Technical Catalogue • TC1005 1

2

Table of Contents

◗ Introduction Cast Iron: Evolution to Versa-Bar ........................................................................................................................ 04 Versa-Bar ............................................................................................................................................................... 05 Advantages of Versa-Bar ..................................................................................................................................... 06 Benefits with Versa-Bar ....................................................................................................................................... 07 Typical applications of Versa-Bar ........................................................................................................................ 09

◗ Gray Iron Description of grades ........................................................................................................................................... 10 Typical applications of Versa-Bar in gray iron .................................................................................................... 11 Versa-Bar V1 - Pearlitic/Ferritic Gray Iron ........................................................................................................... 12 Versa-Bar V2 - Pearlitic Gray Iron ........................................................................................................................ 15 Versa-Bar GMI (Glass Mold Iron) - Gray Iron with refined graphite ................................................................. 18 Evaluation of the Mechanical Properties ........................................................................................................... 20

◗ Ductile Iron Description of grades ........................................................................................................................................... 21 Typical applications of Versa-Bar in ductile iron ................................................................................................ 21 Versa-Bar V3H - Ferritic Ductile Iron ................................................................................................................... 22 Versa-Bar V3 - Ferritic/Pearlitic Ductile Iron ....................................................................................................... 25 Versa-Bar V4 - Ferritic/Pearlitic Ductile Iron ....................................................................................................... 28 Versa-Bar V5 - Pearlitic/Ferritic Ductile Iron ....................................................................................................... 31 Versa-Bar ADI - Austempered Ductile Iron ......................................................................................................... 34 Evaluation of the Mechanical Properties ........................................................................................................... 35

◗ Standard Dimensions Round Shapes ....................................................................................................................................................... 36 Rectangular Shapes .............................................................................................................................................. 38 Square Shapes ...................................................................................................................................................... 39

◗ Additional Information Relational Comparison between Versa-Bar Mechanical Properties and Other Properties .............................. 40 Versa-Bar Grades Compared to Other Standards ............................................................................................... 41 Useful Formulas/Conversion Factors ................................................................................................................... 42

3

Introduction

◗ CAST IRON: Evolution to Versa-Bar Gray and Ductile Irons are alloys of iron-carbon-silicon. Carbon is added to the melt in amounts that exceed the solubility limits of the iron and precipitates as graphite particles. The graphite shape can be lamellar (gray iron) or nodular (ductile iron). Figures 1a and 1b show the typical microstructure of these two types of iron.

The shape and distribution of the graphite, as well as the structure of the matrix, influences directly the properties of the cast iron. This is the reason why the selection of the proper grade of Versa-Bar or any other cast iron is the first and most crucial step in new application development. Besides the standard grades of cast iron to be considered, it may become necessary to look at variations of these grades with alloy additions, or heat treatment processes, which will help meet the best metallurgical properties suited for your needs. Your Versa-Bar sales technician can help you determine the right material selection. The more we know about your product´s application, the better Versa-Bar will meet your needs.

The constant evolution of the iron casting technology continues to boost the development of new applications for cast iron. This evolution is clearly seen in the continuous casting of iron. Versa-Bar in particular is at the leading edge of this evolution. We are constantly refining processes and techniques which are allowing for more economical alternatives to obtain cast iron shapes with superior performance and quality. Versa-Bar is defining what continuous cast iron can be.

Figure 1a - Gray Iron

Figure 1b - Ductile Iron

4

Introduction

◗ Versa-Bar The continuous casting process was developed as an alternative method for the production of cast iron without patterns or conventional molding processes. The process consists of pouring the molten iron into a feeding furnace where a water-cooled graphite die has been mounted to the lower face of the furnace. The bar is pulled horizontally from the furnace as ferrostatic pressure continuously feeds molten iron through the die. The die tightly controlled configuration determines the shape and the structure of the continuous cast bar that is produced. The water cooling of the metal in the die begins the gradual cooling process. This allows for even solidification, yielding a uniform microstructure. As the bar travels the length of the machine the solidification process is complete. It is then notched and broken cleanly into the desired lengths required by the customer. (See Figure 2)

1. Molten Metal 2. Filling Spout 3. Feeding Furnace 4. Water Cooled Graphite Die 5. Roller Supports 6. Control Panel 7. Drawing Unit 8. Cut-off machine 9. Break-off Unit 10. Stock Size 11. Water inlet and outlet 12. Water Cooling Jacket 13. Cast Bar - VERSA-BAR Figure 2 - Versa-Bar Continuous Casting Process

5

Introduction

The continuous casting process makes it possible for the production of bars with fine-grained as-cast structure. This structure is free machining; wear resistance with good mechanical properties. These characteristics, combined with a near net shapes in rounds, squares, rectangles, and special shapes, makes Versa-Bar continuous cast iron a economical and a high performing material, which can be used in many metal component parts applications. (See Figure 3)

Figure 3 - Special shapes close to the final geometry of the piece.

◗ Advantages of Versa-bar Versa-Bar presents many notable advantages when compared to other cast irons. Due to the unique nature of Versa-Bar and its manufacturing process, many typical defects found in the traditional cast methods can be avoided. Those costly defects found in other castings are the main source for scrap and machining losses. These are rarely found in a continuous cast Versa-Bar product. Some of these defects might include the following:

◗ Gas Holes: casting defects that occur internally in a casting and generally appear round in shape with smooth internal surfaces. They also may appear elongated and occur in different sizes. In the production of Versa-Bar, the graphite die, unlike the cores and other tradition molding materials, does not release gases when submitted to the high temperatures of the molten iron. Centerline shrinkage: voids caused by the lack of molten iron in the cross section during the solidification. The continuous flow of homogeneous material through the Versa-Bar casting machine makes this defect almost nonexistent.

