1. Technical University of Denmark
Quantification of Feeding Effects of Spot Feeding Ductile Iron Castings in Vertically Parted Molds
Nikolaj K. Vedel-Smith
Technical University of Denmark

2. My PhD Project
Improvement of Feeder Technologies for Energy Savings in Cast Iron Foundries

3. Agenda INTRODUCTION EXPERIMENT RESULTS CONCLUSIONS Why spot feeding?
What are we testing?
How do ram-up sleeves function
EXPERIMENT
Casting Geometry
Test Variables and Configurations
RESULTS
Porosities
Simulations
Surface Shrinkage
CONCLUSIONS

4. Why Spot Feeding?
Feed heavy sections unreachable by traditional feeders
Reduce melt use
Improved yield and economy
Melting accounts for approx. ¼ of the production cost for cast iron foundries

5. ? We Want To Know… If spot feeding can feed closed off sections
If spot feeding can prevent surface shrinkage
How to model feeding properties correctly ?

6. Casting Geometry
20 x 25 mm
10 x 55 mm
30 x 50 mm

7. Casting Geometry Poured weight ≈ 8 kg Casting weight ≈ 4 kg
Only w/ top feeder
Only w/ center feeder
Without feeders

8. Top feeder sleeve mounted Ram-up sleeve molded in
Molding
Pin for ram-up sleeve
Top feeder
Top feeder sleeve mounted
Ram-up sleeve mounted
Ram-up sleeve molded in
10 PPM foam filter

9. Molding The sleeve is mounted onto the pin (Can be automated)
Sand fills the molding chamber
As the mold is squeezed, the breaker core collapses and compacts the sand

10. Experiment All castings made on the same vertical molding line
Three separate series
Variables
Top feeder
Center feeder
Sleeve material
Alloy

11. Two near eutectic ductile iron alloysC Si Mn P S Mg Cu
EN-GJS-500-7
3.67
2.73
0.50
0.015
0.005
0.049
0.025
EN-GJS
3.35
3.48
0.34
0.017
0.003
0.046
0.010 α β
Cast through three series at:
1,401 ±5 °C (2,554 ±10 °F)
1,408 ±5 °C (2,566 ±10 °F)
1,392 ±5 °C (2,538 ±10 °F)

12. Feeder Configuration Mg = V/A Mt = MEF · Mg
Exothermic Insulating (E/I)
Insulating (Ins)
Exothermic (Exo)

13. Trial Castings

14. Sectioning

15. Porosities Sectioned casting divided into 9 areas
Liquid Penetrant Test according to EN :2011
Of particular interest

16. Results Table

17. Simulations

18. Simulations

19. Surface Shrinkage
Measurement Points
α2C
α5a
β1C

20. Results Table

21. Conclusions The ram-up spot feeders successfully feed the boss section
Without either of the two feeders, the castings were unsound
Great casting reproducibility
Top feeder influences solidification in boss section

22. For additional information, please contact:
Nikolaj K. Vedel-Smith
Produktionstorvet, Building 427A 2800 Kgs. Lyngby, Denmark
Phone: