PRODUCTS

Rotavi understands its market and in based on its vast expertise, has the flexibility to develop new products in short periods of time. Its team of engineers is available to customers both during the development and supply phase. With technical assistance and commercial support, customers feel the confidence that crosses international borders. Global branches of Rotavi count on highly trained professionals in the technical and commercial areas, thus, ensuring the expansion and global commitment to excellence of the company.

SILICON METAL

Particle Size:

0 x 10 mm
10 x 100 mm
50 x 150 mm

 

Other chemical
and particle size compositions can
be consulted

 

There are three types
of Silicon Metal:

Metallurgical Grade

Chemical Grade

Electronic Grade

Metallurgical Grade: mainly used as an alloying element in the Aluminum and other non-ferrous metals. With this grade, the maximum allowed impurity percentage must not exceed 1%. Another application in which Metallurgical Grade is used is within the manufacture of grain oriented silicon sheet rolls. In this case, the Silicon Metal must be refined, that is, the contents of Calcium, Aluminum, Titanium and other elements must be residual so as not to inhibit the magnetic permeability, replacing therefore the FeSi H.P. It can be used in continuous steel casting as a deoxidizer because it contains low aluminum rates, replacing Calcium Silicon in Tundish. These plates are used in high power transformer.

 

Chemical Grade: is an extremely high silicon metal grade used in the manufacture of silicone (chlorosilane), therefore, impurities must be less than 0.01% by weight.

 

Electronic Grade: silicon metal grade used in electronic circuits, such as semiconductors. To produce this grade, production equipment of highest technology is required.

INOCULANT

IM 43

Chemical Composition:

Silicon 74 – 80%

Zirconium 1 – 2%

Calcium 2.2 – 2.7% Aluminum 1.5 – Max. (Green sand mold) Aluminum 1.5 – 2.5% (metal molds)
Melting Point:
1260 + 1360°C

​​​Particle Size:

0,15 x 0,6 mm

0,6 x 3,0 mm

2,0 x 6,0 mm

Silicon: 70-75%
for  Particle Size
below 0,59mm

Mainly used in Ductile iron as a Strong Graphitizer.

 

Other chemical and particle size compositions can be consulted. For many years in Europe, the IM 43 has been used in foundries where the property ranges of the (foundry) parts are very narrow. The chemical elements of IM 43 are well controlled in order to obtain a constant inoculation effect. Silicon, in the above analysis, can be used as a great graphitizing and ferritilizing. This product can also serve as a Silicon augmenter in iron and its performance is 100% at a temperature above 1475° C. Calcium is a strong deoxidizing agent, and it increases the number of eutectic cells. It is maintained at a level of 2.5% to prevent slag formation. Zirconium at a level of 1,5% shows a great affinity with the impurities contained in the base iron in the liquid state. Therefore, when Zirconium combines with Oxygen that has been dissolved in metal, it has a neutralizing effect; this can also be seen with Nitrogen and Sulfur. Aluminum is a strong reducing agent, being limited to 1.5% when the metal is cast in green sand mold and 1.5% to 2.5% when the mold is metallic, as is the case when referring to pipes by centrifugal manufacturing.

 

The amount used can vary from 0.2% - 0.8%, plus the normal addition is around 0.5%, however, this depends on the carbon equivalent in gray cast iron. In the case of ductile iron, it is understood that Magnesium increases super cooling.

 

IM 43 eliminates the negative effects of such an occurrence. Therefore it is mainly used in ductile iron and the amount can vary from 0.3% to 1%. Within the current marketplace, the general concern regarding contamination by undesired mineral / chemical elements has increased. Our IM 43 product, is produced in a submerged arc furnace, where charcoal and iron ore are used respectively, as a reducing agent and a source of iron elements. Therefore, based on this production process, the residual levels of the undesirable elements are very low.

INOCULANT

IM 75-B

Chemical Composition:

Silicon 74 – 79%

Calcium 0.8 – 1,2%

Barium 0.8 – 1,2%

​​​Particle Size:

0,15 x 0,6 mm

0,6 x 3,0 mm

2,0 x 10,0 mm

Silicon: 70-75%
for Particle Size
below 0,59 mm

A Strong Inoculant for Gray and Ductile iron.

Other chemical and particle size compositions can be consulted.

In Gray Cast Iron: Recent literature has shown that the effects obtained from the combined addition of two chemical elements are often greater than the effects added by each individual element. This synergistic effect is recognized and accepted as regards to the performance of Calcium and Barium in the inoculation of cast iron. Combination of Calcium and Barium in the IM 75-B provides a powerful nucleating effect. Consequently, one can use 40% less of IM 75-B to obtain the same degrees of effect, when chilled molding takes place, as to using conventional Ferro Silicon.