◗ Slag inclusion: This nonmetallic residue has always plagued closed mold casting foundries. Those impurities are routinely poured into as material is poured from the ladle into the mold. The Versa-Bar process first pours the molten iron into the feeding furnace. This allows the impurities, such as 6

Introduction

slag, to remain on the surface, where it is easily removed and remain far from the exit of the die on the base of the furnace.

◗ Leakage problems: In sand casting it is not unusual to find sections of open grain structure, which in a pressure application where fluid is applied, can create a leaking through the micro passages in this open structure. With Versa-Bar, the water-cooled graphite die allows for a faster and uniform cooling rate of the molten iron; (cooling modulus). This cooling modulus is responsible for an important characteristic of Versa-Bar. That is grain density which yields good strength, and protection from leakage, a fundamental concern in the production of hydraulic components. (See Figure 4)

Figure 4 - Hydraulic components (manifolds, plungers, caps, valve bodies)

◗ Benefits with Versa-Bar: Compared to Steel. (Weight and Dampening) Density of Versa-Bar = 0.260 lbs / in3 Density of Steel = 0.284 lbs / in3

The density difference of approximately 10% lower in Versa-Bar compared to steel is due to the content of carbon (density = 0,0794 lbs / in3) in form of graphite in the structure of the cast iron. This translates into lower weight consideration and dampening characteristics. As a result, Versa-Bar performs better with reduced noise and vibration: a large concern for gears and other machine components. ◗ Less Stock Removal The continuous casting process of Versa-Bar allows for the production of bars in different shapes and dimensions. Those can be produced very close to the desired dimensions of the finished part. As cast Versa-Bar is free from surface sand inclusion, parting lines, gating, and other feeding or venting inconsistencies found in other castings. This means smoother uninterrupted tool cut and less time to machine finish Versa-Bar part. ◗ Superior Machinability Besides the benefit from less material removal, there are more machining enhancing characteristics present in 7

Introduction

Versa-Bar. The high percentage of graphite in Versa-Bar’s structure works as a natural chip breaker and machining lubricant. It produces superior cutting speed and lower tool wear. You find the best results from the ferritic gray iron and ductile iron grades of Vera-Bar. ◗ High Strength Grades The shape and size of the graphite flake influence enormously the strength of the bar. The bigger the graphite flake size is, the lowest the strength will be. In Versa-Bar the solidification process results in very fine graphite particles with excellent mechanical properties. ◗ Elimination of Tooling Costs: (Patterns and Core Boxes) Since Versa-Bar can be produced in different sizes and shapes, it is possible to select a size or configuration that’s close to the final dimension of the component to be machined. This can often eliminate the high expense of producing casting tooling. Besides, it will greatly deduce the lead-time needed to obtain prototypes or production parts. This reduces significantly the final cost of the product. ◗ Less Scrap after Machining Sand casting defects have always been a constant struggle for any machinist. The problems come and go and it seems it always needs to be factored in the machining cost. Consistency is the the name of the game in machining productivity. Versa-Bar’s freedom from these common casting defects makes it the best machining performer, or, in other words, Versa-Bar is the lowest cost performer. ◗ Surface Heat Treatments Versa-Bar is suitable to different types of heat and other surface treatments . These processes can further improve fatigue strength, wear and corrosion resistance. Traditional heat treatment practices work well with Versa-Bar: (Consult your local heat treatment service on the best process for your needs). Surface hardening in valve guides, hard chromium plating in glass molds (Figure 5), nitriding and shot peening in gears are some examples of surface treatments used in Versa-Bar.

Figure 5 - Shapes and accessories applied to the glass industry. 8

Introduction

◗ Typical Applications of Versa-Bar Any component currently produced in gray iron, ductile iron, steel, aluminum, and bronze could be excellent candidates for conversion to Versa-Bar.. Table 1 shows the more typical applications where Versa-Bar is used or has replaced castings or other materials. MARKET SEGMENT

COMPONENTS Manifolds

Cylinder pistons

Plungers

Cylinder glands

Hydraulic and Pneumatic

Valve Body

Glass Industry

Molds

Neck Rings

Pins

Core Boxes

Punches

Machines and Equipments

Auto parts

Others

Pulleys

Gears

Coupling

Pins

Sheaves

Counterweights

Axles

Tables

Straightedges

Flanges

Bushings

Bearings

Nuts

Washers

Bearing Caps

Valve guides

Brake Piston

Command axles

Rings

Valve seats

Protector tube for

Valve Plates

thermo couplings

Rollers

Patterns

Dies

Retainers Cones Plugs Table 1 - Typical Versa-Bar application.

Those examples show the versatility of Versa-Bar and its several applications. From simple washers and pulleys to complex ones as molds in the glass industry, as well as valve and manifold bodies for the hydraulics industry, Versa-Bar meets the needs of a wide and demanding range of component uses. In order to help you making the best choice please contact our technical support staff at the following location: ◗ In North America: American Iron & Alloys Corp. at 800 5444800 or visit www. versa-bar.com ◗ In other countries: Tupy Fundições Ltda at (5547) 4418193 or (5547) 4418434. ◗ Our electronic addresses are: e-mail: [email protected] or visit www.tupy.com.br 9

Gray Iron

◗ Description of Grades The grades produced in gray iron by continuous casting process are: ◗ Versa-Bar V1 (ASTM A48 Class 30) - Pearlitic/Ferritic Gray Iron ◗ Versa-Bar V2 (ASTM A48 Class 40) - Pearlitic Gray Iron ◗ Versa-Bar V5 (GMI - Glass Mold Iron) - Gray Iron with refined graphite

In all these grades the graphite is lamellar. The characteristics of the graphite and matrix influence the following properties: - Machinability; - Hardness; - Wear Resistance; - Ultimate tensile strength; - Surface Finish and others.

