common Spheroidizing Alloys

Ferro Silicon Magnesium (FeSiMg)

Nickel-magnesium alloys

Rare earth magnesium alloys

Selection Criteria

When selecting an alloy, consider:

Magnesium content

Rare earth percentage

Reactivity level

Compatibility with base iron

Cost-effectiveness

For high-volume B2B production, FeSiMg alloys are commonly preferred due to their balance of performance and stability.

Controlling Base Iron Quality

Spheroidization performance depends heavily on the quality of base iron.

Key Parameters to Monitor

Carbon content (3.4%–3.8%)

Silicon level (2.2%–2.8%)

Sulfur below 0.02%

Low oxygen content

Controlled manganese

Why Base Iron Matters

High sulfur and oxygen levels consume magnesium, reducing its availability for spheroidization. Clean base iron improves magnesium efficiency and lowers treatment cost.

Best Practice

Always desulfurize iron before treatment and maintain consistent furnace operation.

Choosing the Right Treatment Method

Different treatment methods are used depending on production scale and casting type. In advanced steel and iron foundries, Cored Wire Injection is increasingly used for precise magnesium addition, improved recovery rates, and better process automation, especially in high-volume production environments.

1. Sandwich Method

Magnesium alloy is placed at the bottom of the ladle and covered with steel scrap.

Advantages:

Simple and economical

Suitable for small and medium foundries

Limitations:

Lower magnesium recovery

Higher fume generation

2. Tundish Cover Method

The alloy is placed in a pocket and covered by a refractory lid.

Advantages:

Better recovery

Controlled reaction

Reduced splashing

Limitations:

Requires special ladles

3. Converter Method

Uses enclosed vessels for magnesium addition.

Advantages:

High recovery

Low emissions

Stable process

Limitations:

Higher investment

4. In-Mold Treatment

Magnesium is added inside the mold gating system.

Advantages:

Precise treatment

Suitable for thin castings

Limitations:

Limited flexibility

Recommendation

Select a method based on production volume, safety standards, and quality requirements.

Temperature Control During Treatment

Temperature plays a crucial role in magnesium recovery and reaction stability.

Ideal Temperature Range

Treatment temperature: 1450°C–1550°C

Pouring temperature: 1350°C–1450°C

Why Temperature Matters

Low temperature: Poor dissolution

High temperature: Excessive magnesium loss

Best Practice

Maintain stable furnace temperature and minimize treatment delays.

Proper Inoculation After Treatment

Spheroidization alone is not enough. Inoculation is required to improve graphite nucleation.

Purpose of Inoculation

Prevent carbide formation

Increase nodule count

Improve matrix structure

Reduce shrinkage defects

Common Inoculants

Ferrosilicon

Calcium-based inoculants

Barium alloys

Strontium alloys

Timing

Inoculation should be done:

In ladle

In stream

In mold

Late inoculation gives better results.

Monitoring Magnesium Fade

Magnesium content decreases over time due to oxidation and evaporation.

What Is Magnesium Fade?

It is the gradual reduction of residual magnesium after treatment.

Impact

Loss of nodularity

Mixed graphite shapes

Quality variation

Control Measures

Reduce holding time

Improve ladle insulation

Optimize treatment schedule

Monitor chemistry regularly

Shorter treatment-to-pouring time improves stability.

Ensuring Consistent Process Control

Consistency is key for B2B foundries supplying automotive and industrial clients.

Important Control Tools

Spectrometers

Thermal analysis systems

Metallographic testing

Online temperature monitoring

Quality Checks

Residual magnesium testing

Nodule count measurement

Nodularity percentage

Matrix evaluation

Regular testing prevents batch-to-batch variation.

Safety and Environmental Practices

Magnesium treatment involves violent reactions and fumes.

Safety Risks

Fire hazard

Metal splashing

Toxic fumes

Burns and injuries

Best Practices

Use protective equipment

Install fume extraction

Train operators

Follow standard procedures

Safe operations improve productivity and compliance.

Supplier Selection and Material Quality

Reliable raw material suppliers play a major role in process stability.

What to Look For

Consistent alloy composition

Certified quality systems

Technical support

Reliable logistics

Batch traceability

Working with trusted suppliers reduces operational risks and improves output quality.

