Dura-Bar XL 10 Most Frequently Asked Questions
Dura-Bar material is continuously cast in sizes up to 20" diameter. Any larger diameter material is produced as a permanent mold and is called Dura-Bar XL. The material is produced using the same quality focus and raw materials as Dura-Bar continuous cast bars. Even better, it is in stock for quick shipment to meet your processing needs. Listed below are answers to the 10 most frequently asked questions about Dura-Bar XL.
1. What sizes of Dura-Bar XL are available?
Dura-Bar XL is offered in 21, 23, 24, 25 and 26 inch diameters. All ingots are rough turned to provide a quality surface that speeds machine time. Dura-Bar XL is in stock and can be cut-to-length to help speed your processing.
2. What grades of material are available?
Dura-Bar XL is available in G2 gray iron (class 40), 65-45-12 ductile iron and 80-55-06 ductile iron.
3. Why are Dura-Bar XL ingots a better choice than sand castings from a typical foundry?
Dura-Bar XL ingot is a better quality material
- There is no sand involved in the process to cause foundry defects and deteriorate tool life
- The mold size is the same from pour to pour, increasing the performance of the casting process and the quality of the bar
- The melt materials are the same high quality material used for all Dura-Bar products
- The ingot is proof turned to provide an excellent machining surface and give an additional level of comfort about the quality of the material.
Dura-Bar XL ingot is more economical
- No pattern charge, period
- Available from stock
- Eliminate long waits for a custom quotation - be the first back to the customer with price and delivery
- No waste or safety stock - purchase just the length you need
- Less machining because the material is proof turned
- Increase tool life with a proof surface and saw cut ends
- Sand free process improves quality and is environmentally friendly
- Permanent molds are reusable and ultimately recycled
4. What exactly is the permanent mold process?
As its name implies, the permanent mold casting method uses reusable metal molds in place of the sand-based molds used in conventional foundries. The molds are made from steel and the cavity surface is coated with a thin layer of heat resistant material and release agent. There is no sand involved in the process. Molten metal is carefully poured into the open cavity of the mold where it is allowed to cool to temperature before being removed from the mold.
5. How are Dura-Bar XL ingots made from the permanent mold process different from continuous cast bars?
From a performance standpoint, there is no difference. If the application was a success with Dura-Bar continuous cast, it will be with Dura-Bar XL as well.
Visually you may notice less of a visible rim (bull's eye) formed on the ingot because of the different cooling rates of the two processes. In addition, all Dura-Bar XL is sold in a turned condition further reducing the size of the rim. While the actual amount of variation in the microstructure from rim to core is still the same in both processes, there may be a slightly finer grain structure with the Dura-Bar XL.
Finally, the length of the ingots is determined by the mold size, so a longer length cannot be ordered like it is possible to do with continuous cast bar. Shorter pieces are easily cut to length by Dura-Bar Metal Services.
6. Are Dura-Bar XL chemistries, mechanical properties and microstructure the same as continuous cast Dura-Bar?
Yes, Dura-Bar XL is poured from the same quality prepared metal as our continuous cast bars. Chemical, mechanical and microstructure results will be the same as Dura-Bar continuous cast for comparable sizes.
7. Is certification available for the material?
Yes, certification for Dura-Bar XL is available in the normal Dura-Bar format and each ingot is tagged for traceability.
8. How does the certification differ from continuous cast Dura-Bar?
It is exactly the same with one small difference. When a continuous cast bar is made, several wafers are cut for hardness testing throughout each run. The range of those samples is then recorded for certification.
With Dura-Bar XL, only one hardness sample is taken from each ingot. In both cases, we report hardness values at the edge, mid-radius and center of the sample.
9. What is the typical condition of the ingot ends?
Since most orders for material are ordered cut to length, they will come in with both faces cut. In the event an entire length of bar is purchased, one end is left in the as-cast condition unless an additional cut is requested.
The ends of the bar are really the top and bottom of the mold. We utilize the bottom end to locate the support center during turning. This process leaves a small hole in the as-cast end of the bar. By not cutting the end off and using it in the turning process, we reduce the cost of the ingot and increase the length of usable material.
10. Does the Zero Defect Guarantee apply to Dura-Bar XL?
No, not at this time. However, the same quality care in selecting and preparing our melt product, casting the bars and inspecting for consistency is found in all the Dura-Bar products, including Dura-Bar XL.
For more information about Dura-Bar XL, please contact your Dura-Bar Metal Services Account Manager today (888-387-2227).