The most common specification of the gray iron contains graphite form VII, type A, size 3 - 6, according to ASTM A247 standard. The V1 class presents graphite distribution in a pearlitic/ferritic matrix. This material can be better used to manufacture pieces that require medium strength, good vibration dampening, good thermal conductivity and better machinability.

The V2 class presents the same graphite distribution, however, in an essentially pearlitic matrix, which yields better mechanical properties and better heat treatment response.

In the GMI grade, the graphite is essentially type D, size 6 - 8 in a ferritic/pearlitic matrix.

10

Gray Iron

◗ Typical Applications of Versa-Bar In Gray Iron

◗Versa-Bar V1 VERSA-BAR V1 - Presents as the main characteristic an excellent machinability, allowing for the increase of the cutting speed and the reduction of the premature tooling wear. It is suitable for applications that require medium mechanical properties, such as: bushings, pulleys, rings, sheaves, pattern plates, flanges, plugs, structures for machines, bearings, couplings, etc.

◗Versa-Bar V2 VERSA-BAR V2 - with its higher mechanical properties, presents good surface finish and good leaking resistance. It is also very suitable in applications that is subjected to wear, such as: pistons, hydraulic valves, dies, pattern plates, couplings, spacers, etc.

◗Versa-Bar GMI VERSA-BAR GMI - presents as main characteristics excellent surface finish, good machinability excellent thermal conductivity. It is suitable to be applied in the manufacturing of pieces for the glass industry, such as: molds, pins and neck rings.

11

Gray Iron

◗ Versa-Bar V1 - Pearlitic/Ferritic Gray Iron

◗ Description VERSA-BAR V1 is a gray iron that has as its main characteristic excellent machinability, allowing for the increase of the cutting speed and the reduction of premature tooling wear. This specification is similar to ASTM A48 Class 30.

◗ Microstructure The typical microstructure of VERSA-BAR V1 consists on graphite in lamellar shape, form VII, type A, size 3 - 6, as defined in ASTM A247. The matrix is predominantly pearlitic with 5 to 20% of ferrite. The rim consists on graphite type D, size 6 - 8 and essentially ferritic matrix with 5% maximum dispersed carbides. (See Figures 6 and 7)

Figure 6 - Typical microstructure in the center (VERSA-BAR V1)

Figure 7 - Typical microstructure in the rim (VERSA-BAR V1)

12

Gray Iron

◗ Mechanical Properties The hardness values and ultimate tensile strength of VERSA-BAR V1 are specified in Table 2 and refer to results found in test specimen taken from the mid-radius section of the bar.

Dimension (inch)

till 1.001 1.751 2.501 3.126 3.626 4.376 5.001 5.751

-

1.000 1.750 2.500 3.125 3.625 4.375 5.000 5.750 10.000

Hardness (mm)

till 25.4 44.4 63.5 79.4 92.1 111.1 127.0 146.0

-

25.4 44.4 63.5 79.4 92.0 111.1 127.0 146.0 254.0

UTS (min.)

(BHN)

(Psi)

(MPa)

163 - 229 163 - 229 163 - 229 163 - 229 163 - 229 163 - 229 163 - 229 163 - 229 163 - 229

30,000 28,500 27,000 25,500 24,000 22,500 21,000 19,500 18,000

207 197 186 176 166 155 145 135 124

Table 2 - Hardness and Ultimate Tensile Strength VERSA-BAR V1

Ultimate tensile strength varies with section thickness and bar diameter (See Figure 8) The bigger the bar diameter the lower the UTS because of the different solidification and cooling rates. The UTS of 1” bar diameter corresponds to 30.000 psi (minimum specification). Typical results are shown in Figures 8, 9 and 10. Results of different sections of the bar are shown in Figures 9 and 10:

Figure 8 - Ultimate Tensile Strength VERSA-BAR V1 (Typical Results and Minimum Specification)

13

Gray Iron

Figure 9 - Ultimate Tensile strength in different positions on the sections of VERSA-BAR V1 (Typical Results)

Figure 10 - Hardness VERSA-BAR V1

◗ Chemical Composition The general chemical composition of VERSA-BAR V1 as shown in the Table 3, is subordinated to mechanical properties. The chemical analysis refer to samples taken from the melting furnace and may vary slightly if compared with chemistry from the part.

14

Gray Iron

Elemento

%

C1 Si Mn S P

2.0 - 3.70 2.30 - 2.70 0.40 - 0.80 0.20 max. 0.10 max.

Note1: Carbon targets are specified for each group of dimensions in order to control type and size of the graphite flake. The variation in the same target is approximately 0,20%.

Table 3 - Chemical Composition VERSA-BAR V1

◗ Heat Treatment VERSA-BAR V1 can be oil quenched to increase the hardness in the rim, increasing the wear resistance. Another usual heat treatment is the annealing, used to reduce hardness, and then, improve the machinability. For specifics on heat treatment process contact our technical support team.

