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  • DUCTILE IRON MARKETING GROUPSPONSORING MEMBERSDuctile Iron Society

    Miller and Company

    RTZ Iron & Titanium America

    28938 Lorain Road, Suite 202North Olmsted, OH 44070Phone (216) 734-8040Fax (216) 734-8182

    Designs inDuctile Iron

    COST SAVING DESIGN IDEAS COST SAVING DESIGN IDEAS

  • Designs in Ductile Iron

    DUCTILE IRON, also known as nodular iron or S.G.iron, is a member of the family of cast irons, whichincludes gray, malleable, white, and compactedgraphite irons. Although there are chemical and met-allurgical differences that distinguish the family mem-bers, of prime concern to the design engineer are themechanical and physical properties available. DUCTILE IRON is the strongest, the toughest, andhas the highest endurance limit of all the cast irons.

    Since the invention of DUCTILE IRON in 1948, DUCTILE IRON castings have been proven to be areliable, cost effective alternative to steel castings,forgings, and fabrication. Conversions to DUCTILEIRON have been made because of excellent castabilityand machinability, comparable or superior properties,and 10% lower density resulting in cost savings ashigh as 75%.Why DUCTILE IRON? Because it offers the designengineer an outstanding combination of endurance,toughness, reliability, and low cost manufacturing.

    CASTING Bracket-Truck FrontShock Absorber

    APPLICATION Anchors ShockAbsorber to Frame

    SPECIFICATION SAE J-434C (D4512)

    REDESIGN From Reinforced SteelStamping

    COST SAVINGS Reduced Cost 4.2%

    DESIGN Allows for StifferADVANTAGES Suspension Design;

    Improved Performanceand Lower WarrantyCosts

    SIZE & WEIGHT 15" long

    COMPANY Unknown

    FOUNDRY Wagner CastingsDecatur, IL

    DUCTILE IRON MARKETING GROUP

    WHY DUCTILE IRON?

    BEST WORST

    Characteristic

    Castability

    Ease of MachiningVibrationDampingSurfaceHardenabilityModulus ofElasticityImpact ResistanceCorrosionResistanceStrength/WeightWearResistanceCost ofManufacture

    DuctileIron

    MalleableIron

    GreyIron

    0.3%CCast Steel

    WhiteIron

    NA

    NA

    NA

    NA

    NA

    3

    CostSavingDesignIdeas

  • CostSavingDesignIdeas

    CostSavingDesignIdeas

    Designs in Ductile Iron Designs in Ductile Iron

    CASTING Stabilizer Foot

    APPLICATION Support For Loader-Backhoe

    SPECIFICATION ASTM A-536 (80-55-06)

    REDESIGN From Steel Weldment

    COST SAVINGS Reduce Costs 49%Annual Savings$80,000

    DESIGN Eliminated Machining-ADVANTAGES Holes. They Were Cast

    to Size; All FabricationOperations Eliminated

    SIZE & WEIGHT Unknown

    COMPANY Deere & Co.Moline, IL

    FOUNDRY John Deere FoundryEast Moline, IL

    CASTING Rope Clamp and EyeNut

    APPLICATION Belt Conveyor

    SPECIFICATION ASTM A-536 (65-45-12)

    REDESIGN From Steel Forging

    COST SAVINGS Part Cost Reduced82%; $42,000 AnnualSavings

    DESIGN Produced StrongerADVANTAGES Part; Improved

    Appearance

    SIZE & WEIGHT 1" x 2"

    COMPANY Continental Conveyor& EquipmentWinfield, AL

    FOUNDRY Unknown

    CASTING Crankshaft

    APPLICATION Supercharged EngineComponent

    SPECIFICATION ASTM A-897Austempered DuctileIron

    REDESIGN From Steel Forging

    COST SAVINGS Costs Reduced 39%

    DESIGN More Design Flexibility;ADVANTAGES Improved Sound

    Dampening; BetterWear Resistance;Stronger and LighterThan Forging

    SIZE & WEIGHT Unknown

    COMPANY Ford Motor Co.

