Detailed Project Report on ductile iron casting manufacturing from induction furnace (300 to 400 mt/month)

DUCTILE IRON CASTING MANUFACTURING FROM INDUCTION FURNACE [3610]

Ductile iron casting refers to a process in which magnesium/Cerium (as an alloy of magnesium / Cerium) is added to cast iron. It was first manufactured by K.D. Mills in 1943. While most varieties of cast iron are comparatively brittle, ductile iron castings are much more ductile due to the inclusion of nodular graphite. Solidified castings of ductile iron contain nearly perfect spheres of graphite. Ductile iron possesses the processing advantages of grey iron, such as low melting point, good fluidity, castability and machinability, and engineering advantages of steel, including high strength, ductility and wear resistance. Achieving the desired quality consistently at low cost in a production foundry is, however, still a challenge. Addition of small amount of cerium or magnesium to molten cast iron changes the shape of graphite from laminar to spheroidal, giving rise to spheroidal graphite iron or ductile iron. The rapid growth in industrial applications of ductile iron (DI) is driven by its versatility and high performance at low cost. It offers a good combination of tensile strength and ductility. This allows designers to select ductile iron for a wide range of applications. Ductile iron also offers cost savings compared to steel and malleable iron castings through higher yield and thereby lower melting energy. Formation of graphite during solidification leads to lower volumetric shrinkage in ductile iron (compared to steel), necessitating smaller and fewer feeders to prevent the formation of shrinkage defects. Further cost advances can be achieved by eliminating heat treatment of as-cast DI parts. The near-spherical shape of the graphite nodules distributed evenly in the matrix phase of ductile iron enhances its ductility and impact resistance along with tensile and yield strength equivalent to a low carbon steel. While ferritic ductile iron can be used as ‘as-cast’, it may also be annealed to increase its ductility and low-temperature toughness. The pearlitic ductile iron has graphite spheroids in a matrix of pearlite, resulting in high strength, good wear resistance, moderate ductility and impact resistance. The most commonly used ferritic-pearlitic ductile iron containing both ferrite and pearlite in matrix offers a good combination of tensile strength and ductility with good machinability and low production costs. The ductile iron castings are produced in a wide range of weight, from a few grams to a hundred tons or more, greatly varying in shape and size depending on the applications (Figure 1). Many forged and fabricated steel components are getting replaced by ductile iron castings, owing to their good combination of mechanical properties such as strength, wear resistance, fatigue strength, toughness and ductility coupled with economic production. The specifications of ductile irons with ferrite/pearlitic matrix with different grades are shown in Table 1. They are used in safety parts in automobiles, armatures, pumps and machine tools. They are also used in parts subjected to high pressure, such as pressure containers and hydraulics. Many welded assemblies and forgings used in governor housings, armatures and car parts (like brake calipers and gear housings, hydraulic parts, crankcases and blower buckets) are being replaced by ferritic ductile iron castings. Cast or grey iron is an alloy characterized by its relatively high content of carbon flakes (2% to 4%). In contrast, the carbon in ductile iron is in the form of spherical nodules. The formation of such nodules is achieved by the addition of 'nodulizers' like magnesium or cerium into the castings melt. Due to its inherent properties, such nodules resist the creation of cracks and augment its ductility. That is why this process is called as ductile iron casting. In the as-cast condition, the matrix will consist of varying proportions of pearlite and ferrite, and as the amount of pearlite increases, the strength and hardness of the iron also increase. Ductility and impact properties are principally determined by the proportions of ferrite and pearlite in the matrix. The mechanical properties of ductile iron are controlled by the presence of graphite nodules. The Different grades of Ductile Iron Castings are produced by obtaining different matrix microstructures in the Iron. Alloying elements may be added to enhance as cast properties of Ductile Iron. In some special cases Heat Treatment can be employed to achieve the higher properties. The Grades of Ductile Iron Castings are based on the Mechanical Properties of the casting. Ductile iron with high strength and toughness has been available as an engineering material for many years, replacing forging steel, cast steel, and malleable cast-iron. It has undergone a phenomenal development and has become the only ferrous casting material with positive growth rate. The ductile iron will still be an important construction material in the 21st century. Ductile iron is a ternary Fe-C-Si alloy, in which the concentrations of carbon and silicon vary typically from 3.5 to 3.9% and from 1.8 to 2.8%, respectively. The selection of the composition is dictated by the casting section size and by the targeted mechanical properties. The output characteristics depend on the matrix structure and the shape, size, and distribution of the graphite spheroids. Matrix and spheroids, in their turn, depend on the chemical composition of the melt, on the desulphurizing and spheroidizing methods applied in the treatment ladle, onthe inoculation method and finally, on the time elapsing between these events and the casting in the mould . Moreover, the mechanics of spheroid formation itself has not yet been completely understood and many models are still in competition. Production of ductile iron is influenced by a large number of metallurgical, technological, heat transfer, and designing parameters. The first step of the production of ductile iron castings is careful selection of the charge materials. Manganese and chromium have the strongest influence on mechanical properties of the ductile iron. For this reason, their concentration in the metal is of particular importance. These elements arise in the charge from the steel scrap, pig iron, and returns. It is a recommended practice to surchage steel scrap so that the average Cr content remains below 0.1 percent. Ideally, the same advice would be given for Mn but, unfortunately, all steel scraps contain Mn, mostly about 0.5 percent. The amount of steel scrap in the charge must ensure the production of castings that are as free of carbides as possible. It is necessary not to mix grey iron return scrap with the ductile iron one, because grey iron castings have an increased manganese and chromium content. Ductile iron return scrap has large silicon and small sulphur content. However, if spheroidizing elements are present in excessive concentration they act as despheroidizers. Charge materials result in the average size of graphite spheroids. For instance, if the amount of the steel scrap in the charge is more than 50 percent then an average spheroid diameter is 33 µm, if it is 30 percent then the average diameter is 57 µm . The amount of the steel scrap affects the metallic matrix structure as well, increasing the pearlite formation. However, fully pearlitic castings are produced more easily by adding copper. The graphite structure is also affected by the carbon content. If the initial metal does not contain enough carbon then graphite particles have a compact form . The metallic matrix structure is affected not only by carbon equivalent but also by the C/Si ratio. Increasing this ratio in ductile iron decreases the proportion of ferrite and increases the proportion of pearlite. The formation of graphite spheroids is obtained through a special treatment, during which spheroidizing elements are added to the melt. Both Mg and various Mg alloys are most commonly used for ductile iron spheroidization. The choice of a treatment method (open ladle, sandwich, tundish cover, in-mould, plunger, converter, injection, and others for an individual foundry must be based on the circumstances present in the foundry. Inoculation, which may take place at different phases of the process, is a necessary step in the production of ductile iron castings. Most inoculants are ferrosilicons. An inoculant grade FeSi always contains elements in relatively low concentration, which are active inoculants, such as Ca, Al, Zr, Ba, Sr, and Ti. These elements are used to increase the solubility of the alloys. There are three ways to inoculate the metal, which are used individually or in combination: in the ladle, in the stream while pouring or reladling, and in the mould.