Cost Optimization Through Best Practices

Efficient spheroidization improves profitability.

Cost-Saving Benefits

Higher magnesium recovery

Reduced scrap rate

Lower rework

Stable production

Better customer satisfaction

Smart Approach

Focus on total cost of ownership rather than lowest alloy price.

Conclusion: Build a Strong Foundation for Quality Ductile Iron

Producing high-quality ductile iron requires more than adding magnesium. It demands a systematic approach that combines clean base iron, proper alloy selection, controlled treatment methods, accurate temperature management, effective inoculation, and strong quality control.

Key Takeaways for B2B Buyers and Foundries

To achieve reliable spheroidization:

Maintain clean and low-sulfur base iron

Use certified spheroidizing alloys

Select suitable treatment methods

Control temperature and timing

Apply proper inoculation

Monitor magnesium fade

Invest in testing and safety systems

Partner with reliable suppliers

By following these best practices, foundries can deliver consistent, high-performance ductile iron products that meet global standards and customer expectations.

Strong spheroidizing control not only improves product quality but also strengthens long-term business relationships and competitive advantage.

Sulphur control remains one of the most critical challenges in S G iron production. Many foundries today work with high-sulphur base metal due to scrap availability, cost pressure, and raw material variability. But the big question remains:

How should foundries handle high-sulphur metal during S G iron treatment without compromising quality, nodularity, and cost efficiency?

This blog explores the practical, metallurgical, and business-focused answers—with a special focus on S G Iron Treatment with High Sulphur Metal, the role of Ferro Silicon Magnesium, and how to achieve consistent Mg recovery in real foundry conditions.

Why Is High Sulphur a Major Concern in S G Iron Treatment?

Sulphur is a strong magnesium-consuming element. During S G iron treatment, magnesium reacts aggressively with sulphur before it can perform its primary role—graphite spheroidization.

Key problems caused by high sulphur metal:

Excessive magnesium loss

Poor nodularity

Inconsistent mechanical properties

Higher treatment costs

Increased process instability

From a B2B and production standpoint, uncontrolled sulphur directly impacts:

Casting rejection rates

Alloy consumption

Production predictability

Customer confidence

That’s why handling high sulphur metal is not optional—it’s essential.

What Sulphur Levels Are Acceptable for Effective S G Iron Treatment?

One of the most common questions asked by foundry managers is:

How much sulphur is too much?

While exact limits depend on process and alloy quality, general industry benchmarks suggest:

Preferred sulphur before treatment: ≤ 0.02%

Manageable sulphur with proper strategy: 0.02% – 0.05%

High risk zone: > 0.05%

When sulphur exceeds safe limits, achieving Consistent Mg Recovery becomes difficult—even with higher Ferro Silicon Magnesium addition.

Can Foundries Treat High Sulphur Metal Successfully?

Yes—but only with the right strategy.

Foundries that succeed with S G Iron Treatment with High Sulphur Metal focus on control, preparation, and alloy selection, rather than trial-and-error.

Let’s break this down step by step.

Step 1: Why Pre-Treatment Desulphurization Matters

The first and most effective way to handle high-sulphur metal is desulphurization before magnesium treatment.

Common desulphurization methods:

Calcium carbide injection

Lime-based desulphurization

Synthetic slag treatment

Business advantage:

Reduces Ferro Silicon Magnesium consumption

Improves Mg recovery

Stabilizes production

Lowers overall treatment cost

Foundries that skip this step often pay more later, through higher alloy usage and rejections.

Step 2: How Does Ferro Silicon Magnesium Help in High Sulphur Conditions?

Ferro Silicon Magnesium is the backbone of S G iron treatment. However, not all FeSiMg alloys perform equally when sulphur levels are high.

What foundries should look for:

Controlled Mg percentage

Low aluminum and rare earth balance

Stable reaction behavior

Predictable Mg recovery

Using inconsistent or low-quality FeSiMg can result in:

Violent reactions

Low nodularity

Uneven graphite structure

This is where supplier reliability becomes a strategic decision, not just a purchase choice.

How Can Foundries Achieve Consistent Mg Recovery with High Sulphur Metal?

This is one of the most important B2B questions.

