The present invention refers to a vermicular cast iron alloy specially designed for blocks and heads of internal combustion engines that have special requirements for mechanical strength and machinability; said vermicular alloy has a microstructure that results in high values of mechanical properties, such as a minimum strength limit of 500 Mpa, a minimum yield limit of 350 MPa, along with good machinability; also, wherein the ferritization factor must be such that it is between 3.88 and 5.48. This set of properties makes it possible to design new engine blocks and heads with complex geometry, high mechanical properties, without compromising machinability, making it attractive both from a technical and economic point of view.

A method for the production of cast iron starting from pre-reduced iron ore (DRI) with an electric arc furnace includes the steps of preparing a charge of pre-reduced iron ore DRI having a metallization higher than 90% and containing over 2.8% by weight of carbon, wherein at least 80% of the carbon is combined with the iron to form iron carbide Fe.sub.3C; charging the charge of pre-reduced iron ore into the electric arc furnace; and melting the DRI charge to form liquid cast iron having at least 80% by weight of actual carbon content deriving from the carbon in the charge of pre-reduced iron ore, the melting step being in a reducing atmosphere and in a melting chamber of the electric arc furnace subjected to a positive internal pressure generated by the gases produced by reduction reactions that develop during melting.

A method for the production of cast iron starting from pre-reduced iron ore (DRI) with an electric arc furnace includes the steps of preparing a charge of pre-reduced iron ore DRI having a metallization higher than 90% and containing over 2.8% by weight of carbon, wherein at least 80% of the carbon is combined with the iron to form iron carbide Fe.sub.3C; charging the charge of pre-reduced iron ore into the electric arc furnace; and melting the DRI charge to form liquid cast iron having at least 80% by weight of actual carbon content deriving from the carbon in the charge of pre-reduced iron ore, the melting step being in a reducing atmosphere and in a melting chamber of the electric arc furnace subjected to a positive internal pressure generated by the gases produced by reduction reactions that develop during melting.

A method for the production of cast iron starting from pre-reduced iron ore (DRI) with an electric arc furnace includes the steps of preparing a charge of pre-reduced iron ore DRI having a metallization higher than 90% and containing over 2.8% by weight of carbon, wherein at least 80% of the carbon is combined with the iron to form iron carbide Fe.sub.3C; charging the charge of pre-reduced iron ore into the electric arc furnace; and melting the DRI charge to form liquid cast iron having at least 80% by weight of actual carbon content deriving from the carbon in the charge of pre-reduced iron ore, the melting step being in a reducing atmosphere and in a melting chamber of the electric arc furnace subjected to a positive internal pressure generated by the gases produced by reduction reactions that develop during melting.

A method for the production of cast iron starting from pre-reduced iron ore (DRI) with an electric arc furnace includes the steps of preparing a charge of pre-reduced iron ore DRI having a metallization higher than 90% and containing over 2.8% by weight of carbon, wherein at least 80% of the carbon is combined with the iron to form iron carbide Fe.sub.3C; charging the charge of pre-reduced iron ore into the electric arc furnace; and melting the DRI charge to form liquid cast iron having at least 80% by weight of actual carbon content deriving from the carbon in the charge of pre-reduced iron ore, the melting step being in a reducing atmosphere and in a melting chamber of the electric arc furnace subjected to a positive internal pressure generated by the gases produced by reduction reactions that develop during melting.

The present invention pertains to a non-magnesium process to produce Compacted Graphite Iron (CGI) by placing a treatment alloy into a treatment ladle, and then placing an inoculant over die treatment alloy in the treatment ladle and pouring a molten base metal there over. The treatment alloy comprises iron, silicon and, lanthanum, wherein lanthanum is 3-30% by weight of the treatment alloy, silicon is 40-50% by weight of the treatment alloy, and the remaining is Iron. Lanthanum in the treatment alloy makes the graphite precipitate as vermiculite (compacted form) instead of flake or spheroids. With extended process window offered by this new process (0.03-0.1% residual lanthanum in the metal) required to make CGI, this new process removes the stringent process control (0.01-0.02% residual magnesium in the metal) dictated by the magnesium process of making CGI.

A method is provided for fabricating iron castings for metallic components. The method for fabricating the iron castings may include forming a molten solution by melting carbon and iron and combining carbon nanomaterials with the molten solution. A first portion of the carbon nanomaterials combined with the molten solution may be dispersed therein. The method may also include cooling the molten solution to solidify at least a portion of the carbon thereof to fabricate the iron castings. The first portion of the carbon nanomaterials may be dispersed in the iron castings.

A method is provided for fabricating iron castings for metallic components. The method for fabricating the iron castings may include forming a molten solution by melting carbon and iron and combining carbon nanomaterials with the molten solution. A first portion of the carbon nanomaterials combined with the molten solution may be dispersed therein. The method may also include cooling the molten solution to solidify at least a portion of the carbon thereof to fabricate the iron castings. The first portion of the carbon nanomaterials may be dispersed in the iron castings.

A ferrosilicon inoculant for gray cast iron containing between 0.1 to 10% by weight strontium, less than 0.35% by weight calcium, 1.5 to 10% by weight aluminum and 0.1 to 15% zirconium, The inoculant, method for producing the inoculant, method for inoculating the melt and a gray cast iron inoculated with the inoculant are covered.

A ferrosilicon inoculant for gray cast iron containing between 0.1 to 10% by weight strontium, less than 0.35% by weight calcium, 1.5 to 10% by weight aluminum and 0.1 to 15% zirconium, The inoculant, method for producing the inoculant, method for inoculating the melt and a gray cast iron inoculated with the inoculant are covered.