When using lower levels of IM 75-B, one can obtain lower levels of chilled molding, than those obtained with common inoculants and the equivalent Carbon use. The IM 75-B is generally used when greater resistance in carbon-equivalent irons of 3.6 to 3.8% is desired. Furthermore, the inoculation effect improves the mechanical properties. The combination of Calcium and Barium minimizes super-cooling and promotes eutectic solidification with type A graphite.

The high silicon content serves to further increase the number of eutectic cells, ensuring the desired mechanical properties for a given chemical analysis of iron. Due to the fact that the alloy contains close to 75% of Silicon, its reaction in liquid iron is exothermic and ensures excellent repeatability of results.

 

In Ductile iron: Inoculants containing more than 70% of Silicon are the most used materials to obtain ductile iron. In some castings where parts have a tendency to carbide, the problem is solved with greater additions of this inoculant, due to the stronger effect of Calcium associated with Barium. During a recent two-day trial in a foundry, comparing a calcium-barium-based inoculant with two other inoculants, one being Ferro Silicon containing normal Calcium and the other with high Aluminum, the Calcium and Barium alloy obtained 18% more nodules than the two other alloys. Currently, the concern regarding contamination by undesirable elements has increased.

Our IM 75-B product, is produced in a submerged arc furnace, where charcoal and iron ore are used respectively, as a reducing agent and a source of iron elements. Therefore, based on this production process, the residual levels of the undesirable elements are very low.

INOCULANT

IM CA BA LA

Chemical Composition:

Silicon 72 – 80% Aluminum 0.8 – 1.2% Calcium 1.2 – 1.6%

Barium 1.2 – 1.6% Lanthanum 1.3 – 1.5%

​​​Particle Size:

Sieve (mm) 9,50 –
Sieve retainer <= 5%

Sieve (mm) 2,00 –
S
ieve retainer >= 85%

Sieve bottom pan
(mm) <= 10%

 

Melting Point:
1260° a 1320°C

Silicon 70 – 75%
for  Particle Sizes below 0,59mm

A strong High Quality Inoculant for Gray and Ductile Iron.

Other chemical and particle size compositions can be consulted.

Important: When using this inoculant, it is necessary to have a metal composition with correct amount of S balanced stoichiometrically with the contained La, otherwise, there may be formation of carbides, mainly in nodular (ductile) iron.

 

In Gray Cast Iron: The inoculant IM CA BA LA reacts or acts as a deoxidizing or nucleating agent. The reaction with O or S provides a greater number of eutectic and type A graphite. Adding CA BA LA to the reaction of both O and S dissolved in the metal, forms inclusions of type X2 Y3 where X is Lanthanum and Y is S or O, and in summary avoids overheating. The elements, IM CA BA LA are resistant to fading due to the high boiling point of the elements Ba, La (2130º C and 3450º C) preventing the formation of iron carbides in the metallic structure. The inclusions of La containing Ca, Al are favorable to nucleation. This inoculant is very useful in the production of large parts where solidification is very slow.

 

In Ductile iron: The CA BA LA effect increases localized nucleation, resulting in a large number of nodules. An excess of Lanthanum may cause formation of undesirable graphite structures and carbides. Exploded graphite or chunky graphite may occur, and both will reduce the mechanical properties of final product (therefore, the reason for balancing these properties with sulfur). This inoculant also facilitates the removal of slag, as it`s proven that Ba can agglomerate slag.

 

In the case of Ductile iron, we suggest using it before the addition of Ferro Silicon Magnesium, since it`s more likely that the sulfur of the base metal is higher and therefore has a better condition to balance it. The normal addition is of approximately 0.2 - 0.5%.

ALLOY MG 5R-1 E MG 5R-2

Chemical Composition

MG 5R-1:

Silicon 43 – 48% Magnesium 5.5 – 6.5% Calcium 1.5 – 2.0%

Aluminum 1.2% máx. Rare Earth (RE)
0.5 – 0.8%

Chemical Composition

MG 5R-2:

Silicon 43 – 48% Magnesium 5.0 – 7.0% Calcium 0.8 – 1.3%

Aluminum 1.2% máx. Rare Earth (RE)
0.9 – 1.2%

​​​Particle Size:

2,38 x 6,35 mm

2,38 x 12,7 mm

6,35 x 12,7 mm

9,52 x 25,4 mm

19,1 x 38,1 mm

Alloy Ferro Silicon Magnesium at 6% with Rare Earth for Ductile iron.

Other chemical compositions and particle sizes can be consulted.

MG 5R 1 and 5R 2 provide several advantages in nodulation of spheroidal iron parts, such as: high quality of finished parts by improving the nodulation process due to the addition of magnesium; reduction in the amount of alloy required to obtain good nodulation; small amount of carbonate in the final sections of the cast iron parts; high levels of ferrite and therefore low hardness for a set composition and thickness; and greater tolerance for higher levels of carbide and perlite forming elements.

