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Green Sand Metalcasting Foundry News

Elimination of Pinhole Porosity in Alloy Steels

Posted by Hill and Griffith Company on Feb 23, 2021 4:50:06 PM

Adding small amounts of ferroselenium and keeping charged nitrogen volumes low is effective in preventing subsurface porosity.

Excerpt from Foundry Management & Technology's February 2020 issue by Dr. R. L. (Rod) Naro and D. C. Williams

Nothing is more frustrating in foundry operations than finding an outbreak of subsurface porosity after costly machining operations. Outbreaks of subsurface porosity always seem to occur during high humidity seasons, especially during the rainy spring. The prime culprit universally blamed is hydrogen absorption into molten steels.

The hydrogen atom is the smallest and simplest of all the elements. Hydrogen can be absorbed only in its mono-atomic state. Nitrogen also can play a significant role in the development of porosity, especially in the production of high-alloy steel castings.

Hydrogen and nitrogen absorption in steel casting may result from alloy additions and reactions at the mold-metal interface. The ability of molten steel to absorb large amounts of hydrogen and nitrogen is shown in Figure 1.

Sub-Surface Porosity on Steel Axle Bracket

Molten steels can readily absorb both hydrogen and nitrogen in excess of their solubility limits. When a casting containing elevated hydrogen and nitrogen levels solidifies, subsurface porosity will result. Hydrogen pickup may occur from almost any source of moisture, such as refractories, green sand molds, chemical mold- and core-binder decomposition, slag additives, and atmospheric humidity. Nitrogen pickup can result from ferroalloy additions as well as decomposition products from chemical mold and core binders. Figure 2 illustrates typical subsurface pinholes in a high-alloy steel casting.

Mold-Metal Interface Reactions. With few exceptions, core and mold binders used in steel foundries industry are organically based, meaning on carbon, hydrogen, and oxygen, and in some cases nitrogen. The approximate chemical make-up of some of the common binder systems is shown in Table 1 (a typical, Western bentonite, bonded green sand is shown for comparison.)

At ferrous casting temperatures, the presence of these elements (carbon, hydrogen, oxygen and nitrogen) and their subsequent decomposition products can produce a variety of casting defects.

Hydrogen can be absorbed into molten steel from moisture in atmosphere and refractory materials, deoxidation and alloying elements, and slag additives. Nitrogen also can readily be absorbed in molten steels from gaseous decomposition products from mold and core binders as well as certain charge materials. Roach and Simmons(2) reported that all stainless steels will tend to pick up nitrogen when melted in air.

Sub-surface pinholes

Alloying Materials. The solubility of nitrogen in chromium alloys can be quite high, unless the foundry specifies the need for a low-nitrogen ferrochrome grade. In one reported instance, a stainless steel foundry was experiencing severe subsurface porosity and upon further investigation, it was found that low-carbon ferrochrome being used contained over 10,000 ppm (1.0%) nitrogen. Nitrogen and hydrogen also are very soluble in manganese alloys, so great care must be taken to specify low-hydrogen and nitrogen grades, particularly with electrolytic grades of manganese metal. Hydrogen also has been found in electrolytic nickel cathode squares.

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