Consistent Mg recovery means:

Predictable alloy consumption

Stable microstructure

Repeatable casting quality

Key factors influencing Mg recovery:

Initial sulphur level

Treatment temperature

Method of treatment (sandwich, tundish, wire injection)

Quality of Ferro Silicon Magnesium

Reaction control and slag removal

Even with high-sulphur metal, foundries can achieve stable results by optimizing all five factors together, rather than adjusting only Mg addition.

Why Treatment Method Matters More with High Sulphur Metal

High sulphur increases reaction intensity. Choosing the wrong treatment method can lead to:

Excessive fume loss

Magnesium burn-off

Safety risks

Preferred methods for high sulphur metal:

Sandwich method with proper cover

Tundish cover with a controlled reaction chamber

These methods improve magnesium utilization, making them ideal for managing sulphur-heavy melts.

What Role Does Process Discipline Play?

One overlooked aspect is process consistency.

Foundries struggling with sulphur-related issues often face:

Inconsistent charge mix

Variable scrap quality

Poor temperature control

Handling high sulphur metal is not only a metallurgical challenge—it’s an operational discipline challenge.

Successful foundries:

Monitor sulphur at every stage

Standardize treatment practices

Train operators on reaction control

How Can Alloy Suppliers Support Better Results?

This brings us to the supplier’s role.

Why M/S Bansal Brothers Matters

M/S Bansal Brothers is a trusted name in Ferro Silicon Magnesium and S G iron treatment solutions. Their focus on:

Consistent alloy chemistry

Reliable Mg recovery behavior

Foundry-specific technical understanding

helps customers handle S G Iron Treatment with High Sulphur Metal more confidently.

For B2B buyers, this means:

Reduced trial costs

Better production planning

Long-term process stability

A reliable alloy partner is not just a vendor—it’s a process enabler.

Is Increasing Magnesium Addition a Good Solution?

This is a common but costly mistake.

Simply increasing FeSiMg addition:

Raises cost

Increases slag volume

Causes reaction instability

Without sulphur control, extra magnesium mostly gets consumed by sulphur, not graphite formation.

Smart sulphur management always beats higher alloy addition.

How Should Foundry Decision-Makers Approach High Sulphur Challenges?

From a management perspective, the right questions to ask are:

Are we measuring sulphur consistently?

Are we using the right grade of Ferro Silicon Magnesium?

Is our Mg recovery predictable?

Are we treating symptoms or solving root causes?

Foundries that ask the right questions achieve better margins and fewer surprises.

Frequently Asked Questions (FAQs)

What is S G Iron Treatment with High Sulphur Metal?

S G Iron Treatment with High Sulphur Metal is the magnesium treatment of ductile iron when the base metal contains elevated sulphur levels. High sulphur reacts with magnesium first, reducing its effectiveness for graphite spheroidization unless sulphur is properly controlled before treatment.

Why is high sulphur a problem during S G iron treatment?

High sulphur consumes magnesium rapidly, leading to low magnesium recovery, poor nodularity, and inconsistent mechanical properties. It also increases Ferro Silicon Magnesium consumption and treatment cost, making sulphur control critical for stable and economical S G iron production.

What is the ideal sulphur level before S G iron treatment?

For effective S G iron treatment, sulphur should ideally be 0.02% or lower before magnesium addition. Higher sulphur levels can still be managed, but they require proper desulphurization and high-quality Ferro Silicon Magnesium to maintain consistent Mg recovery.

How does Ferro Silicon Magnesium help in high-sulphur metal?

Ferro Silicon Magnesium supplies magnesium needed for spheroidization. When properly designed, it reacts in a controlled manner, improves magnesium recovery, and supports nodular graphite formation—even in high sulphur metal—especially when supplied by experienced manufacturers like M/S Bansal Brothers.

Can consistent Mg recovery be achieved with high sulphur metal?

Yes. Consistent Mg recovery can be achieved through pre-treatment desulphurization, correct treatment temperature, controlled treatment methods, and the use of high-quality Ferro Silicon Magnesium. Managing sulphur before treatment is more effective than increasing magnesium addition.

Is increasing magnesium addition the right solution for high sulphur?

No. Increasing magnesium addition raises cost, slag volume, and process instability. Without sulphur control, most of the added magnesium is consumed by sulphur rather than improving nodularity. Proper sulphur management is a more efficient and reliable solution.