◗ Versa-Bar V2 - Pearlitic Gray Iron

◗ Description VERSA-BAR V2 is a gray iron with fully pearlitic structure that provides high mechanical properties, good surface finish and good hardenability. Another important characteristic to be mentioned is the good leakage resistance. It is well suited for pressure applications such as hydraulic components. This specification is similar to ASTM A48 Class 40.

◗ Microstructure The typical microstructure of VERSA-BAR V2 consists on graphite in lamellar shape, form VII, type A, and size 3 – 6 as defined in ASTM A247. The matrix is predominantly pearlitic, with a maximum of 10% ferrite maximum. The rim consists of graphite type D, size 6 - 8 in a ferritic/pearlitic matrix with approximately 5% of well dispersed carbides. (See Figures 11 and 12)

Figure 11 - Typical microstructure in the center (VERSA-BAR V2)

Figure 12 - Typical microstructure in the rim (VERSA-BAR V2) 15

Gray Iron

◗ Mechanical Properties The hardness values and ultimate tensile strength of VERSA-BAR V2 are specified in Table 4 and refer to results found in test specimen taken from the mid-radius section of the bar.

Dimension (inch)

till 1.001 2.001 3.126 4.126 6.251 10.251 13.501

-

1.000 2.000 3.125 4.125 6.250 10.250 13.500 21.000

Hardness (mm)

till 25.4 50.8 79.4 104.8 158.7 260.3 342.9

-

25.4 50.8 79.4 104.7 158.7 260.3 345.0 533.4

UTS (min.)

(BHN)

(Psi)

(MPa)

197 – 285 197 – 269 197 – 269 197 – 269 197 – 269 179 – 255 179 – 255 179 – 255

40,000 37,000 35,500 34,000 30,000 27,000 25,500 24,000

276 255 245 235 207 186 176 166

Table 4 - Hardness and Ultimate Tensile Strength of VERSA-BAR V2

Ultimate tensile strength varies with section thickness and bar diameter (See Figure 13) The bigger the bar diameter the lower the UTS because of the different solidification and cooling rates. The UTS of 1” bar diameter corresponds to 40.000 psi (minimum specification). Typical results are shown in the Figures 13, 14 and 15. Results of different sections of the bar are shown in Figures 14 and 15:

Figure 13 - Ultimate Tensile Strength VERSA-BAR V2 (Typical Results and Minimum Specification)

16

Gray Iron

Figure 14 - Ultimate Tensile Strength in different positions in the section VERSA-BAR V2 (Typical Results)

Figure 15 - Hardness VERSA-BAR V2

◗ Chemical Composition The general chemical composition for VERSA-BAR V2 is subordinated to the mechanical properties and it is shown in Table 5. The chemical analysis refers to samples taken from the melting furnace: Note1: Carbon targets are specified for each Elemento

%

C1 Si Mn S P

2.80 - 3.70 2.30 - 2.70 0.40 - 0.80 0.20 max. 0.10 max.

group of dimensions in order to control type and size of the graphite flake. The variation in the same target is approximately 0.20%. Note 2: Addition of pearlite promoting elements may be made to obtain pearlite, depending on the size of the bar.

Table 5 - Chemical Composition VERSA-BAR V2 17

Gray Iron

◗ Heat Treatment VERSA-BAR V2 is applied when hardness is critic for the component, allowing for the utilization of heat treatments to increase mechanical strength, hardness and wear resistance. The most usual heat treatments are: induction and flame hardening and oil quenching process. Our technical staff is at your service to give more technical information about heat treatment for specific dimensions.

◗ Versa-Bar GMI (Glass Mold Iron) - Gray Iron with Refined Graphite

◗ Description VERSA-BAR GMI is a gray iron with essentially type D graphite.

Originally developed for the production of glass mold for the glass industry, VERSA-BAR GMI presents extremely refined graphite providing an excellent surface finishing. It is also well known for its excellent machinability and good heat conductivity.

When submitted to repetitive heat cycles of heating/cooling, this grade of Versa-Bar shows good dimensional stability due to the small flake graphite size in a predominantly ferritic matrix.

◗ Microstructure The typical microstructure of VERSA-BAR GMI consists of refined graphite, form VII, type D (70% min.), size 6 8, as evaluated by ASTM A247 . The matrix is ferritic with approximately 15% of pearlite with 5% maximum of dispersed carbides. (See Figure 16)

Figure 16 - Typical microstructure of VERSA-BAR GMI

18

Gray Iron

◗ Mechanical Properties The hardness values and ultimate tensile strength of VERSA-BAR V5 (GMI) are specified bellow and refer to results found in test specimen taken from the mid-radius section of the bar.

Ultimate tensile strength (min) = 24.600 psi (170 MPa) Hardness (BHN) = 131 - 207

Typical results are presented in Figure 17 as follows:

Figure 17 - Hardness VERSA-BAR GMI

◗ Physical Properties Heat Conductivity 212 to 752 F = 41 to 44 Coefficient of Thermal Expansion (10-6/K) 68 oF/68 to 752 oF = 10 to 12.5

◗ Chemical Composition The general chemical composition for VERSA-BAR GMI is subordinated to the mechanical properties and it is shown in Table 7. The chemical analysis refers to samples taken from the melting furnace and may vary slightly if compared to chemistry from the part. Elemento

%

C1 Si Mn S P Ti2

3.10 - 3.80 2.30 - 2.80 0.20 max. 0.015 max. 0.08 max. 0.35 max.

Note 1: Carbon targets are specified for each group of dimensions and variation in the same target is approximately 0,20%.

Note 2: Titanium is added to promote Type D graphite.

