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During the process of cast iron smelting, particularly 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") tend to occur. These defects are primarily influenced by factors like the chemical composition of the alloy, the smelting process, mold conditions, and the overall casting plan. When the alloy's composition and mold setup remain consistent, the smelting process and its quality become key areas of focus for improvement.
Through years of practical experience, it has been observed that shrinkage cavities, porosity, and cracks are closely linked to the chemical makeup 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 procedure, these defects are generally minimized. Most of the current shrinkage and porosity issues stem from improper chemical compositions in the cast iron.
To address this, it is essential to follow specific guidelines when batching the molten iron. The strategy should focus on keeping the carbon content at its upper limit, while maintaining the silicon and manganese levels at their lower limits. This approach helps reduce the risk of defects and improves the overall quality of the final product.
For example, in the production of a clutch platen made from HT250 cast iron with a thickness of 30mm or more, the recommended batching formula is: carbon content (wC) = 3.35%, silicon (wSi) = 1.75%, and manganese (wMn) = 0.6%. A carbon loss rate of 5% and a manganese loss rate of 10% are typically accounted for during the smelting process.
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 significantly decreased, and the overall quality of the castings remains highly reliable and consistent. This success highlights the importance of proper chemical control and process optimization in achieving high-quality cast iron products.
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