Which treatment method works best for high-sulphur metal?

For high-sulphur metal, sandwich and tundish cover methods work best. These methods reduce magnesium loss, control reaction intensity, and improve Mg recovery, making them suitable for stable S G iron treatment under challenging sulphur conditions.

How does sulphur control improve S G iron quality?

Effective sulphur control improves magnesium recovery, nodularity, microstructure consistency, and mechanical properties. It also reduces Ferro Silicon Magnesium consumption, lowers rejection rates, and ensures predictable casting performance in S G iron production.

How does M/S Bansal Brothers support S G iron treatment with high-sulphur metal?

M/S Bansal Brothers supplies consistent-quality Ferro Silicon Magnesium designed for stable reactions and predictable Mg recovery. Their alloys help foundries manage high-sulphur metal efficiently, reduce process variation, and achieve reliable S G iron treatment results.

Final Thoughts: Turning High Sulphur into a Manageable Variable

High sulphur metal is no longer unusual—it’s a reality of modern foundry operations. The key is not avoiding it, but handling it intelligently.

With:

Proper desulphurization

High-quality Ferro Silicon Magnesium

Controlled treatment methods

Focus on consistent Mg recovery

Support from experienced suppliers like M/S Bansal Brothers

foundries can successfully manage S G Iron Treatment with High Sulphur Metal while maintaining quality, efficiency, and profitability.

Ductile iron, also known as nodular cast iron or spheroidal graphite iron, has become one of the most widely used engineering materials in modern foundries. Its strength, toughness, and machinability make it ideal for automotive components, pipes, gears, heavy machinery, and countless industrial applications.

But what gives ductile iron its unique properties? The answer lies in spheroidizing treatment—a metallurgical process that transforms the graphite in cast iron from flake form into rounded, nodular structures. This change drastically improves ductility, toughness, and fatigue resistance, making ductile iron far superior to traditional gray cast iron.

In this article, we’ll explore the spheroidizing techniques, treatment methods, and best practices that ensure consistent, high-quality ductile iron production.

What is Spheroidizing in Ductile Iron?

In regular gray cast iron, graphite appears as sharp flakes. These flakes act as stress concentrators, leading to brittleness and cracking under load. By contrast, in ductile iron, the graphite forms spherical nodules. This shape reduces stress concentration and enhances mechanical properties such as:

Higher tensile strength

Improved ductility

Better impact resistance

Superior fatigue strength

Good machinability

Spheroidizing is achieved by treating molten cast iron with nodularizing agents, usually alloys containing magnesium (Mg), rare earth elements (RE), or a combination of both.

Key Spheroidizing Techniques

Several methods are used in foundries to introduce magnesium into molten iron for spheroidizing. The choice depends on production scale, cost considerations, and the level of control required.

1. Sandwich Method

The magnesium alloy is placed at the bottom of a ladle and covered with steel scrap or a refractory material.

Molten iron is then poured into the ladle, covering the alloy.

The covering layer helps control the violent reaction of magnesium with iron.

Advantages:

Simple and cost-effective.

Requires less equipment.

Challenges:

Lower recovery of magnesium compared to other methods.

Less consistent results for high-volume production.

2. Tundish Cover Method

Magnesium alloy is placed inside a small pocket or cavity at the bottom of the ladle.

Molten iron enters through a tundish (a refractory-lined chamber) and covers the alloy, ensuring controlled reaction.

Advantages:

Safer and cleaner process than the sandwich method.

Better magnesium recovery rate.

Challenges:

Slightly more complex setup.

Requires skilled handling.

3. Converter (Treatment Ladle) Method

Magnesium alloy is added to a specially designed treatment ladle, often equipped with a lid and venting system.

Molten iron is poured into the ladle, where the reaction is carefully controlled.

Advantages:

Consistent Mg Recovery. 

Suitable for larger production batches.

Challenges:

Requires special equipment.

Higher operational cost.

4. In-Mold Method

Magnesium alloy (often in cored wire or pressed briquette form) is placed inside a cavity in the mold itself.

As molten iron fills the mold, spheroidization occurs directly before solidification.

Advantages:

Very efficient magnesium utilization.

Reduced fading of magnesium effect.