Table 7 - Chemical Composition of VERSA-BAR GMI 19

Gray Iron

◗ Heat Treatment VERSA-BAR V2 is applied when hardness is critic for the component, allowing for the utilization of heat treatments to increase the mechanical strength, hardness and wear resistance. The most usual heat treatments are: induction and flame hardening and oil quenching process. Our technical staff is at your service to give more technical information about heat treatment for specific dimensions.

◗ Evaluation of the Mechanical Properties

◗ Standards: The following standards are used to evaluate the mechanical properties in gray iron: • ASTM A48 • ASTM E-8 • DIN EN 1561

◗ Section for taking the test specimen The specimen used for mechanical analysis is taken from the cross section in bars up to 5” (See Figures 18 and 19). In bars under 5”, test specimen is taken from the longitudinal section.Test specimens may be taken from other sections in special shapes. Hardness testing is done using a 5 mm ball with 750 kgf load in bars under 2” and 10 mm ball with 3000 kgf load in bars up 2”.

Figure 18 - Evaluation of the Mechanical Properties in Round Shape

Figure 19 - Evaluation of the Mechanical Properties in Square Shape

20

Ductile Iron

◗ Description of Grades The grades produced in ductile iron by continuous casting processes are: • VERSA-BAR V3H (ASTM A536 Class 60-40-18) - Ferritic Ductile Iron • VERSA-BAR V3 (ASTM A536 Class 65-45-12) - Ferritic/Pearlitic Ductile Iron • VERSA-BAR V4 (ASTM A536 Class 80-55-06) – Ferritic/Pearlitic Ductile Iron • VERSA-BAR V5 (ASTM A536 Class 100-70-03) – Pearlitic/Ferritic Ductile Iron

The main characteristic of the ductile iron grades of Versa-Bar is a spheroidal shaped graphite structure that emphasizes the strength, machinabiltiy and wear resistance.

To obtain graphite type I and II - as per ASTM A247 standard - it is necessary to add some chemical elements and/ or specific production conditions that turn the graphite into spheroidal shape. These ductile iron grades of Versa-Bar are recommended for applications that require high mechanical properties, high toughness and excellent leakage resistance.

The percentage of ferrite or pearlite in the matrix determines the mechanical properties of the material and, consequently, the grade to which it is rated.

The ultimate tensile strength of VERSA-BAR ductile iron in the as-cast condition can range from 60.000 to 100.000 psi with elongation results from 18% to 2%.

Typical Applications of Versa-Bar in Ductile Iron ◗Versa-Bar V3 Versa-Bar V3 - The main characteristics in ductile iron classes 60-40-18 and 65-45-42, with ferritic and ferritic/pearlitic matrix, are good machinability, excellent surface finish and very good leakage strength.

They present ultimate tensile strength and yield strength similar to SAE 1020/1030 steel grades. This grade is good for applications such as machine components that suffer impact and are crack-resistance. Versa-Bar V3 is an excellent choice for hydraulic components which operate in high pressures such as manifolds, pistons, guides, cylinder heads, injector jackets, hydraulic pumps, and dies.

21

Ductile Iron

◗ Versa-Bar V4 and V5 Versa-Bar V4 and V5 - The ferritic/pearlitic and pearlitic/ferritic ductile iron classes 80-55-06 and 100-70-03 offer good hardenability, high mechanical properties with their ultimate tensile strength and yield strength similar to that of SAE 1040/1045 steel. This makes these grades a good choice in applications for machine components that require wear resistance and surface heat treatment response. Some examples: gears, axles, axles pin, tie rod nuts, chuck bodies, piston glands, spindles housings, camshafts, valve seats, etc.

◗ Versa-Bar V3H - Ferritic Ductile Iron

◗ Description VERSA-BAR V3H (class 60-40-18) is a ductile iron with graphite type I and II, in a fully ferritic matrix obtained through heat treatment. Besides the excellent machinability, the ferritic matrix provides high toughness and high magnetic permeability.

This material presents at as-cast condition, ultimate tensile strength and yield strength similar to hot rolled steels SAE 1020.

This specification is similar to ASTM A536 class 60-40-18.

◗ Microstructure The typical microstructure of VERSA-BAR V3H (class 60-40-18) consists o spheroidal-shaped graphite, form I and II, size 5 - 8, as defined in ASTM A247. The matrix is totally ferritic. (See Figure 20 and 21)

Figure 20 - Typical microstructure in the center (VERSA-BAR V3H)

Figure 21 - Typical microstructure in the rim VERSA-BAR V3H) 22

Ductile Iron

◗ Mechanical Properties The hardness values , ultimate tensile strength, yield strength and elongation of VERSA-BAR V3H (class 60-4018) are specified in Table 7.

Dimensions

Hardness

(inch)

(mm)

(BHN)

1.000 – 21.000

25.4 – 533.4

131- 207

Ultimate tensile strength (min.) = 60,000 psi (414 MPa). Yield strength (min.) = 40,000 psi (276 MPa). Elongation (min.) = 18 (%). Table 7 – Mechanical Properties VERSA-BAR V3H

Typical results are presented in Figures 22, 23 and 24 as follows:

Figure 22 - Ultimate Tensile Strength and Yield Strength VERSA-BAR V3H

23

Ductile Iron

Figure 23 - Hardness of VERSA-BAR V3H

Figure 24 - Elongation VERSA-BAR V3H

◗ Chemical Composition The general chemical composition, as shown in Table 8. for VERSA-BAR V3H (class 60-40-18), is subordinated to the mechanical properties. The Chemical analysis refers to samples taken from the melting furnace and may vary slightly if compared with chemistry from the part:. Elemento 1

C Si Mn S P Mg2

% 3.30 - 4.00 2.40 - 3.10 0.20 max. 0.020 max. 0.10 max. 0.03 – 0.05

Note 1: Carbon targets are specified for each group of dimensions and variation in the same target is approximately 0,20%. Note 2: Mg is added to promote spheroidal graphite shape.

