Industrial foundry group
The foundry required specific FeSi 75% grade with controlled aluminum content for ductile iron production, but their previous supplier had inconsistent lot-to-lot chemistry.
We implemented lot-specific CoA (Certificate of Analysis) documentation and pre-shipment sampling, allowing the buyer to verify chemistry before each shipment.
Lot consistency improved measurably, reducing rework rates and enabling the foundry to maintain tight mechanical property targets in their final castings.
An industrial foundry group producing ductile iron castings for the automotive sector was experiencing unacceptable variation in final casting mechanical properties. Root cause analysis traced the issue back to inconsistent ferrosilicon chemistry, specifically fluctuating aluminum content in the FeSi 75% grade they were using as an inoculant base. Their previous supplier provided only generic certificates, and the foundry had no way to verify lot-specific chemistry before the material arrived on site.
We introduced a lot-specific Certificate of Analysis program that included full elemental breakdown for each production batch. Before every shipment, we sent pre-shipment samples to the foundry’s quality lab for independent verification, ensuring the silicon content stayed within the 74-76% band and aluminum remained below the agreed ceiling. This pre-shipment approval process gave the foundry confidence that each lot would perform predictably in their inoculation process.
The results were immediate and measurable. Rework rates dropped as the foundry achieved consistent nodularity counts and tighter tensile strength distributions across production runs. With reliable ferrosilicon chemistry, the quality team was able to narrow their mechanical property targets and reduce the safety margin they had previously built into their pouring parameters. The foundry group has since extended the arrangement to include metallic silicon for their high-specification alloy grades.
Standard FeSi 75% ferrosilicon alloy, the workhorse deoxidizer and silicon source in steelmaking. Provides reliable silicon recovery for deoxidation, alloying, and cast iron inoculation across the full spectrum of steel grades.
Primary metallic silicon with 98%+ Si content, providing a high-purity silicon source for steel alloying, deoxidation, and specialty alloy production. Offers superior silicon recovery and lower impurity introduction compared to ferrosilicon.