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COMPOSITE DUCTILE IRON CASTINGS WITH “CAST IN”

HIGH CHROME WEAR RESISTANT INSERTS
by
Reginald D. Forrest, Sorelmetal Technical Services

There are many service applications where Ductile One solution to these limitations is to produce a
Iron is required to withstand arduous and abrasive composite casting whereby a tough, durable,
conditions. Careful selection of the grade of Ductile machinable grade of Ductile Iron is produced with
Iron is necessary and the RIT publication “Ductile Iron “cast-in” inserts of the required highly alloyed material
Data for Design Engineers” is most useful in this located in the critical areas.
regard.
The Magotteaux Group of Industries whose
The pearlitic grades of Ductile Iron respond well to headquarters are sited in Belgium, has developed and
quench and temper heat treatments as well as patented a unique technique for producing such a
localized induction or flame hardening to provide hard, composite material – called DUOCAST.
wear resistant areas. Chill casting and selection of
alloying, as in the case of Ductile Iron rolls, will further
extend the wear resistance and durability of Ductile
Iron castings. “Double Poured” rolls, where a hard
chilled (carbidic) wear resistant outer layer is
supported by a core of tough, durable Ductile Iron are
frequently used in steel rolling mills – considerable
skill and experience is required to optimize the
structure and performance of double poured Ductile
Iron rolls.

There are some very abrasive service conditions

where only highly alloyed steels or irons can perform
satisfactorily. Such conditions are encountered, for
instance, in cement plants and thermal power stations
where castings are required for grinding coal, Figure 1. Schematic Showing Duocast Rollers in Use in a Loesche Mill.
limestone, slag, clinker and other additives such as
iron ore, pouzzolane, etc... In such situations, highly
alloyed steels or high chrome white irons – often
containing up to 30% chromium together with nickel
and molybdenum – are required to overcome wear
phenomena: thanks to the high hardness of those
special grades. Such hard castings however are more
expensive, difficult to machine and relatively brittle if
not manufactured and installed properly.

Figure 2. Close up Photograph of Duocast Roll in Service.

Duocast wear resistant rollers are now well
established in grinding plants using vertical mills. As
already mentioned above, they consist of a tough
pearlitic Ductile Iron supporting base with specially
designed Magotteaux high chrome iron inserts cast in
at selected locations on the wear areas. The bonding
between both grades is mechanical.

Typical compositions of the base Ductile Iron are 3.35

– 3.4 % C with 1.85% Si and very low levels of P, S,
Cr and other elements which could impair the
necessary toughness characteristics required in the
large backing Ductile Iron casting. Tensile strengths
exceeding 600 N/ mm² (85,000 psi) are looked for. Figure 4. Preparing a Duocast Roller (Composite DI Casting with High Cr.
Great care is taken in the selection of furnace charge Insert) for Installation in a Loesche Mill.

materials in the production of these Ductile Iron

castings and Sorelmetal has proved to be highly
suitable for this application.
The high chrome iron inserts are carefully specified
according to the application requirements.
Magotteaux provides a wide range of high chrome
solutions, tailor made to the final application.
Chrome contents, varying between 12 and 35%, as
well as a superficial final hardness, generally above
60 HRc, are among the criteria which are studied in
order to achieve the best compromise between cost
and expected wear resistance.
Likewise the design of these inserts, in particular the
contoured keying design and the attention given to
ensure complete bonding between the Ductile Iron
casting and the inserts (Figure 3), are features of the
Duocast patented technique. Even if small cracks are
initiated in these special inserts under use, the
integrity of the roller is maintained by the toughness of
the high quality Ductile Iron backing and crack
propagation is prevented.
Duocast rollers have been widely accepted in vertical
roller mills – increasing life, mill average capacity and
reducing energy specific consumption. Compared
with NiHard and other high chrome monometal cast
irons, Duocast has a greatly improved fracture
resistance and reliability especially in large grinding
mills. As a consequence, reductions in the frequency
of shutdowns associated with increased lifetimes have
resulted in major operating cost reductions in all
vertical mill types, such as for instance, Raymond,
Loesche, Polysius, Pfeiffer, etc.. mills.
Duocast technology using high quality Ductile Iron
castings - as achieved with Sorelmetal in the base
charge - with cast in high chromium iron inserts is
becoming the preferred choice for wear resistant
composite castings in cement plants, thermal power
stations and in many general engineering applications.
This is another example of the diversity of uses and
adaptability of Ductile Iron castings.
Acknowledgments: Magotteaux International, S.A.
Belgium

Figure 3. Schematic Drawing of Insert Design and Contoured Keying to Ensure REV – March 2006
Bonding between DI Casting and High Chrome Insert.