Proprietary Inoculants

Gray Iron

75% Calcium Bearing Ferrosilicon – Special sized 75% ferrosilicon typically containing 1% calcium and 1% aluminum to reduce chill and carbide formation in both gray and ductile iron.

Sphere-O-Dox G (U.S. Patent No. 6,293,988 B1) – A high performance inoculant with up to 30 times the level of active ingredients normally found in ferrosilicon based ladle inoculants, in-stream inoculants, or cast and/or sintered inserts. Fractional amounts of Sphere-O-Dox, typically 1/4 to 1/2 of traditional ferrosilicon based inoculants, can provide improved chill reduction, nodule count and mechanical property increases. In gray irons, Sphere-O-Dox will promote the formation of fine Type A flake graphite. This inoculant is also available in ASI’s InocuBloc inoculant tablets and pressed briquettes.

InocuBloc In-Mold Inoculating Tablets (U.S. Patent No. 6,293,988B1) – InocuBloc In-Mold Inoculating Tablets contain up to 30 times the level of active ingredients normally found in ladle inoculants, in-stream inoculants, or cast and/or sintered inserts. The incorporation of just a single InocuBloc tablet provides sufficient nucleating power to effectively treat up to 150 lbs. or more of liquid iron. Recent research has found that one 7 gram InocuBloc tablet has more inoculating capability than a 60 gram cast in-mold insert or 70 grams of granulated calcium bearing 75% Ferrosilicon (see Riposan, et al. American Foundry Society Paper 07–023, Houston, Texas). Ductile iron users have found it not unusual to achieve a 50 to 75 percent increase in nodule count. Gray iron users have reported reduced carbide levels, increased Type A graphite, levels and overall improved microstructures.

Zirconium-Bearing Inoculant – Ashalloy 1 is a potent inoculant which contains a proprietary blend of silicon, zirconium, manganese, calcium and barium. This alloy has a blue-gray crystalline appearance and can be used for the inoculation of gray and ductile irons. It works well as a ladle addition and is very effective when used with in-stream inoculant injectors.

Resulf 30 (U.S. Patent 6,733,565 B1) – A briquetted ferroalloy which makes adding controlled amounts of sulfur easy and accurate, without the odors normally associated with fine mesh sized iron pyrites. Resulf 30 eliminates the inconsistent recoveries associated with the use of iron pyrites. Just one 20 gram Resulf 30 briquette provides approximately 6 grams of sulfur and will increase the sulfur level of 1,000 lbs of molten iron by exactly 0.001%. Recent research has shown that Resulf 30 additions after nodulizing provide an excellent alternative for production of CGI (compacted graphite irons) compared to alternate methods employing either titanium or rare earths or methods employing sophisticated thermal analysis techniques.

Resulf 30 IE – Resulf 30 IE represents a new, easy to use, and accurate method for adding controlled amounts of sulfur and oxygen to molten gray and ductile irons. Reduced chill and carbide formation, improved graphite structures and improved machinability result when Resulf 30 IEP is used. Recent research has shown that Resulf 30 IEP used in conjunction with most inoculants improves the inoculating ability of all current inoculants. Because inoculant efficiency is improved, it is possible to reduce the overall level of inoculation.

Resulf 30 IEP Inoculant Enhancer – A powdered form of Resulf 30 IE.

Resulf 30 IEP Plus (U.S. Patent 6,866,696B1) – A ferroalloy powder blend that is used to rejuvenate "dead" cast irons and enhance the inoculating capability of foundry grade 75% ferrosilicon as well as other proprietary inoculants containing strontium, cerium, barium, calcium, manganese, zirconium or aluminum. In gray irons, reduced chill and carbide formation, improved graphite structures and improved machinability result when Resulf 30-IEP Plus is used. In ductile irons, adding controlled amounts of sulfur and oxygen can increase nodule count, increase ferrite levels, and reduce carbides (improving elongation). Foundry tests have shown than inoculant levels may be reduced by 33% by substituting 25% Resulf 30-IEP Plus by weight of the original inoculant level.

Ductile Iron

15% Mg NoduBloc Iron Magnesium Briquettes – A pressed iron-magnesium briquette used as a replacement/supplement for magnesium ferrosilicon alloys. NoduBloc briquettes provide outstanding recoveries with only a modest increase in magnesium flare, allow flexibility in silicon control, and provide significant cost reductions by allowing greater utilization of returns in the charge. Savings ranging from $7.50 to $30.00 per ton have been achieved by foundries using NoduBloc technology. It can also be used as a desulfurizing agent and in all ladle treatment processes.

