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Ferrosilicon
Ferrosilicon is an alloy of iron and silicon with a typical silicon content by weight of 15–90%. It contains a high proportion of iron silicides. Ferrosilicon is produced by reduction of silica or sand with coke in the presence of iron. Ferrosilicons with silicon content up to about 15% are made in blast furnaces lined with acid fire bricks.
Ferrosilicons with higher silicon content are made in electric arc furnaces. The usual available formulations are ferrosilicons with 15%, 45%, 75%, and 90% silicon. Ferrosilicon is used as a source of silicon to reduce metals from their oxides and to deoxidize steel and other ferrous alloys. This prevents the loss of carbon from the molten steel.
Ferrosilicon is also used for manufacture of silicon, corrosion-resistant and high-temperature-resistant ferrous silicon alloys, and silicon steel for electromotors and transformer cores. In the manufacture of cast iron, ferrosilicon is used for inoculation of the iron to accelerate graphitization. In arc welding, ferrosilicon can be found in some electrode coatings. Ferrosilicon is a basis for manufacture of prealloys like magnesium ferrosilicon (MgFeSi), used for production of ductile iron.
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Ferrosilicon is also important as an additive to cast irons for controlling the initial content of silicon. It contributes an increase in hardness and deoxidising properties but also with an improvement in strength and quality of iron steel products. Using it to manufacture inoculants and nodularisers can give specific metallurgical properties to the final products produced.
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