Background: I had the pleasure of visiting my mentors at a commercial foundry in Western Washington that casts grey and ductile iron, steels and stainless in amounts up to 10,000 pounds. The owner together with his metallurgist and foundry foreman, in the course of discussion about I was having trouble with a small casting, provided me some information about their use of ferrosilicon. I am sure they mentioned this a few years ago as I was beginning my small foundry quest, but I was so preoccupied with a hundred other questions that I failed to pay close enough attention. I also think that back then I missed the crucial part about inoculating the melt only a very few minutes (5 or
less)
Goto CHIDA to know more.
prior to pouring. Anyway, I fumbled around and ended up using much more ferro than was needed for quite a while, but gradually decreasing and decreasing amounts used. Most recently I've been using about an ounce per ten pounds of iron melted and for quite a while have been meticulous about adding it within 2 minutes of actual pour. I ahve gotten good results that way, but may have had more shrinkage than was necessary though I have been able to overcome that by use of risers.so for 50 pounds of iron I should be using
The recommendation is that I use what they use---a 1:800 ratio of FeSi to iron. So for 50 pounds of iron I need only use 1 ounce of FeSi. I will be doing just that later today along with repositioning my pattern in this deceptively "simple" casting that has been giving me fits. More on that in a separate thread when I have more time to write and post pics.
How does this ratio of 1:800 square with others' experience?
Incidentally the spectrometry they did on my failed casting showed spot-on analysis except for Si which was 3 times the amount called for. That amount of silicon is not likely to cause any problems except possibly excessive shrinkage. But machinability, strength, and stability should be unaffected.
DenisClick to expand...
Time: 03 15, Author :wanhua
The melting point of ferrosilicon is ° C to ° C. The boiling point is ° C. Ferrosilicon contains about 2% calcium and aluminum. As an additive to the ferrous metal production process, ferrosilicon will impart several desirable properties to the resulting alloy.
What are the main benefits of adding ferrosilicon to the alloy? That is:
1. Improve the corrosion resistance of new compounds.
2. Increase the high temperature and heat resistance of the new alloy. For example, steel used in transformer cores in the production of silicon.
Ferrosilicon is an iron alloy composed of iron and silicon. Ferrosilicon production process:
First, silica (or sand) is mixed with coke. The reduction process is then carried out in the presence of scale, waste or other sources of iron.
The blast furnace is used for the production of ferrosilicon. However, for larger levels of silica, an electric arc furnace is used. A large portion of the global Ferro Silicon supply is produced in China, the US and India.
Ferrosilicon alloys are used in the following areas:
1. Used as a reducing agent in the production of ferroalloys.
Not only is the chemical affinity between silicon and oxygen high, but the high silicon ferrosilicon has a very low carbon content. Therefore, ferrosilicon is a commonly used reducing agent in the production of low carbon iron alloys in the iron alloy industry.
2. Used as a deoxidizer and alloying agent in the steelmaking industry.
The ferrosilicon powder can emit a large amount of heat when it is burned at a high temperature. Therefore, it is often used as a heat generating agent for steel ingot caps to improve the quality and recovery rate of steel ingots.
3. Ferrosilicon is used in the high-temperature smelting process of magnesium metal.
If you want to learn more, please visit our website High Purity Silica Sand.
Magnesium in CaO.MgO was replaced. Each ton of metal magnesium produced consumes about 1.2 tons of ferrosilicon. It plays a big role in the production of magnesium metal.
4. Can be used as a coating for welding rods in the electrode manufacturing industry.
5. Ferrosilicon can be used in the chemical industry to manufacture products such as silicone.
6. Used as an inoculant and spheroidizing agent in the cast iron industry.
Cast iron is an important metal material in modern industry. It is cheaper than steel and is easy to melt and smelt. It has excellent casting properties and much better seismic resistance than steel.
7. Ferrosilicon is extensively used in the metallurgical industry for the processes of atomization, casting, melting and heavy media separation reactions.
8. The alloy is used as a basic raw material for inoculation, adjusting, suspending, mineral processing and in the melting rod industry. It is also used for deoxidization and coating in steel melting.
9. Ferrosilicon is used as a source of pure silicon in the electric industry.
10. It is used to manufacture silicon copper in the chemical industry.
11. Ferrosilicon is used in the manufacturing of semiconductors.
The steelmaking industry and the foundry industry are the largest users of ferrosilicon. They consume more than 90% of ferrosilicon.
Among the various grades of ferrosilicon, the most widely used is 75% ferrosilicon. In the steelmaking industry, about 3-5 kg of 75% ferrosilicon is consumed for every 1 t of steel produced.
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