 

MG 5R 1 and 2 greatly favor nodulization. Although the contents of Cerium and Rare Earth are low, the sum of the two in the same addition provides an excellent composition of Magnesium and Rare Earth, The choice of using Rare Earth gives flexibility to the smelters to determine which content of Rare Earth, best fits their needs.

 

Rare Earth have a nodulizing effect and therefore help Magnesium provide better returns on their application. When the level of Rare Earth reaches certain values, it is possible, depending on the above nodulizing effect, to reduce the amount of nodulizing alloy from 10 to 20%. The MG 5R 1 and 2 products are cast into ingot molds (with lids) and therefore generate ingots of thin thickness which, when ground-up, do not cause a high generation of undesirable fines. Currently, the concern regarding contamination by undesirable elements has increased.

 

Our MG 5R 1 and 2 are produced in submerged arc furnaces, where charcoal and iron ore are used, respectively, as a reducing agent, and also provide a strong source of iron elements. Therefore, the residual levels of the undesirable elements are very low. For example, the Chromium level is 0.05%, with a Manganese level of 0.025%. The alloys used with scrap steel may have higher levels of these elements.

ALLOY MG 9R-1 E MG 9R-2

Chemical Composition

MG 9R-1:

Silicon 43 – 48% Magnesium 8 – 10% Calcium 1.5 – 2.0%

Aluminum 1.2% máx.

Cerium 0.25 - 0.40%

Rare Earth 0.5 – 0.8%

Chemical Composition

MG 9R-2:

Silicon 43 – 48% Magnesium 8 – 10% Calcium 0.8 – 1.3%

Aluminum 1.2% máx.

Cerium 0.40 - 0.55%

Rare Earth 0.9 – 1.2%

​​​Particle Size:

2,38 x 6,35 mm

2,38 x 12,7 mm

6,35 x 12,7 mm

9,52 x 25,4 mm

For Ductile Iron Nodulization.

Other chemical compositions and particle sizes can be consulted.

The MG 9R 1 and 2 product line allows for the reduction of material addition, thus allowing to reduce the unwanted increase of Silicon during the nodulization treatment. These alloys are predominantly used in smelters that are experiencing problems with the high utilization on their returns, or that have high levels of sulfur in the base iron (ex. Cubilot Case).

 

The Rare Earth Metals (REM) of MG 9R 1 and 2 are extremely important. They neutralize the inhibitory effects of harmful elements that can create spheroidal graphite, encourage nucleation, reduce the formation of primary carbides, and finally, favor the Magnesium yield. Calcium is a graphitizing element; it supports inoculation, in addition to contributing to the control of Magnesium reactivity during the nodulization process. The choice of Rare Earth Metals provides the metal castings foundry with the flexibility to determine which raw material contents best suits their needs.

 

Currently, there is a growing concern about the contamination of base iron due to the presence of undesirable elements.

 

The MG 9R 1 and 2 products are poured into ingots with lids. These ingots have a thin thickness, to avoid the magnesium segregation during the solidification of the alloy. This casting technique ensures the reduction of fines during crushing and screening.

 

The MG 9R 1 and 2 products are produced in submerged arc furnaces, where charcoal and iron ore are used respectively, as a reducing agent and as a source of iron. Therefore, the residual levels of the undesirable elements are very low. For example, the Chromium level is 0.05%, with a Manganese level of 0.025%. Alloys prepared using scrap steel may have higher levels of these elements.

75% FERRO SILICON

Chemical Composition:

Silicon 74 - 79% Aluminum 1.25% max Calcium 1.0% max Phosphorus 0.035% max Carbon 0.10% max Sulfur 0.025% max

 

Description:

Silver gray Exothermic - increase of 3.3°C
per percentage point
of added silicon

 

Melting Point:

1266 + 1330°C

Particle Size:

0,15 x 0,6 mm

10 x 50 mm

50 x 127 mm

50 x 150 mm

Silicon 70 - 75%
for particle sizes
below 0.59 mm

For Ductile Iron Nodulization.

Other chemical compositions and particle sizes can be consulted.

In Cast Iron: Ferro Silicon 75% can be used to correct Silicon.

 

In today’s age, concern about contamination by undesirable elements is increasing. Our (Rotavi) Ferro Silicon is produced in submerged arc furnaces, where charcoal and iron ore are used respectively, both as a reducing agent and as a source of iron elements. Therefore, the residual levels of undesirable elements are very low. For example, the typical Chromium level is 0.05%, with a typical Manganese level of 0.025%. However, Alloys prepared using scrap steel may have higher levels of these elements.

 

In Steel: Ferro Silicon 75% is used mainly in the manufacture of steel as a deoxidizer and as an alloy in the manufacture of steel for springs and plates with high magnetic permeability; an example would be the use in transformers.

