Scholarly record
APPLICATION OF THERMAL ANALYSIS FOR CONTROL OF THE MELTING PROCESS IN DUCTILE IRON
Abstract
Current applications of thermal analysis in ductile iron production are largely limited to routine monitoring, while its potential for quantitative prediction and resource-efficient process control remains underutilized. This study addresses this gap by establishing direct relationships between melt composition, thermal parameters, and resulting material performance. Sixteen industrial melts of ferritic ductile iron were produced with systematically varied charge compositions and metallurgical treatments. Cooling curves and their first derivatives were analysed to determine key parameters, including liquidus temperature (TL) and undercooling (ΔT). The predictive capability of thermal analysis was validated against mechanical properties (Rm: 401–439 MPa; A5: 18–24%) and quantitative microstructural evaluation. Stable solidification conditions (TL ≈ 1150–1155 °C; ΔT = 4–8 °C) were found to ensure optimal graphite morphology and consistent mechanical performance, whereas excessive undercooling (ΔT > 15 °C) led to increased structural variability. A clear dependence between the C/Si ratio, saturation degree, and thermal behaviour was confirmed, enabling targeted adjustment of melt chemistry. The results demonstrate that data-driven control based on thermal analysis enables reduction of process variability, optimization of charge composition, and elimination of unnecessary high-cost inputs without compromising material properties. This approach contributes directly to improved resource efficiency, reduced defect rates, and lower energy and material consumption in ductile iron production.
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References10
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