    FOUNDRY Unknown

    CASTING Car Stop

    APPLICATION Keeps Railcars FromMoving Past aDesignated Spot

    SPECIFICATION ASTM A-536 (65-45-12)

    REDESIGN From Steel Casting

    COST SAVINGS Casting Cost ReducedUp to 25%

    DESIGN Comparable Function;ADVANTAGES Improved Machinability

    SIZE & WEIGHT Several Different Sizes

    COMPANY Unknown

    FOUNDRY Manitowoc Grey IronFoundryManitowoc, WI

    DUCTILE IRON MARKETING GROUP DUCTILE IRON MARKETING GROUP4 5

  • CostSavingDesignIdeas

    CostSavingDesignIdeas

    Designs in Ductile Iron Designs in Ductile Iron

    CASTING Tow Bar Head

    APPLICATION Aircraft Tow Bar

    SPECIFICATION ASTM A-536 (80-55-06)

    REDESIGN From Steel Weldment

    COST SAVINGS Part Cost Reduced 76%;$94,000 Annual Savings

    DESIGN Better Yield and TensileADVANTAGES Characteristics;

    Minimum Machining;Good Appearance

    SIZE & WEIGHT 31" x 10" x 3"

    COMPANY Wooland AircraftEquipmentMiami, FL

    FOUNDRY Goldens Foundry &MachineColumbus, GA

    CASTING Worm Gear & Post Screw

    APPLICATION Pulp Refining Machinery

    SPECIFICATION ASTM A-536 (60-40-18)

    REDESIGN From Bronze & SteelFabrication

    COST SAVINGS Part Cost Reduced 46%;$77 Savings per Unit

    DESIGN Provided PreciseADVANTAGES Clearances Regardless

    of Internal Pressure;Simplified Final Assembly

    SIZE & WEIGHT Approximately 18" x 30"

    COMPANY E. D. Jones CorpPittsfield, MA

    FOUNDRY Unknown

    CASTING Wheel Hub

    APPLICATION Four Wheel Drive AllTerrain Vehicle

    SPECIFICATION ASTM A-536 (65-45-12)

    REDESIGN From Aluminum Casting

    COST SAVINGS Part Cost Reduced 50%

    DESIGN Lightweight; IncreasedADVANTAGES Strength and Safety;

    Pleasing Aesthetics

    SIZE & WEIGHT Only 7 oz. Heavier thanPrevious Aluminum Part

    COMPANY Dotson CompanyRoseau, MN

    FOUNDRY Unknown

    CASTING Fertilizer Knife

    APPLICATION Fertilizer Injection

    SPECIFICATION ASTM A897 AustemperedDuctile Iron

    REDESIGN From Forging andWeldment

    COST SAVINGS Part Cost Reduced 44%

    DESIGN All Components Can BeADVANTAGES Made in the Casting:

    Excellent WearCharacteristic;Components NotDamaged in Service

    SIZE & WEIGHT Est. 7 lbs.

    COMPANY Unknown

    FOUNDRY Hayes-Albion Corp.Albion, MI

    DUCTILE IRON MARKETING GROUP DUCTILE IRON MARKETING GROUP6 7

  • CostSavingDesignIdeas

    CostSavingDesignIdeas

    Designs in Ductile Iron Designs in Ductile Iron

    CASTING Nose and Mount

    APPLICATION Tension and Cut Stainless Steel Banding

    SPECIFICATION ASTM A-897 AustemperedDuctile Iron-Investment Casting

    REDESIGN From Tool Steel Investment Casting

    COST SAVINGS Reduced 77% per Machine

    DESIGN Major Reduction in Machining ADVANTAGES Costs; Equivalent Performance

    and Wear Resistance; NoWarping During Heat TreatmentAllowing Machining to Be DoneBefore H.T.

    SIZE & WEIGHT Less Than 1 lb.

