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The final properties of ductile iron are decided by the inoculant processing while pouring the melt. The shape and size of nodules generated during solidification are of paramount importance in solidification of ductile cast iron. The purpose of this study is to examine the effect of different inoculant addition on the solidification of ductile cast iron melt through thermal analysis.

Thermal analysis has recently grown as a tool for modeling the solidification behavior of ductile cast irons. Iron properties will be predicted by analyzing the cooling curve patterns of the melts and predicting the related effectiveness of inoculant processing. In this study, thermal analysis is used to evaluate the need for inoculation.

The amount and type of inoculation will affect the amount of undercooling during the solidification of ductile cast iron. It is found that the addition of 0.1 to 0.4 Wt.% inoculant lowers the austenite dendrite formation starting temperature while increasing the eutectic freezing temperature. Microstructure analysis revealed that the addition of inoculation increases the nodule count from 103 to 242 nodules. The beneficial effects of inoculation are sustained by an improved graphitization factor, which shows the formation of graphite nodules in the second phase of the eutectic reaction.

The inoculation treatment has improved metallurgical occurrences such as carbide to graphite conversion, graphite microstructure control, graphite nodule count at the start of solidification and the last stage of solidification, which determines the soundness of casting. The foundry industry can follow these steps for monitoring the solidification of ductile iron castings.

This study aims to evaluate the suitability of Ferrock as a green construction material by analysing its engineering properties, environmental impact, economic viability and adoption challenges. It also aims to bridge knowledge gaps and provide guidance for integrating Ferrock into mainstream construction to support the decarbonisation of the built environment.

It presents a systematic and holistic review of existing literature on Ferrock, comprehensively analysing its mechanical properties, environmental and socio-economic impact and adoption challenges. The approach includes evaluating both quantitative and qualitative data to assess Ferrock’s potential in the construction sector.

Key findings highlight Ferrock’s superior mechanical properties, such as higher compressive and tensile strength, and enhanced durability compared to traditional Portland cement. Ferrock offers significant environmental benefits by capturing more CO₂ during curing than it emits, contributing to carbon sequestration and reducing energy consumption due to the absence of high-temperature processing. However, the material faces economic and technical challenges, including higher initial costs, scalability issues, lack of industry standards and variability in production quality.

This review provides a comprehensive and up-to-date analysis of Ferrock. Despite being discussed for a decade, Ferrock research has been overlooked, with existing studies often limited and published in poor-quality sources. By synthesising current research and identifying future study areas, the paper enhances understanding of Ferrock’s potential benefits and challenges. The originality lies in the holistic evaluation of Ferrock’s properties and its implications for the construction industry, offering insights that could drive collaborative research and policy support to facilitate its integration into mainstream use.