Table 8 - Chemical Composition VERSA-BAR V3H 24

Ductile Iron

◗ Heat Treatment VERSA-BAR V3 (class 60-40-18) can be oil quenched to achieve a hardness of approximately, 45 HRC. This material is not recommended for superficial hardening. When a high superficial hardness is necessary, however, nitriding treatment can be used successfully. Figure 25 presents some typical results. Please contact our technical support for specific questions.

Figure 25 - Superficial Hardness results in ferritic ductile iron samples. Nitriding by plasma at 930°F for 2 hours.

◗ Versa-Bar V3 - Ferritic/Pearlitic Ductile Iron

◗ Description VERSA-BAR V3 (class 65-45-12) is a ductile iron with type I and II graphite, in a ferritic/pearlitic matrix obtained as-cast or by heat treatment. This material has the ultimate tensile strength and yield strength similar to SAE 1030 hot rolled steel grade. Its main characteristics are good machinability, surface finish and leakage resistance. This specification is similar to ASTM A536 class 65-45-12.

◗ Microstructure The typical microstructure of VERSA-BAR V3 (class 65-45-12) consists of spheroidal shaped graphite, form I and II, size 5 - 8. The matrix is essentially ferritic containing approximately 30% pearlite and 5% maximum of dispersed carbides. (See Figures 26 and 27)

Figure 26 - Typical microstructure in the center (VERSA-BAR V3)

Figure 27 - Typical microstructure in the rim (VERSA-BAR V3) 25

Ductile Iron

◗ Mechanical Properties The hardness values, ultimate tensile strength, yield strength and elongation of VERSA-BAR V3 (class 65-45-12) are specified in Table 9.

Dimensions

Hardness

(inch)

(mm)

(BHN)

11.000 – 2.000 2.001 – 21.000

25.4 – 50.8 50.8 – 533.4

143 – 217 143 – 207

Ultimate tensile strength (min.) = 65,000 psi (450 MPa) Yield strength (min.) = 45,000 psi (310 MPa) Elongation (min.) = 12 (%) Table 9 – Mechanical Properties VERSA-BAR V3

Typical results are presented in Figure 28, 29 and 30 as follows:

Figure 28 - Tensile and Yield Strength Limit

26

Ductile Iron

Figure 29 - Hardness VERSA-BAR V3

Figure 30 - Elongation VERSA-BAR V3

◗ Chemical Composition The general chemical composition,as shown in Table 10 for VERSA-BAR V3 (class 65-45-12), is subordinated to the mechanical properties. The Chemical analysis refers to samples taken from the melting furnace and may vary slightly if compared with chemistry from the part:.

27

Ductile Iron

Elemento

%

C1 Si Mn S P Mg2

3.30 - 4.00 2.40 - 3.10 0.20 max. 0.020 max. 0.10 max. 0.03 – 0.05

Note 1: Carbon targets are specified for each group of dimensions and variation in the same target is approximately 0,20%.

Note 2: Mg is added to promote spheroidal graphite shape.

Table 10 - Chemical Composition VERSA-BAR V3

◗ Heat Treatment VERSA-BAR V3 (class 65-45-12) can be oil quenched to achieve a hardness of, approximately, 45 HRC.

This material is not recommended for surface hardening such as flame and induction heat treatment. When a high superficial hardness is necessary, nitriding treatment is recommended for this grade. If you have any specific questions please contact our technical support.

◗ Versa-Bar V4 – Ferritic/Pearlitic Ductile Iron

◗ Description VERSA-BAR V4 (class 80-55-06) is a ductile iron with graphite type I and II, in a ferritic/pearlitic matrix. This ferritic/pearlitic matrix provides higher mechanical properties and wear resistance when compared to a ferritic grade of ductile iron. This material will be easily machinable with good suface finished.

This material in its as cast condition provides tensile strength and yield strength similar to hot rolled steels SAE 1040. This specification is similar to ASTM A536 class 80-55-06.

◗ Microstructure The typical microstructure of VERSA-BAR V4 (class 80-55-06) consists of spheroidal shaped graphite, form I and II, size 5 - 8. The matrix is ferritic/pearlitic with approximately 45% of pearlite and 5% maximum of well dispersed carbides. (See Figures 31 and 32).

Figure 31 - Typical microstructure in the center (VERSA-BAR V4)

Figure 32 - Typical microstructure in the rim (VERSA-BAR V4) 28

Ductile Iron

◗ Mechanical Properties The hardness values , ultimate tensile strength, yield strength and elongation of VERSA-BAR V4 are specified in Table 11. Dimensions

Hardness

(inch)

(mm)

(BHN)

1.000 – 3.000 3.001 – 21.000

25.4 – 76.2 76.2 – 533.4

187 – 269 187 – 255

Ultimate tensile strength (min.) = 80,000 psi (552 MPa) Yield strength (min.) = 55,000 psi (380 MPa) . Elongation (min.) = 6 (%). Table 11 – Mechanical Properties Versa-Bar V4

Typical results are presented in the Figure 33, 34 and 35 as follows:

Figure 33 - Ultimate Tensile Strength and Yield Strength VERSA-BAR V4

Figure 34 - Hardness VERSA-BAR V4 29

Ductile Iron

Figure 35 - Elongation VERSA-BAR V4

◗ Chemical Composition The general chemical composition* for VERSA-BAR V4 (class 80-65-06) is shown in Table 12 which is subordinated to the mechanical properties. The Chemical analysis refers to samples taken from the melting furnace and may vary slightly if compared with chemistry from the part:.

