Dura-Bar Continuous Cast Iron Machine More Parts per Hour • Decrease Costs and Improve Profitability • Increase Productivity

Break o�

Hold down

Crucible

Notching saw

Grippers

Control panel

Roll strands andstrand supports

Gray Iron Ni-Resist•Excellentwearresistance•Vibrationdamping•Superiorsurfacefinish•Respondswelltoconventional heattreatmethods HeatTreatMethods

• Idealforcorrosive environments

1. Agraphitedieismachinedtoform theshapeofthebar(Round,Square, Rectangle,oraCustomShape)

2. Thedieismountedtothebottomofa crucibleinawater-cooledjacket

3. Thebarispulledhorizontally throughthedie

Dura-Bar Continuous Casting Process

4. Anyimpuritiesfloattothetopofthe crucible,allowingonlythehighestquality irontoenterthedie.Theresulting materialis:

• Freeofdefectstypicallyassociatedwith castiron

• Densewithafine-grainedmicrostructure

• Highlymachinable

•Alternativetolow&medium carbonsteel•Excellentmachiningproperties•Lowerheattreatcostsvssteel•Comparablestrength

Ductile Iron

Various Grades:

Rounds Squares/RectanglesAs-CastorCold-Finished

Tubes CustomShapesAs-Cast

Cut-To-SizeCut-to-Length

Dura-Bar Shapes and Sizes

Molteniron

Water �ow

Cast barGraphite die

Water cooler

Refractorylining

Crucible

Arecentindustry-widestudyconductedbyamajortoolingmanufacturerdeterminedthattheaveragecosttomanufactureacomponentbreaksdownasfollows:5%toolingcost,20%materialcostand75%manufacturingcost.

Thegraphicbelowillustratesthecostreductionpossibilitiesofsaving30%ineachcostcategory.ThetruebenefitofDura-Barcomesfromthereductioninmanufacturingtimewhichgenerallymakesupthelargestpercentageofacomponent’scost.

Forexample,a30%reductioninmanufacturingtimeona$10component,wouldsave$2.25percomponent.Anannualvolumeof100,000pieceswouldincreaseyourprofitabilityby$225,000.

Reducing Manufacturing Costs

Cost Reduction:

Machining Dura-Bar

ManufacturingCosts.......$7.50

WorkpieceMaterial..........$2.00

CuttingTools.......................$.50

More Parts per Hour

Advantages of Dura-Bar:•Fastermachiningspeedsandfeeds

•Consistentlyoutperformsalternativematerials

•Lowersthetotalcostofmachinedcomponentparts

•Longertoollifeandlesstoolwear

Advantages of Graphite in Dura-Bar:•Enhancesmachiningbyactingasachipbreaker

•Reducesfrictionontheinsert&increasestoollife

• Improveswearperformanceintheapplication

•Graphiteisanaturallubricant

30%ReductioninToolingCost=$0.15

30%ReductioninMaterialCost=$0.60

30%ReductioninManufacturingTime=$2.25

More Parts Per Hour

TheuniquecontinuouscastingprocessusedtoproduceDura-Baryieldsanumberofcost-savingadvantagesformanufacturersofmetalcomponentswithoutsacrificingmaterialstrength.ThechartontherightprovidesthematerialpropertiesofDura-Bar65-45-12and80-55-06ductileironcomparedwithcommongradesofsteel.

Comparable StrengthDura-Bar vs Steel

Material PropertyDura-Bar Hot Rolled Steel

65-45-12 80-55-06 1018 1045 1117 1144 12L14

TensileStrength(psi/ksi) 65,000 80,000 58,000 81,900 58,000 102,000 57,300

YieldStrength 45,000 55,000 31,900 45,000 31,900 60,900 34,100

Elongation(%In2") 12 6 25 16 25 21 22

Hardness–Average(BHN) 180 229 116 163 116 212 121

Insituationswhereproducingacomponentrequiresahighdegreeofturning,milling,drilling,and/ortapping,usingDura-Barwillresultindramaticsavingsinmachiningcosts.

Faster Machining

1212 Steel = 100%

G2

65-45-12

80-55-06

100-70-03

8620

1045

1117

12L14

0%20%40%60%80%100%120%140%160%

Machinability RatingG

rade

Dura-Bar vs Steel

Machine at Higher Speeds with Reduced Tool Wear

Dura-Bar vs Steel (continued)

TheDura-Baradvantageistheabilitytomachineathigherspeedswithoutnegativelyimpactingtoollife.

• Toollifeisoftenupto2timeslonger at800SFM

• Comparablemechanicalproperties,beforeand afterheattreat

• Dura-Baris8%lighterbydensityandhas superiorvibrationdampingproperties

• Superiorwearresistance

Advantages of Dura-Bar vs Steel

Dura-Barductileironchips;consistentandcontrollablechipformation

Steelchips;typicalstringyanduncontrollablechipformation

1045 1117 80-55-06 G2 65-45-12

0 400200 600 800 1000 1200 1400SFM

Inse

rt W

ear R

ate

Wear Rate Comparison

Machinability ratingsbased on tool life

di erences at 450 sfm

Dura-Bar Ductile ironis often machined at

speeds exceeding1000 sfm

Dura-Bar vs Steel (cont.)