    COMPANY Panduit Corp.Romeoville, IL

    FOUNDRY Precision Metalsmiths, Inc.Markesan, WI

    CASTING Wire Rope Clamp

    APPLICATION Belt Conveyor

    SPECIFICATION ASTM A-536 (80-55-06)

    REDESIGN From Steel Forging

    COST SAVINGS Part Cost Reduced 92%;$42,000 Annual Savings

    DESIGN Provide CloseADVANTAGES Tolerances; Higher Strength;

    Marketing Advantages

    SIZE & WEIGHT Unknown

    COMPANY Modern Handling SystemsBirmingham, AL

    FOUNDRY Unknown

    CASTING Anvil

    APPLICATION Blacksmiths ForgingAnvil

    SPECIFICATION ASTM A-536 (100-70-03)

    REDESIGN From Iron Casting withTool Steel Plate Weldedto Top Surface to ReduceWear and Chipping

    COST SAVINGS Cost Reduced 35% perPiece

    DESIGN Good Response to HeatADVANTAGES Treatment; Reduced

    Chipping on Corners;Better Looking Part;Eliminated WeldingOperation

    SIZE & WEIGHT Est. 300 lbs.

    COMPANY Unknown

    FOUNDRY Fountain Foundry, Inc.Pueblo, CO

    CASTING Door Mechanism Fixture

    APPLICATION Aircraft Bomber Door

    SPECIFICATION ASTM A-536 (65-45-12)

    REDESIGN From Steel Weldment

    COST SAVINGS Part Cost Reduced 78%

    DESIGN Solved WarpageADVANTAGES Problem; Provided

    Strength; ReducedNumber of Parts

    SIZE & WEIGHT Unknown

    COMPANY Field Aviation Co., Ltd.

    FOUNDRY Unknown

    DUCTILE IRON MARKETING GROUP DUCTILE IRON MARKETING GROUP8 9

  • CostSavingDesignIdeas

    CostSavingDesignIdeas

    Designs in Ductile Iron Designs in Ductile Iron

    CASTING Shift Lever

    APPLICATION Shifter For 4 x 4Transfer Case

    SPECIFICATION SAE J-434C (D4512)

    REDESIGN From Weldment thatwas Reinforced withMultiple Stamping

    COST SAVINGS Greatly Reduced Priceand Tooling Costs

    DESIGN Combined MoreADVANTAGES Functions Into Casting;

    Improved Test Life;Better Shift Feel

    SIZE & WEIGHT 6" x 3"

    COMPANY Ford Motor Co.

    FOUNDRY Wagner CastingDecatur, IL

    CASTING U-Joint Slip Yoke

    APPLICATION Truck Drive ShaftConnector

    SPECIFICATION ASTM A-536 (100-70-03)

    REDESIGN From Steel Forging

    COST SAVINGS Cost Reduced 47%

    DESIGN Produced Reliable PartADVANTAGES with Lower Machining

    and Material Costs

    SIZE & WEIGHT 18 lbs.

    COMPANY Dana Corp.

    FOUNDRY Dana Corp.New Castle, IN

    CASTING Brake Anchor

    APPLICATION Agricultural Tractor

    SPECIFICATION ASTM A-536 (80-55-06)

    REDESIGN From Steel Fabrication

    COST SAVINGS Part Cost Reduced 44%From Steel Fabrication

    DESIGN Withstood High ImpactADVANTAGES Force; Minimized

    Machining Costs

    SIZE & WEIGHT 3" x 6"

    COMPANY John Deere TractorWorksDubuque, IA

    FOUNDRY John Deere FoundryMoline, IL

    CASTING Air Compressor Block

    APPLICATION Multi-Stage Compressor

    SPECIFICATION ASTM A-536 (65-45-12)

    REDESIGN From Steel Weldment

    COST SAVINGS Part Cost Reduced 46%;$93,000 Annual Savings

    DESIGN Improved SoundADVANTAGES Dampening and Product

    Integrity; Reduced Mfg.Operations; BetterAppearance

    SIZE & WEIGHT 36" x 48"

    COMPANY Worthington Corp.Buffalo, NY

    FOUNDRY Unknown

    DUCTILE IRON MARKETING GROUP DUCTILE IRON MARKETING GROUP10 11

  • CostSavingDesignIdeas

    CostSavingDesignIdeas