Ideal for small castings.

Challenges:

Limited to specific casting sizes and applications.

Precise control is needed to avoid defects.

5. Cored Wire Injection Method

A continuous cored wire containing magnesium and other additives is injected into molten iron using a wire-feeding machine.

The process allows precise control of magnesium addition.

Advantages:

Highest consistency and control.

Best suited for automated, large-scale production.

Minimal fume and slag generation.

Challenges:

Requires specialized wire-feeding equipment.

Higher initial investment.

Best Practices in Spheroidizing Treatments

To achieve high-quality ductile iron with uniform properties, foundries follow proven best practices:

1. Control of Base Iron

The chemical composition of the base iron before spheroidizing is critical.

Carbon and silicon must be within specific ranges.

Sulfur must be minimized, as it counteracts the effect of magnesium.

2. Selection of Nodularizer

Ferro Silicon Magnesium (FeSiMg)  is the most commonly used nodularizer.

Rare earth elements may be added to stabilize the nodules and improve consistency.

The choice depends on casting size, cooling rate, and mechanical property requirements.

3. Process Control

The temperature of molten iron should be carefully controlled, usually around 1400–1500°C during treatment.

Proper ladle design ensures uniform treatment.

Reaction gases (from Mg vaporization) must be safely vented.

4. Avoiding Magnesium Fading

Magnesium has a strong tendency to fade (lose effectiveness) if there’s a delay between treatment and pouring.

To minimize fading:

Pour castings immediately after treatment.

Use in-mold or wire injection methods for better retention.

5. Post-Inoculation Treatment

After spheroidizing, inoculants (like FeSi) are added to refine graphite structure.

This helps prevent carbide formation and ensures uniform nodule distribution.

Common Defects & Solutions

Even with proper treatment, some issues may arise:

Chunky Graphite: Caused by excessive rare earths or high cooling rates. Solution: Optimize alloy composition and cooling.

Carbide Formation: Due to insufficient inoculation or low silicon. Solution: Proper inoculation and silicon adjustment.

Poor Nodule Count: Results from fading or low magnesium recovery. Solution: Ensure timely pouring and effective Mg addition.

Applications of Ductile Iron

Because of effective spheroidizing treatments, ductile iron finds widespread use in:

Automotive components (crankshafts, gears, suspension parts)

Pipes and fittings for water and sewage systems

Wind turbine hubs and energy equipment

Machine tool components

Agricultural machinery

Its balance of strength, ductility, and cost-effectiveness keeps ductile iron at the forefront of modern engineering.

Conclusion

Spheroidizing Methods For Ductile Iron are the backbone of producing high-performance castings. Whether using the sandwich method for small foundries or advanced cored wire injection for large-scale production, the goal remains the same—achieving consistent nodularity and superior mechanical properties.

By carefully controlling base iron quality, treatment techniques, and post-treatment practices, foundries can ensure defect-free ductile iron that meets the growing demands of industries worldwide.

Mastering these techniques not only enhances casting quality but also ensures cost efficiency and reliability—making ductile iron a preferred material for the future of engineering.

In modern metallurgical and foundry operations, magnesium (Mg) plays a crucial role in Nodularization and desulfurization—especially in ductile iron and steelmaking. But the efficiency of these processes doesn't just depend on the magnesium alloy used; it heavily relies on the delivery system—particularly the magnesium cored wire feeder.

If you're aiming for Consistent Mg Recovery, investing in the right cored wire feeder system isn't a luxury—it's a necessity.

In this blog, we’ll explore why consistency matters, how cored wire feeders work, and how selecting the right feeder can drastically improve your results, efficiency, and cost savings. If you're a plant manager, engineer, or decision-maker in the metal industry—this one's for you.

The Importance of Stable Mg Recovery in Foundry Operations

Stable magnesium absorption in molten metal is not just a technical requirement—it directly impacts your bottom line.

When your recovery process is steady and repeatable, you benefit from:

Improved product quality

Better control over mechanical properties

Reduced magnesium consumption

Fewer defects and less rework

More predictable casting and steelmaking results

On the other hand, if the recovery fluctuates, the entire batch can become unreliable—leading to costly corrections or scrap.