Elemento

%

C1 Si Mn S P Mg2

3.30 - 4.00 2.40 - 3.10 0.20 max. 0.020 max. 0.10 max. 0.03 – 0.05

Note 1: Carbon targets are specified for each group of dimensions and variation in the same target is approximately 0,20%. Note 2: Mg is added to generate spheroidal graphite.

Table 12 - Chemical Composition VERSA-BAR V4

* Additions of pearlite promoting element may be made to obtain pearlite, depending on the size of the bar.

◗ Heat Treatment The matrix of the VERSA-BAR V4 offers good hardenability, allowing for induction hardening, oil quenching (to achieve hardness of 50 HRC) and normalization treatments. This can be done to obtain a variety of improvements on the mechanical properties.

Please contact our technical support if you have any questions.

30

Ductile Iron

◗ Versa-bar V5 – Pearlitic/Ferritic Ductile Iron

◗ Description VERSA-BAR V5 (class 100-70-03) is a ductile iron with graphite type I and II, in a predominantly pearlitic matrix obtained as cast or by the addition of pearlite promoting elements.

This material in its as cast condition has tensile strength and yield strength limits similar to hot rolled steels SAE 1045. This specification is similar to ASTM A536 class 100-70-03.

◗ Microstructure The typical microstructure of VERSA-BAR V5 consists on spheroidal shaped graphite, form I and II, size 5 – 8 as defined in ASTM A247. The matrix is predominantly pearlitic containing till 25% of ferrite and 5% maximum of well dispersed carbides. (See Figures 36 and 37)

Figure 36 - Typical microstructure in the center (VERSA-BAR V5)

Figure 37 - Typical microstructure in the rim (VERSA-BAR V5)

◗ Mechanical Properties The hardness values, ultimate tensile strength, yield strength and elongation of VERSA-BAR V5 are specified in table 13.

Dimensions

Hardness

(inch)

(mm)

(BHN)

1.000 – 21.000

25.4 – 533.4

229 – 302

Ultimate tensile strength (min.) = 100,000 psi (700 MPa). Yield strength (min.) = 70,000 psi (480 MPa). Elongation (min.) = 2 (%).

Table 13 - Mechanical Properties Versa-Bar V5

31

Ductile Iron

Typical results are presented in Figures 39, 40 and 41 as follows:

Figure 38- Ultimate Tensile Strength and Yield Strength VERSA-BAR V5

Figure 39 - Hardness VERSA-BAR V5

Figure 40 - Elongation VERSA-BAR V5 32

Ductile Iron

◗ Chemical Composition The general chemical composition* for VERSA-BAR V56 is shown in Table 14, which is subordinated to the mechanical properties. The Chemical analysis refers to samples taken from the melting furnace and may vary slightly if compared with chemistry from the part:.

Elemento

%

C1 Si Mn S P Mg2

3.0 - 4.00 2.40 - 3.10 0.20 max. 0.020 max. 0.10 max. 0.03 – 0.05

Note 1: Carbon targets are specified for each group of dimensions and variation in the same target is approximately 0.20%. Note 2: Mg is added to generate spheroidal graphite.

Table 15 - Chemical Composition VERSA-BAR V5

* Additions of pearlite promoting element may be made to obtain pearlite, depending on the size of the bar.

◗ Heat Treatment The matrix of the VERSA-BAR V5 offers good hardenability, allowing induction hardening, oil quenching (to achieve hardness of 50 HRC) and normalization, to obtain a combinations of improved mechanical properties.

This class of material can also be submitted to nitriding treatment. Typical results are shown in Figure 41.

Figure 41 - Superficial Hardness results in pearlitic ductile iron samples. Nitriding by plasma at 930°F for 2 hours.

33

Ductile Iron

◗ Versa-Bar Adi – Austempered Ductile Iron Versa-Bar ADI is an alloyed and heat-treated ductile iron. Cu, Ni and Mo are added to enhance the ability to be heat treated and attain higher mechanical properties of the iron in the as cast condition. The heat treatment consists of full austenitizing followed by quenching at a temperature of 450 F – 840 F to obtain an ausferritic or bainitic structure. This structure yields a good combination of toughness, ultimate tensile strength and wear resistance.

The range of properties available for Versa-Bar ADI is dependent on the choice of heat treatment parameters. The parameters are established at ASTM 897 standard. (See Table 15).

Our technical staff can give you additional technical information about this grade of ductile iron.

Grade

UTS (psi)

YS (psi)

Elong. (%)

Hardness (HB)

1 2 3 4

125,000 150,000 175,000 200,000

80,000 100,000 125,000 155,000

10 7 4 1

269 – 321 302 – 363 341 – 444 388 – 477

Table 15 – Mechanical Properties Versa-Bar ADI

Some applications of Versa-bar ADI are shown in Figure 42.

Figure 42. Applications of Versa-Bar ADI. Gears in Versa-Bar ADI are usually alloyed with Cu-Mo and are produced on grade 3.

