Prediction of Chunky Graphite in Nodular Cast Iron on the Base of Numerical Simulation and Experimental Data

Chunky graphite has been recognized for a long time as one of the major problems in production of heavy section nodular cast iron. A great number of studies have been conducted to describe the chunky graphite formation, but a clear understanding of its appearance and a safe mastering of the melt preparation to avoid chunky graphite are not yet available. In the present work the cooling curves were recorded in large cone blocks and standard TA cup. According to measured data from the cone block, melt characteristics and heat transfer coefficient between casting and mould were adjusted in the ProCAST^® simulation software. For a near-eutectic nodular cast iron test melt with 0.7 wt.% Ni, relationship between the area of the cone block affected by chunky graphite and simulation software results has been observed, i.e., thermal modulus and time to solidus.