COST ESTIMATION

Plant Capacity                          20 MT/Day  
Land & Building (10000 sq.mt)     Rs. 7.02 Cr
Plant & Machinery                    Rs. 5.15 Cr
Working Capital for 1 Month   Rs. 3.32 Cr
Total Capital Investment          Rs. 16.24 Cr
Rate of Return                         44%
Break Even Point                     57%



INTRODUCTION    
COMPOSITION OF DUCTILE IRON CASTINGS    
DUCTILE IRON    
COMPOSITION    
COMMON DUCTILE IRON GRADES    
THE FAMILY OF DUCTILE IRON    
PROPERTIES OF DUCTILE IRONS    
BENEFITS OF DUCTILE IRON    
USES AND APPLICATION    
APPLICATIONS    
DUCTILE IRON APPLICATION    
1. PRESSURE PIPES AND FITTINGS    
2. AUTOMOTIVE APPLICATIONS    
3. AGRICULTURE, ROAD AND CONSTRUCTION APPLICATIONS    
4. GENERAL ENGINEERING APPLICATIONS    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
PRODUCTION PROCESS    
(1) RAW MATERIAL    
CHEMICAL COMPOSITION OF THE BASE IRON    
A. TOTAL CARBON    
B. MANGANESE    
C. PHOSPHORUS    
D. SULPHUR    
E. SILICON    
F. NICKEL    
G. OTHER ELEMENTS    
PHYSICAL CONDITION OF THE BASE IRON    
CHARGE MATERIALS    
A. PIG IRON    
B. STEEL SCRAP    
C.S.G. IRON RETURNS    
D. OTHER CHARGE MATERIALS    
(2). MELTING AND COMPOSITION CONTROL    
MELTING UNITS    
A. CUPOLAS    
B. AIR FURNACES    
C. INDUCTION MELTIUG FURNACES    
D. ELECTRIC ARC FURNACES    
CONTROL OF MELT    
A. DESULPHURIZATION OF THE MELT    
B. NODULISATION OR SPHERIODATION (MAGNESIUM TREATMENT)    
TREATMENT ALLOYS    
A. MAGNESIUM MASTER ALLOYS    
CHOICE OF MASTER ALLOYS    
POURING TEMPERATURES FOR CASTINGS    
SPHEROIDIZATION TECHNIQUES    
CLASSIFICATION OF PROCESSES    
I) PROCESSES WHICH USE MG MASTER ALLOYS    
A) LADLE TRANSFER PROCESSES,    
A) LADLE TRANSFER PROCESSES    
I) OPEN LADLE PROCESS    
II) SANDWICH PROCESS    
III) PUDDING PROCESS    
IV) TRIGGER PROMS    
B) PROCESSES OTHER THAN LADLE TRANSFER    
I) PLUNGING PROCESS    
II) POROUS PLUG PRACTICE    
III) INSMOULD PROCESS    
IV) T-KNOCK PROCESS    
V) FLOTRET PROCESS    
B) PROCESSES WHICH USE PURE MAGNESIUM    
I) PRESSURE LADLE AND PRESSURE CHAMBER TECHNIQUES    
II) INJECTION PROCESS    
III) G.F. CONVERTOR PROCESS    
IV) DETACHABLE BOTTOM LADLE PROCESS    
INOCULATION    
EFFECT OF INOCULATION    
(3) CASTING    
SAND CASTING    
ADVANTAGES OF SAND CASTING    
DISADVANTAGES OF SAND CASTING    
(A) PATTERNMAKING    
(B) CORE MAKING    
(C) MOLDING    
(D) CLAMPING    
(E) MELTING & POURING    
(F) COOLING    
(G) REMOVAL    
(H) TRIMMING    
(I) CLEANING    
(J) QUALITY CONTROL    
CASTING DEFECTS    
DEFECTS RELATED WITH SAND MOLDS    61
INSPECTION METHODS    
(4) HEAT TREATMENT    
I) STRESS RELIEF    