Magnesium Ferrosilicon – Magnesium Ferrosilicon alloys have a light gray to silvery crystalline appearance. They are mainly used for producing ductile iron. These alloys are produced with magnesium levels of 3.0%, 5.0% and 9.0%. The various alloys are available in rare earth free grades, cerium bearing grades and lanthanum enriched rare earth grades.

Sphere-O-Dox S (U.S. Patent No. 6,293,988B1) – Sphere-O-Dox S is a new, low silicon, high performance, patented inoculant incorporating the latest advances in contemporary inoculation concepts. Sphere-O-Dox S contains up to 30 times the amount of the active ingredients normally found in ferrosilicon-based inoculants. Incorporation of just fractional amounts of Sphere-O-Dox, typically 25% to 50% of ferrosilicon-based inoculants, can provide outstanding chill reduction, nodule count and mechanical property increases. These low addition levels can significantly reduce inoculation costs. Sphere-O-Dox S is also available as a tablet or a pressed briquette (InocuBloc).

InocuBloc HCTM In-Mold Inserts – Inocu-Bloc HC™ high performance inoculating inserts (available as 5, 10 gram cylindrical inserts) incorporate state of the art powder metallurgy technology which provide potent nuclei (oxy-sulfide) forming elements in a concentrated form, far more concentrated than can be accomplished with either cast inserts or pressed and sintered by-product magnesium ferrosilicon fines. HC tablets contain up to 10 times the level of active ingredients that provide the inoculating effect in solidifying gray and ductile irons. Incorporation of just a single HC tablet provides sufficient nucleating power to effectively treat a 100 lb. poured weight casting. Hence, metal treatment costs with HC inserts are extremely economical compared to traditional treatment techniques.

Resulf 30 IE - Resulf 30 IE represents a new, easy to use, and accurate method for adding controlled amounts of sulfur and oxygen to molten gray and ductile irons. Reduced chill and carbide formation, improved graphite structures and improved machinability result when Resulf 30 IEP is used. Recent research has shown that Resulf 30 IEP used in conjunction with most inoculants improves the inoculating ability of all current inoculants. Because inoculant efficiency is improved, it is possible to reduce the overall level of inoculation.

Resulf 30 IEP Inoculant Enhancer – A powdered form of Resulf 30 IE.

Nickel Magnesium Master Alloys – Nickel magnesium alloys are available as Nickel Magnesium No 1 alloy that contains 15% magnesium with the balance being nickel. Nickel Magnesium No. 4 is a 4.5% magnesium containing alloy with the balance composed of 30% iron with the balance being nickel. The density of NiMag No. 4 is 7.30 grams/cc, which means it can simply be tossed in ductile base iron and it sinks, no cover steel is needed and recoveries of magnesium are very high and consistent..

SteelMag (Magnesium Booster Bars) – A proprietary, thick-walled, low carbon steel tube containing a ½ pound pure magnesium insert that is used for controlled additions of magnesium directly to a pressure pour furnace or ductile iron treatment vessel. With a bulk density greater than that of molten ductile base iron, SteelMag will either stay submerged at the bottom of a treatment vessel or can simply be tossed into the ladle where it will immediately sink to the bottom and liberate magnesium. The magnesium reaction proceeds gradually and in a controlled manner from the tube ends. Recoveries of over 90% have been obtained during field trials. When used with ASI’s Resulf 30 briquettes, the narrow magnesium range over which compacted graphite forms is widened, thereby allowing greater flexibility in controlling structure.

Compacted Graphite Iron

Resulf 30 Denodulizing Tablets – Resulf 30 Denodulizing Tablets make adding controlled amounts of sulfur easy and accurate, without the odors normally associated with fine mesh sized iron pyrites. Recent research has shown that Resulf 30 additions after nodulizing provide an excellent alternative for production of CGI (compacted graphite irons) compared to alternate methods employing either titanium or rare earths or methods employing sophisticated thermal analysis techniques. Resulf 30 eliminates the inconsistent recoveries associated with the use of iron pyrites. Just one 20 gram Resulf 30 tablet provides approximately 6 grams of sulfur and will increase the sulfur level of 1,000 lbs of molten iron by exactly 0.001%.