THORS eLearning Solutions

Ductile Iron Fundamentals


Ductile Iron Fundamentals introduces the learner to the properties, processes, and terminology associated with ductile iron production.
Learning Hours: 3

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Course Description

Ductile Iron Fundamentals introduces the learner to the properties, processes, and terminology associated with ductile iron production. This course also includes defect analysis of the manufactured product. Presented in THORS’ highly visual and interactive learning format, this course will help foundry employees become familiar with the important equipment processing steps associated with their profession.

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Who will benefit from this Ductile Iron course?

Companies, individuals, or educational institutions that require an understanding of the terminology, properties, processes, and quality improvement procedures associated with ductile iron foundries.

Course Classification

This manufacturing course by THORS eLearning Solutions covers identification of key terms and understanding of key concepts.

*THORS uses the Bloom’s Taxonomy Methodology for our course development.

Certificate Awarded for Ductile Iron Fundamentals

Example of certificate awarded upon successful completion of the course.

*upon successful completion

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Learning Objectives

  1. Differentiate between ductile iron and other forms of iron.
  2. Understand the relationship between the microstructure and properties of ductile iron.
  3. Recall the ductile iron grades that are used for application-specific purposes.
  4. Comprehend the treatment methods of ductile iron processing.
  5. Understand the concepts of nodularity, inoculation, fading, and tensile and hardness testing.
  6. Understand the various heat treatment processes that might be used for ductile iron.
  7. Identify common defects that occur during the production of ductile iron castings.
Illustration of graphite flakes and austenite having grown during the solidification of ductile iron
Ductile Iron Fundamentals

Table of Contents

  1. Ductile Iron Properties
    1. Ductile Iron Mechanical Properties
    2. Microstructure of Iron
      1. Phases of Iron
      2. Influences of Ferrite and Pearlite
      3. Ferrite Phase
      4. Pearlite Phase
    3. Ductile Iron Chemistry
      1. Carbon
      2. Silicon
      3. Manganese
      4. Phosphorous
      5. Sulfur
      6. Copper
      7. Molybdenum
      8. Chromium
      9. Nickel
    4. Spheroidizing Elements
      1. Magnesium
      2. Rare Earth Elements (Cerium and Lanthanum)
      3. Calcium
      4. Barium
    5. Ductile Iron Grades
      1. General Applications
      2. High Temperature Applications
      3. Low Temperature Impact Applications
      4. Corrosion Resistance Applications
      5. Wear Resistance Applications
  2. Ductile Iron Processing
    1. Nodularity
    2. Treatment (Conversion)
      1. Treatment Outside of the Mold
        1. Wire Injection Method
        2. Open Ladle Method (Pour-Over Method)
        3. Sandwich Ladle Method
        4. Covered Tundish Ladle Method
        5. Porous Plug Method
        6. Plunging Method
        7. Fischer Converter Method
        8. Flow-Through Method
      2. Treatment Inside of the Mold (In-Mold Conversion)
    3. Inoculation (Post-Inoculation)
    4. Fading
    5. Undercooling
    6. Solidification
  3. Ductile Iron Defect Analysis
    1. Carbides
      1. Inverse Chill Carbides
      2. Grain Boundary Carbides
    2. Low Nodularity
    3. Abnormal Graphite Shapes
      1. Exploded Graphite
      2. Graphite Floatation
      3. Vermicular Graphite
      4. Flake Graphite
      5. Chunk Graphite
    4. Shrinkage Porosity
      1. Open Shrinkage
      2. Shrinkage Under Riser
      3. Interior Shrinkage Porosity
      4. Microporosity
      5. Pinholes
    5. Slag and Dross Inclusions
      1. Slag Inclusions
      2. Dross Inclusions

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