Dura-Bar vs Castings

•Continuouscastingprocesseliminates typicalcastingdefects

•Densefine-grainedmicrostructure

•Zero-DefectGuarantee

•Superiorsurfacefinish

Advantages of Dura-Bar vs CastingsDura-Bar vs Castings

Dura-Barcontinuouscastironisahighqualityalternativetocastings.WithDura-Bartherearenodefectslikethosetypicallyfoundincastings–e.g.,porosity,slag,hardspots,shrinkage,etc.Infact,Dura-BarcomeswithauniqueZeroDefectGuaranteethatnotonlyprovidesforthereplacementofanydefectivematerial,butalsoforreimbursementofcostsinvolvedwithmachiningit.*

Dura-Bar SandCasting

•Nopatternortoolingcosts

•Fastermachiningandreducedtoolwear

•Over500sizesavailablefrominventory

•Minimalcarbides

Dura-Bar’s Zero Defect Guarantee

For a complete description of the Zero Defect Guarantee, including a description of the exclusions and limitations that apply to such guarantee, please see: www.dura-barms.com/dura-bar/zero-defect-guarantee.cfm

*

Inhigh-pressurehydraulicapplications,Dura-Barconsistentlyoutperformsaluminum.Aluminumisgenerallynotusedinpressureapplicationsgreaterthan3,000psi.

Tough Under Pressure

Dura-Bar vs Aluminum

•Higherfatiguestrengths

•Higherelasticmodulus(underthesameload aluminumwilldeflectanddistortmorethan twiceasmuchas65-45-12)

•Littleornodeburringrequired

Incontrast,Dura-Barductileironhasbeenpressureratedto6,500psi.*Therefore,amanifoldproducedfromDura-Barcanoperateatmuchhigherpressuresthananaluminummanifoldwiththesamedesign.Assystemsgetsmaller,withthinnerwallsections,Dura-Bar’shigherpressureratingversusaluminummakesforaneasymaterialselectioninpressurecontainingapplications.

Advantages of Dura-Bar vs Aluminum

Material Property 6061-T6 2024-T3 65-45-12

Hardness(BHN) 95 120 180

TensileStrength(psi) 45,000 70,000 65,000

YieldStrength(psi) 40,000 50,000 45,000

Elongation(%) 12 19 12

ElasticModulus(psi) 10,000,000 10,600,00 25,000,000

FatigueStrength(psi) 14,000 20,000 40,000

Density(lbs/in3) 0.098 0.100 0.255

ThermalExpansion(micro-in/in/F) 13.1 12.9 5.5

Dura-Bar consistently outperforms aluminum

* Rated in accordance with NFPA T2.6.1

Dura-Bar vs Aluminum

The possibilities are endless…

CylinderLinerCylinderLiner CylinderLiner HydraulicManifold HydraulicManifold RotaryVanePumpMotor

HydraulicCylinderPiston

HydraulicHousingPumpHousings

Bushing LawnTractorBushing

WaterPumpBushing

Camshaft HydrostaticCylinderSwashPlate

GlassMoldPlunger

SealingBlock

PistonPumpCylinderBlock

HydraulicSwivelClamp

HydraulicSwivelClamp

FlexibleShaftCoupling

HydraulicHoseCoupling

ShaftCoupling

GyrotorRing SealingRingsMachineToolChuck

BearingCap

HydraulicHoseFitting

RadialPumpCylinder

AccessoryDriveGear

TransmissionPlanetaryGear

BalanceShaftGear

SteelMillRoll ChainLinkRoller

RadialPumpCylinder

LockCylinder

CrankShaftGear

CamGear OilPumpGear

EnginePumpGear

DistributorGear

VanePumpRotor

CompressorRotorCamGearBalanceShaftGears

DieselPumpGear

HydraulicOilPumpGear

SynchronizingGears

TimingGear WastePumpGear

HydraulicSwivelSpool

HydraulicSwivelHydraulicOilPumpGear

HydraulicOilPumpGear

CoffeeGrindingRoller

HydraulicCylinderRodGuide

FeederScrew HydraulicSwivel BeltPully LockSleeve SpoolPoppetHydraulicCylinderPiston

Bushing

Dura-Bar Applications

Woodstock,Illinois2195W.LakeShoreDriveWoodstock,IL60098Phone:888-DURA-BARFax:815-338-4608

Salisbury,NorthCarolina770CedarSpringsRd.Salisbury,NC28147Phone:888-DURA-BARFax:704-637-9736

York,Pennsylvania90GrumbacherRd.York,PA17404Phone:888-DURA-BARFax:973-589-3645

dura-barms.com