II) SUB-CRITICAL ANNEALING    
III) FULL ANNEALING    
IV) NORMALIZING    
V) QUENCHING AND TEMPERING    
(5) QUALITY CONTROL (INSPECTION AND TESTING)    
INSPECTION METHODS    
INSPECTION METHODS TO DUCTILE IRON CASTINGS    
1. VISUAL INSPECTION    
2. MAGNETIC PARTICLE (POWDER) INSPECTION    
3. ULTRASONIC TESTING    
A. TENSILE TEST    
B. IMPACT TEST    
C. HARDNESS TEST    
MARKING    
FURNACE USED FOR MELTING    
(A) COUPLA FURNACE    
COLD BLAST CUPOLA OPERATION    
METALLIC CHARGE MATERIALS    
HARMFUL MATERIALS    
SIZE OF METALLIC CHARGE MATERIALS    
FERROALLOYS    
CUPOLA OUTPUT    
EMISSIONS FROM CUPOLAS    
HOT BLAST CUPOLA    
CONSTRUCTION OF COUPLA FURNACE    
STRUCTURE OF CUPOLA FURNACE    
AS SEEN FROM THE FIG, THE MAIN PARTS OF CUPOLA ARE    
(I) SHELL    
(II) FOUNDATION    
(III) CHARGING DOOR    
(IV) CHARGING PLATFORM    
(V) AIR BLOWER    
(VI) TUYERES    
(VII) VOLUME METER    
(VIII) TAP HOLE (MOLTEN METAL HOLE)    
(IX) SLAG HOLE    
(X) CHIMNEY    
OPERATION OF CUPOLA FURNACE    
THE OPERATION OF CUPOLA FURNACE CONSISTS OF FOLLOWING STEPS    
(I) PREPARATION OF CUPOLA    
(II) FIRING OF CUPOLA    
(III) CHARGING THE CUPOLA    
(IV) SOAKING OF IRON    
(V) STARTING THE AIR BLAST    
(VI) CLOSING THE CUPOLA    
ZONES OF CUPOLA FURNACE    
THE FOLLOWING ARE THE SIX IMPORTANT ZONES    
(I) WELL OR CRUCIBLE ZONE    
(II) COMBINATION ZONE    
(III) REDUCING ZONE    
(IV) MELTING ZONE    
(V) PREHEATING ZONE    
(VI) STACK ZONE    
CAPACITY OF CUPOLA FURNACE    
ADVANTAGES OF CUPOLA FURNACE    
LIMITATIONS OF CUPOLA FURNACE    
(B) INDUCTION FURNACE    
THE CHANNEL FURNACE    
THE CORELESS INDUCTION FURNACE    
CHARGE MATERIALS    
SLAG REMOVAL    
REFRACTORIES FOR CORELESS INDUCTION FURNACES    
OPERATING SYSTEMS    
FUME EXTRACTION    
IRON MAKING IN INDUCTION FURNACE    
RAW MATERIALS    
CHARGE PREPARATION AND CHARGING    
MELTING AND SLAG REMOVAL    
MAKING THE HEAT READY, TAPPING AND EMPTYING THE FURNACE    
PROCESS CONTROL AND AUTOMATION    
PROCESS AUTOMATION    
PROCESS MONITORING    
INFORMATION DISPLAY AND RECORDING    
INTERFACING WITH OTHER FURNACES AND CONTROL SYSTEMS    
MARKET OVERVIEW    
NEED FOR THE PROJECT AND ITS IMPORTANCE TO REGION    
EXPORT POSSIBILITY    
INDIAN FOUNDRY INDUSTRY9
GENERAL ECONOMIC SCENARIO    
FORECASTS OF GROWTH BY LEADING INSTITUTIONS    
MAJOR FOUNDRY CLUSTERS    
TOTAL PRODUCTION OF TRACTORS IN INDIA    
GLOBAL SCENARIO    
ROLE IN MANUFACTURING SECTOR    
PRODUCTION IN MILLION TONS    
EXPORTS IMPORT TRENDS    
SECTORWISE CONSUMPTION OF CASTING    
INDIAN FOUNDRY INDUSTRY EXPECTS US 3 BN INVESTMENT    
THE BRIGHT FUTURE OF CASTING IN INDIA    
1. THE ‘MAKE IN INDIA’ CAMPAIGN    
