Modelling was carried out to investigate the internal dendrite grains structure formation from a liquid two-component solution in the area adjacent to a mould wall. For the simulation, our own model and computer program based on CAFD (Cellular Automata Finite Differences) were used. In modelling, the effect of process conditions and material-related parameters, e.g. nucleation temperature, heat exchange rate, interfacial energy, crystal orientation with respect to the casting wall, etc. on the nature of the dendritic grain growth was examined. It was demonstrated that the profile of concentration field in a near-mould-wall zone impedes the growth of the solid phase in the direct vicinity of the wall. A local melting down of the grains of a solid phase due to the segregation of admixtures reducing the alloy point of liquidus is also possible.

The mathematical model of the globular eutectic solidification in 2D was designed. Pro¬posed model is based on the Cellular Automaton Finite Differences (CA-FD) calculation method. Model has been used for studies of the primary and of globular eutectic grains growth during the ductile iron (DI) solidification. A hyper-eutectic composition has been analyzed but this model can be used in the solidification modeling of hypo- and eutectic DI. The proposed model makes possible to trace the unrestricted growth of primary grains of two phases from the liq¬uid, transition from free to cooperative solidification, and cooperative growth of globular eutectic.

Inoculation of cast iron has become a commonly used metallurgical process, which is carried out in a foundry in order to improve the mechanical properties of utility alloys. It consists in changing the physicochemical state of the melted alloy. This change is caused by the introduction of cast iron with a low ability to nucleate graphite, shortly before pouring a small mass of the substance—an inoculant that increases the number of active nuclei. It is also justified that the literature often connects an increase in the tensile strength UTS of the inoculated grey cast iron, with changes in the characteristics of the particles of graphite. However, in strongly hypoeutectic cast iron, in which a large number of primary austenite grains crystallize, the interdendritic distribution of graphite is usually the result. It also follows that the nature of the graphite precipitates is determined by the mutual relations between the interfacial distances in eutectic grains and the interdendritic distances in the grains of primary austenite occurring in the Fe–C alloys. The article presents the influence of the inoculant on the characteristics of the precipitation of primary austenite grains in relation to the sulphur content in grey cast iron with flake graphite. The study also showed that primary grains in grey cast iron have a great influence on mechanical properties, such as the tensile strength UTS. In this case, the key is to know the value of the degree of undercooling ΔT. The type of inoculant used affects the ΔT value. The study related the number of N primary austenite grains with the degree of undercooling ΔT and the tensile strength UTS with the number of primary austenite N grains.

Volume changes of the binary Fe-C alloy with nodular graphite were forecast by means of the Cellular Automaton Finite Differences (CA-FD) model of solidification. Simulations were performed in 2D space for differing carbon content. Dependences of phase density on temperature were considered in the computations; additionally density of the liquid phase and austenite were deemed as a function of carbon concentration. Changes of the specific volume were forecast on the base of the phase volume fractions and changes of phase density. Density of modeled material was calculated as weighted average of densities of each phase.

Density change occurring in ductile iron castings is a phenomenon far more complicated than in other casting alloys. Initially, graphite nodules grow directly from liquid phase. That is the reason for decrease in alloy density and casting expansion. Decaying carbon concentration in liquid phase adjacent to graphite nodules favours growth of austenite, which covers them isolating from the liquid. In order for graphite to grow further diffusion of carbon through thickening solid solution layer is needed. At this time expansion fades and shrinkage begins. Industrial experience shows that whether or not shrinkage defects in ductile iron castings will occur depends on wall thickness.In the paper an attempt to identify mechanism of shrinkage porosity formation in nodular iron castings during solidification was made. To that end a two-dimension simulation of binary Fe-C system solidification by cellular automaton method was carried out. Using data obtained with Thermo-CALC software, dependencies of temperature on density for each present phase were determined. For liquid phase and austenite influence of carbon concentration on density was also appended. Applying those relationships to the model, density of each individual cell of used grid as well as mean value for whole analysed region were assessed. The method allowed to consider volume fractions of phases and heterogeneity of solid and liquid solutions to find the mean density of the material.The paper presents results of computer simulation of nodular iron density change, with eutectic saturation of 0,9 to 1,1.