FERRO SILICON 75% Ca´Bearing

Chemical Composition:

Silicon 74 – 79%

Calcium 0.8 – 1.2% Aluminum 0.5 – 1.0%

 

Particle Size:

 

0,15 x 0,6 mm

0,6 x 3,0 mm

2,0 x 10,0 mm

Silicon 70 - 75%
for Particle Sizes
below 0.59 mm

For Inoculation in Gray and Ductile iron.

Other chemical compositions and particle sizes can be consulted.

In Gray Cast Iron: Ferro Silicon 75% Ca´Bearing acts as a good inoculant, serving to reduce the chilling on edges and parts of final sections. The inoculation effect, obtained mainly by the controlled content of Calcium, results in a better form of graphite, generating an increase in the physical and mechanical properties, as well as a better machinability. The typical amounts of addition to gray cast iron are 1 Kg of alloy per ton of metal.

 

In Ductile Iron: Ferro Silicon 75% Ca´Bearing has been the inoculants of choice for the ductile iron industry for several years. Unlike gray cast iron, in most cases, patented and expensive inoculants do not produce a better inoculation effect. Usually the amounts of element addition are much higher in ductile iron than in gray cast iron, ranging from 3 to10 kg per ton of metal.

 

Post-inoculation: size 0.15 x 0.60 mm, This type is specially manufactured to be used within the inoculation of the leakage jet for the mold of injection systems by way of blow or mechanical molding.

 

Currently, the concern regarding contamination by undesirable elements has increased. Our 75% Calcium Ferro Silicon is produced in submerged arc furnaces, where charcoal and iron ore are used respectively as a reducing agent and as a source of Iron element. Therefore, the residual levels of undesirable elements are very low. For example, the typical Chromium level is 0.05%, with a typical Manganese level of 0.025%.

 

Alloys prepared using steel scrap may contain higher levels of these elements.

FERRO SILICON ZIRCONIUM

Chemical Composition:

Zirconium 30 – 35% Silicon 50 – 57%

Carbon 0.50%

 

Particle Size:

0 x 2 mm

0 x 10 mm

10 x 50 mm

Other chemical and particle size compositions can be consulted.

Application: Ferro Silicon Zirconium has its application directed towards the following markets, casting of molded steel and for conventional or continuous casting in steel mills.

 

Properties: Zirconium is a chemical element with great applicability with O2, N2 and S. Therefore, unlike most common deoxidizers, Zirconium can have multiple effects on the properties of steels. The introduction of Silicon increases the solubility of Zirconium in the metal bath and thus increases its yield.

 

In continuous casting, the appearance of transverse cracks, (mainly in sections greater than 10 mm² during secondary cooling), are due to the precipitation of the AIN (Aluminum Nitrade) in the authentic contours. Because it has free energy the ZrN it is more stable than AIN. Thus, fixing either Nitrogen or Zirconium prevents the formation of the AIN, without impairing the casting speed.

 

Just like in steel, such as Boron, Zirconium can be used as a nitrogen fixer, increasing the soluble Boron content. This is an important factor in achieving the required properties of the finished good.

 

In micro alloyed steels, such as Niobium, Zirconium plays an important role. Nitrogen fixation minimizes the precipitation of Niobium carbonitrides during solidification, thereby subsequently reducing the solubilization temperature of Nb for further reductions in lamination. Thus, lower levels of Nb will be needed when combined with Zirconium in order to achieve the same results.

 

In carbon and low alloy steels that require isotopic properties, the addition of Zr causes the formation of sulphides of the type (FeMnZr) S. Thus, final products are produced with greater ductility and tenacity.

 

In molded steels, Zirconium can be used as a deoxidizer, Nitrogen fixer and sulfide inclusions modifier. As an example, we can use Zirconium in the manufacturing of steel wheels for railway wagons or wear / abrasion points in earth moving equipment.

CORED WIRE

Nodularizing Alloy Diameter = 13 mm

Contained Alloy = 200
a 230 g/m

 

Chemical Composition: Silicon 43 a 48% Magnesium 28 a 31% Rare Earth 1.0 a 2.0% Aluminum 1.0% Max.

 

Other chemical compositions can
be consulted

CONTACT US

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COMMERCIAL DIVISION

FACTORY / PRODUCT DIVISION

Av. Nossa Senhora do Sabará, 2077
District Campo Grande | Zip Code: 04685-004 – City: São Paulo - State: São Paulo - Brazil

+55 11 5631-0200 - Extension 244 / 255 / 372

e-mail: comercial@rotavi.com.br

R. Salvador Roberto, 1963 - District Progresso
Zip Code: 39.260-000 - City: Várzea da Palma - State: MG - Brazil
+55 11 5631-9676

e-mail: assistenciatecnica@rotavi.com.br

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