MET MET MET MET METAL CASTING AL CASTING AL CASTING AL CASTING AL CASTING 
BENEFITS 
Project Fact Sheet 
Internet tool
MACRO-INCLUSIONS ATLAS 
ï Publically-available, easily accessible 
ï Analysis and photos available on a 
wide range of samples applicable to 
foundry operators 
ï Atlas of oxide macro-inclusions found 
in foundry-produced steel grades 
APPLICATIONS 
Troublesome macro-inclusions may be 
identified from the atlas and the actual 
foundry practice parameters may be 
compared. When the composition of the 
inclusion has been determined, the origin 
of the inclusion and the factors causing 
its occurrence are deduced. This tool 
assists foundrymen to take corrective 
measures to prevent the reappearance 
of the inclusion. The analysis includes 
determining the size and composition of 
oxide macro-inclusions found in foundryproduced 
steel grades, investigating the 
stable and metastable phases which 
form during steel processing, and determining 
the mechanisms of inclusion formation 
and elimination. 
INTERNET SITE ASSISTS FOUNDRIES ANALYZE MACRO-INCLUSIONS 
WHICH OCCUR DURING FOUNDRY PROCESSING 
The Macro-Inclusions Atlas provides foundry operators with access to information 
which they can apply on a real-time basis to reduce the frequency of 
macro-inclusions. Through the analysis of the chemistry and size of problematic 
inclusions, foundry operators can determine potential sources of macro-inclusions 
and identify countermeasures to reduce their occurrence. The Atlas is 
available on the Internet at http://neon.mems.cmu.edu/afs/atlas.html. 
The problem of macro-inclusions in steel castings has plagued all stages of 
steel castings and is particularly problematic in foundry processing and in the 
continuous casting of sheet steels and wires. 
Macro-inclusions are a major factor in the rejection of castings, contribute to the 
reduced in-service life of cast components and result in component 
remanufacturing. Reducing macro-inclusions, through the use of tools such as 
the Macro-Inclusions Atlas, can significantly increase foundry productivity and 
result in significant energy savings by reducing remanufacturing requirements. 
MACRO-INCLUSIONS ATLAS: SAMPLE ANALYSIS 
Samples are being analyzed by microprobe, SEM and optical microscope. The Inclusions Atlas 
characterizes and provides the results of each sample analyzed including information on: 
ï Chemical analysis (weight percent) of the cast metal 
ï Defect characterization including information on point of 
detection, location of defect, and melting practice data 
ï Final deoxidation practices 
ï Ladle treatment of the steel and ladle data 
ï Lining type 
ï Pouring practice on defective casting 
ï Molding process on defective casting 
ï Molding binder 
ï Coring process on defective casting 
ï Coring binder 
ï Gating practice 
The illustration shows a sample that has been analyzed by the CMU researchers. This 7 lb. sample, 
97.507% iron by weight, was melted in an induction furnace. 
The Atlas provides defect descriptions, mapping and chemical composition for 
foundry samples. 
OFFICE OF INDUSTRIAL TECHNOLOGIES 
ENERGY EFFICIENCY AND RENEWABLE ENERGY • U.S. DEPARTMENT OF ENERGY
Project Description 
Goal: To classify and determine the origin of the macro-inclusions formed during 
casting. To develop an atlas of the oxide macro-inclusions found in foundry 
produced steel grades and make the resource available on the World Wide 
Web. 
Macro-inclusions are related to three major problems: 1) deoxidation/reoxidation, 
2) slag entrapment and 3) erosion of refractory materials during steel pouring. 
All three problems occur during foundry processing. 
Researchers at Carnegie Mellon University analyzed inclusions samples provided 
by over 13 foundries and the University of Alabama. The results of the 
analysis, identifying the causes of macro-inclusions and corrective measures to 
reduce their occurrence, are now available on the World Wide Web. 
Progress and Milestones 
• Collected samples from over 13 foundries and the University of Alabama. All 
company-level information is held confidential. 
• Evaluated the effect of melt and ladle refractories and molding refractories 
on the macro-inclusion content of steel. 
• Thermodynamic calculations were made to determine the stability of specific 
inclusions and were compared to inclusions data. 
• Through computer analysis, researchers calculated the equilibrium concentrations 
of solutes in the metal-inclusion and slag metal-inclusion systems. 
• Developed a macro-inclusions atlas that correlates inclusion identification 
with potential operating problems and solutions. 
• Instituted a World Wide Web site to make the Atlas publically available. 
PROJECT PARTNERS 
American Foundrymen's Society 
Des Plaines, IL 
Carnegie Mellon University 
Pittsburgh, PA 
Eagle Alloy 
Muskegon, MI 
Minteq International, Inc. 
Easton, PA 
Nupro Corporation 
New Berlin, WI 
Process Metallurgy International, Inc. 
Arlington Heights, IL 
Taussig 
Skokie, IL 
FOR ADDITIONAL INFORMATION, 
PLEASE CONTACT: 
Harvey Wong 
Office of Industrial Technologies 
Phone: (202) 586-9235 
Fax: (202) 586-6507 
Harvey.Wong@ee.doe.gov 
http://www.oit.doe.gov/IOF/metalcast/ 
Please send any comments, 
questions, or suggestions to 
webmaster.oit@ee.doe.gov. 
Visit our home page at 
www.oit.doe.gov 
Office of Industrial Technologies 
Energy Efficiency 
and Renewable Energy 
U.S. Department of Energy 
Washington, D.C. 20585 
April 1998