2. FOCUSING ON STRUCTURAL CHANGE SINCE 2015    
3. THE BOOMING GROWTH OF THE AUTO INDUSTRY    
4. MISCELLANEOUS OPPORTUNITIES    
CASTECH FOUNDRIES    
OBJECTIVES OF THE STUDY    
TARGET AUDIENCE    
SCOPE OF THE REPORT    
MANUFACTURERS/SUPPLIERS OF DUCTILE IRON CASTING    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PIG IRON    
SUPPLIERS OF CAST IRON SCRAP    
SUPPLIERS OF STEEL SCRAPE    
SUPPLIERS OF SILICON CARBIDE    
SUPPLIERS OF FERRO SILICON    
SUPPLIERS OF MAGNESIUM INGOT    
SUPPLIERS OF FERRO MANGANESE    
SUPPLIERS OF FIRE CLAY    
SUPPLIERS OF BENTONITE    
SUPPLLIRS OF COAL DUST    
SUPPLIERS OF GRAPHITE POWDER    
SUPPLIERS OF SILICA SAND    
SUPPLIERS OF LIME STONE    
SUPPLIERS OF PLANT AND MACHINERIES    
SUPPLIERS OF ANNEALING FURNACE    
SUPPLIERS OF HEATREATMENT FURNACE    
SUPPLIERS OF INDUCTION FURNACE    
SUPPLIERS OF ALUMINIUM PATTERNS    
SUPPLIERS OF INTENSIVE SAND MIXTURE AND MULLER    
SUPPLIERS OF SAND SIEVING MACHINE    
SUPPLIERS OF SQUEEZE MOLDING MACHINE    
SUPPLIERS OF SHAKEOUT MACHINE    
SUPPLIERS OF CORE SHOOTER MACHINE    
SUPPLIERS OF DRYING OVEN    
SUPPLIERS OF FOUNDRY TOOLS    
SUPPLIERS OF MOLDING BOXES    
SUPPLIERS OF METAL TESTING MACHINE    
SUPPLIERS OF PRECISION MEASURING TOOLS    
SUPPLIERS OF PRECISION MEASURING TOOLS    
SUPPLIERS OF NDT INSPECTION EQUIPMENT    
SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES    
SUPPLIERS OF GRINDING MACHINE    
SUPPLIERS OF EOT CRANE    
SUPPLIERS OF POWER TRANSFORMERS    
SUPPLIERS OF ELECTRICAL PANEL    
SUPPLIERS OF ELECTRIC MOTOR    
SUPPLIERS OF COOLING TOWER    
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)    
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS    
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS    
SUPPLIERS OF AIR COMPRESSORS    
SUPPLIERS OF PLATFORM WEIGHING MACHINE    
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS    
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS    
SUPPLIERS OF SHOT BLASTING MACHINE    
SUPPLIERS OF JIGS AND FIXTURE    
SUPPLIERS OF SUBMERSIBLE WATER PUMP    
PLANT LAYOUT   


APPENDIX – A:

01.    PLANT ECONOMICS    
02.    LAND & BUILDING     
03.    PLANT AND MACHINERY    
04.    OTHER FIXED ASSESTS    
05.    FIXED CAPITAL    
06.    RAW MATERIAL    
07.    SALARY AND WAGES    
08.    UTILITIES AND OVERHEADS
09.    TOTAL WORKING CAPITAL    
10.    TOTAL CAPITAL INVESTMENT    
11.    COST OF PRODUCTION    
12.    TURN OVER/ANNUM    
13.    BREAK EVEN POINT     
14.    RESOURCES FOR FINANCE    
15.    INSTALMENT PAYABLE IN 5 YEARS    
16.    DEPRECIATION CHART FOR 5 YEARS    
17.    PROFIT ANALYSIS FOR 5 YEARS    
18.    PROJECTED BALANCE SHEET FOR (5 YEARS)