How the Right Feeder Impacts Mg Recovery

If you’re aiming to make your magnesium treatment process more reliable, your wire feeding equipment must perform consistently. Here’s how a high-quality system improves results:

1. Precise Wire Feeding Speed

The feeder’s motor and control system determine how fast the wire is injected. Feeding too fast may cause violent reactions and increased fume loss. Feeding too slowly can result in a delayed reaction or inadequate penetration.

The right feeder ensures adjustable, programmable, and smooth speed control, giving you greater consistency in recovery.

2. Accurate Wire Positioning

Wire insertion depth and angle into the ladle or tundish must be optimized for each process.

A well-designed feeder ensures accurate positioning, reducing turbulence, improving reaction efficiency, and minimizing Mg loss.

3. Steady Tension and Drive System

Inconsistent feeding can break the wire, cause jams, or result in erratic dosing—all of which ruin your recovery rates.

A quality Magnesium Cored Wire Feeder uses tension control mechanisms and servo motors to maintain steady wire delivery.

4. PLC-Based Automation

Modern feeders come equipped with programmable logic controllers (PLC) for precision automation.

With PLC, operators can:

Pre-set feed rates

Monitor wire consumption

Trigger alarms for anomalies

This automation ensures that human errors are minimized, and Mg delivery remains accurate and repeatable.

5. Compatibility with Various Wire Types

Not all feeders handle all types of wires well. Your process might need FeSiMg, pure magnesium, or multi-strand wires.

A good feeder can handle a variety of wire diameters and compositions without sacrificing feed quality.

The Cost of Using the Wrong Feeder

If you’re using outdated, poorly maintained, or improperly sized cored wire feeder systems, you risk:

Higher Mg consumption (more cost)

Increased fume and smoke loss (poor environment & safety)

Irregular Mg absorption (product inconsistency)

More scrap and rework (profit loss)

Operator safety hazards

Simply put: cutting corners on your feeder system can cost you a lot more than upgrading it.

Features to Look for in a Reliable Wire Feeding System

When selecting a system for your magnesium treatment process, ensure it includes:

Choosing a system with these features ensures that every gram of magnesium delivers maximum value.

Real-World Impact: A Foundry's Experience

A medium-sized Ductile Iron foundry in northern India was facing inconsistent nodularity levels in castings. Despite using high-grade magnesium alloy, their recovery rates varied between 30–50%.

After installing a digitally controlled wire injection system with adjustable feed speed and automated feedback loops, the results were dramatic:

Recovery stabilized at above 55%

Magnesium consumption dropped by 12%

Quality rejections reduced by 40%

ROI was achieved in under 6 months

The takeaway? Precision equipment led to consistent results and cost savings—all without changing their magnesium source.

Final Thoughts

Consistency in magnesium recovery is not just about the alloy—it's about how you deliver it.

If your current feeding setup lacks automation, stability, or precision, it’s likely costing you more than you realize. In today’s competitive industrial environment, investing in the right system can significantly boost both quality and profitability.

Ready to Improve Your Recovery Results?

Looking to upgrade your treatment process? Need help selecting the right wire injection system for your operation?

Contact our experts today for a tailored recommendation based on your plant size and metal output.

Or, request a demo and see firsthand how the right feeding system can deliver better consistency, safety, and savings.

Consistent magnesium and magnesium recovery have always been subjects for discussions amongst foundry people. This presentation summarises the most important factors that will affect the recovery and adding rate of magnesium in ladle treatment processes.

Factors influencing the Consistent Magnesium Recovery and Addition.

In order to evaluate the basics of ductile iron production the advanced mechanism of the graphite has to be considered. It is planned that growth normally occurs along the pole of the plane with the lowest interfacial energy in connection with the melt. This will be the plane with the highest packing density and this will have the main growth rate.

With surface-active elements like O and S present the prism plane will grow fastest, but if these elements are neutralised the basal plane will again have the highest growth rate.

The main growth rate from the basal plane will result in ductile iron and from the prism level in grey iron. Hence consistent Mg recovery is added in order to neutralise surface active elements such as Sulphur and oxygen.

This means that improved content of Sulphur and oxygen in base iron require advanced adding of consistent Mg recovery. An example presentation of the effect of higher Sulphur level in the base iron without increasing the count rate of MgFeSi.