Dura-Bar has a compound metal matrix, which gives it properties similar to steel with machinability unmatched by most steel grades. There are multiple benefits of using Dura-Bar, making it an ideal fit to solve many basic application and manufacturing challenges. To view the full Dura-Bar Advantages Flip-Chart click here.
Dura-Bar Continuous Casting Process
Dura-Bar continuous cast iron is a high-quality alternative to carbon steel, iron castings and aluminum. The continuous casting process used to create Dura-Bar produces a product with a fine-grained, dense, as-cast microstructure.
- A graphite die is machined to form the shape of the bar (Round, Square, rectangle, or a Custom Shape)
- The die is mounted to the bottom of a crucible in a water-cooled jacket
- The bar is pulled horizontally through the die
- Any impurities float to the top of the crucible, allowing only the highest quality iron to enter the die. The resulting material is:
- Free of defects typically associated with cast iron
- Dense with a fine-grained microstructure
- Highly machinable
More Parts Per Hour
A recent Industry-wide study conducted by a major tooling manufacturer determined that the average cost to manufacture a component breaks down as follows: 5% tooling cost, 20% material cost and 75% manufacturing cost.
The graphic illustrates the cost reduction possibilities of saving 30% in each cost category. The true benefit of Dura-Bar comes from the reduction in manufacturing time which generally makes up the largest percentage of a component's cost.
For example, a 30% reduction in manufacturing time on a $10 component, would save $2.25 per component. An annual volume of 100,000 pieces would increase your profitability by $225,000.
Dura-Bar vs Steel
The unique continuous casting process used to produce Dura-Bar yields a number of cost-saving advantages for manufacturers of metal components without sacrificing material strength. Dura-Bar 65-45-12 and 80-55-06 have similar, or better, mechanical properties than common grades of steel.
In situations where producing a component requires a high degree of turning, milling, drilling, and/or tapping, using Dura-Bar will result in dramatic savings in machining costs. The chart to the right shows the machinability rating of grades of Dura-Bar versus Steel.
There are several other advantages of choosing Dura-Bar over Steel including:
- Tool life is often up to 2 times longer at 800 SFM
- Comparable mechanical properties, before and after heat treat
- Dura-Bar is 8% lighter by density and has superior vibration damping properties
- Superior wear resistance
Dura-Bar vs Castings
Dura-Bar has several advantages versus castings such as:
- Continuous casting process eliminates defects typically found in sand castings
- Dense fine-grained microstructure
- Superior surface finish
- No pattern or tooling costs
- Over 500 sizes available from inventory
- Minimal carbides
- Zero-Defect Guarantee
Dura-Bar's Zero Defect Guarantee
Dura-Bar continuous cast iron is a high quality alternative to castings. With Dura-Bar there are no defects like those typically found in castings - e.g., porosity, slag, hard sports, shrinkage, etc. In fact, Dura-Bar comes with a unique Zero Defect Guarantee that not only provides for the replacement of any defective material, but also for reimbursement of costs involved with machining it.
Follow the link for a complete description of the Zero Defect Guarantee.
Dura-Bar vs Aluminum
Dura-Bar has several advantages versus Aluminum such as:
- Higher fatigue strength
- Higher elastic modulus (under the same load aluminum will deflect and distort more than twice as much as 65-45-12)
- Little or no deburring required
In high-pressure hydraulic applications, Dura-Bar consistently outperforms aluminum. Aluminum is generally not used in pressure applications greater than 3,000 psi.
In contrast, Dura-Bar ductile iron has been pressure rated to 6,500 psi ( Rated in accordance with NFPA T2.6.1) Therefore, a manifold produced from Dura-Bar can operate at much higher pressures than an aluminum manifold with the same design. As systems get smaller, with thinner wall sections, Dura-Bar's higher pressure rating versus aluminum makes for an easy material selection in pressure containing applications.
|Tensile Strength (psi)||45,000||70,000||65,000|
|Yield Strength (psi)||40,000||50,000||45,000|
|Elastic Modulus (psi)||10,000,000||10,600,000||25,000,000|
|Fatigue Strength (psi)||14,000||20,000||40,000|
|Density (lbs/in 3)||0.098||0.100||0.255|
|Thermal Expansion (micro-in/in/°F)||13.1||12.9||5.5|