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During the process of cast iron smelting, especially in medium frequency induction furnaces, several common defects such as shrinkage cavities, slag holes, pores, and cracks (collectively known as "three holes and one crack") often occur. These defects are primarily influenced by factors like the alloy's chemical composition, the smelting process, mold conditions, and the overall casting plan. When the chemical composition and mold conditions remain consistent, the smelting process and its quality become the key areas to focus on for defect prevention.
Through years of practical experience, it has been observed that shrinkage cavities, porosity, and cracks are closely linked to the composition of the cast iron. If the melting temperature reaches 1500°C or higher, and the alloy composition remains stable with no changes in the casting process, these defects tend to be significantly reduced. Most of the current shrinkage and pore-related issues can be traced back to improper chemical compositions in the cast iron.
To address this, it is essential to follow specific principles when batching the molten iron. This includes setting a high limit for carbon content, a low limit for silicon content, and a low limit for manganese content. These adjustments help ensure better control over the final properties of the castings.
For example, when producing clutch plates using HT250 cast iron with a thickness of 30mm or more, the recommended batching formula is: carbon content at 3.35%, silicon at 1.75%, and manganese at 0.6%. The carbon loss during smelting is typically around 5%, while the manganese loss is about 10%.
After years of continuous production, our company has achieved consistently stable mechanical properties in the castings we produce. The occurrence of "three holes and one crack" has become rare, and the overall quality of the castings remains highly reliable. This success is largely due to strict adherence to proper smelting practices and careful control of the alloy composition throughout the process.
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