Shandong Xinyuantai Pipe Industry Co., Ltd. outlines the first step in the ductile iron pipe production process: the ductile cast iron is melted in a medium-frequency induction furnace. The temperature does not need to be excessively high, typically reaching around 1480°C. Once the molten iron is ready, it is allowed to rest in the crucible for a while to stabilize. Depending on the size of the casting, pouring temperatures usually range between 1380°C and 1410°C.
The second stage involves the furnace lining, which can be either acidic or alkaline. The lining ratio, tamping, drying, and sintering are all carried out following standard procedures to ensure durability and performance during the melting process.
In the third step, the charging process follows a conventional sequence. Initially, refractory iron alloys such as gray pig iron or molybdenum iron are placed at the bottom of the furnace. Then, scrap steel is added based on the principle of "loose on the bottom," which helps the material collapse more easily during melting.
The fourth step involves the melting of high-chromium cast iron, which requires a higher melting temperature compared to regular cast iron—around 1200°C. The tapping temperature is typically around 1500°C, and this process is also conducted using a medium-frequency induction furnace.
Once all the metal charge has been fully melted and the temperature reaches approximately 1480°C, deoxidation is performed by adding ferromanganese, ferrosilicon, and aluminum to remove excess oxygen from the melt.
Next, the electric power is applied to complete the melting process. The furnace is operated at maximum power to ensure efficient melting. Due to the significant chromium loss (approximately 5% to 15%), ferrochromium is usually added at the end of the process, after the scrap has completely melted and the bath is in a molten state.
This detailed process ensures that the final ductile iron pipes meet high-quality standards, offering excellent mechanical properties and corrosion resistance. Shandong Xinyuantai Pipe Industry Co., Ltd. continues to refine its techniques to maintain industry leadership in ductile iron pipe manufacturing.
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