34

Ductile Iron

◗ Evaluation of the Mechanical Properties

◗ Standards: The following standards are used to evaluate the mechanical properties in ductile iron: • ASTM A536 • ASTM E-8 • ASTM A897 • DIN EN 1563

◗ Section for taking the test specimen The specimen used for mechanical analysis is taken from the cross section in bars up to 5” (See Figures 43 and 44). In bars under 5”, test specimen is taken from the longitudinal section.Test specimens may be taken from other sections in special shapes. Hardness testing is done using a 5 mm ball with 750 kgf load in bars under 2” and 10 mm ball with 3000 kgf load in bars up 2”.

Figure 43 – Evaluation of the Mechanical Properties in Round Shape

35

Figure 44 - Evaluation of the Mechanical Properties in Square Shape

Standard Dimensions

◗ Round Shapes Nominal Diameter

Average Stock Allowance

Dimensional Tolerance (+ / -)

Theoretical Weight

(inch)

(mm)

(inch)

(mm)

(inch)

(mm)

(Ib/ft)

(kg/m)

0.625 0.750 0.875 1.000 1.125 1.250 1.375 1.500 1.625 1.750 1.875 2.000 2.125 2.250 2.375 2.500 2.625 2.750 2.875 3.000 3.125 3.250 3.375 3.500 3.625 3.750 3.875 4.000 4.250 4.375 4.500 4.750 5.000

15.88 19.04 22.23 25.40 28.58 31.74 34.93 38.10 41.28 44.44 47.63 50.80 53.98 57.15 60.33 63.50 66.68 69.85 73.03 76.20 79.38 82.55 85.73 88.90 92.08 95.25 98.43 101.60 107.94 111.13 114.30 120.64 127.00

0.085 0.085 0.085 0.085 0.085 0.085 0.085 0.085 0.085 0.085 0.085 0.085 0.110 0.110 0.110 0.110 0.110 0.110 0.110 0.110 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.125 0.140 0.140 0.140 0.140 0.140

2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.8 2.8 2.8 2.8 2.8 2.8 2.8 2.8 3.2 3.2 3.2 3.2 3.2 3.2 3.2 3.2 3.6 3.6 3.6 3.6 3.6

0.012 0.012 0.012 0.012 0.012 0.012 0.012 0.012 0.012 0.012 0.012 0.012 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.039 0.039 0.039 0.039 0.039 0.039 0.039 0.039 0.043 0.043 0.043 0.043 0.043

0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.1 1.1 1.1 1.1 1.1

1.210 1.680 1.882 2.890 3.562 4.368 5.242 6.182 7.190 8.266 9.408 10.685 12.230 13.642 15.120 16.733 18.346 20.026 21.840 23.722 25.872 27.955 30.038 32.189 34.474 36.826 39.245 41.731 47.242 49.056 52.752 58.598 64.781

1.8 2.5 2.8 4.3 5.3 6.5 7.8 9.2 1.7 12.3 14.0 15.9 18.2 20.3 22.5 24.9 27.3 29.8 32.5 35.3 38.5 41.6 44.7 47.9 51.3 54.8 58.4 62.1 70.3 73.0 78.5 87.2 96.4

Standard Length: 72" (+3"/- 0")/1830mm (+76.2mm/-0mm) Bending: 1.125" x 3ft section/2.5mm/m

36

V1 Class 30

V2 Class 40

V3 V4 Class Class 65-45-12 80-55-06

Standard Dimensions

◗ Round Shapes Nominal Diameter

Average Stock Allowance

Dimensional Tolerance (+ / -)

Theoretical Weight

(inch)

(mm)

(inch)

(mm)

(inch)

(mm)

(Ib/ft)

(kg/m)

5.250 5.500 5.750 6.000 6.250 6.500 6.750 7.000 7.250 7.500 7.750 8.000 8.250 8.500 8.750 9.000 9.250 9.500 9.750 10.000 10.250 10.500 11.000 11.500 12.000 12.500 13.000 14.000 15.000 16.000 17.000 18.000 20.000 21.000

133.35 139.70 146.05 152.40 158.75 165.10 171.45 177.80 184.15 190.50 196.85 203.20 209.55 215.90 222.25 228.60 234.95 241.30 247.65 254.00 260.34 266.70 279.40 292.10 304.80 317.50 330.20 355.60 381.00 406.40 431.80 457.20 508.00 533.40

0.155 0.155 0.155 0.155 0.170 0.170 0.170 0.170 0.190 0.190 0.190 0.190 0.216 0.216 0.216 0.216 0.254 0.254 0.254 0.254 0.400 0.400 0.400 0.582 0.582 0.582 0.582 0.582 0.582 0.582 0.762 0.762 0.762 0.762

3.9 3.9 3.9 3.9 4.3 4.3 4.3 4.3 4.8 4.8 4.8 4.8 5.5 5.5 5.5 5.5 6.5 6.5 6.5 6.5 10.2 10.2 10.2 14.8 14.8 14.8 14.8 14.8 14.8 14.8 19.3 19.3 19.3 19.3

0.055 0.055 0.055 0.055 0.063 0.063 0.063 0.063 0.083 0.083 0.083 0.083 0.106 0.106 0.106 0.106 0.130 0.130 0.130 0.130 0.150 0.150 0.150 0.205 0.205 0.205 0.205 0.205 0.205 0.205 0.260 0.260 0.260 0.260

1.4 1.4 1.4 1.4 1.6 1.6 1.6 1.6 2.1 2.1 2.1 2.1 2.7 2.7 2.7 2.7 3.3 3.3 3.3 3.3 3.8 3.8 3.8 5.2 5.2 5.2 5.2 5.2 5.2 5.2 6.6 6.6 6.6 6.6

71.635 78.422 85.478 92.870 101.069 109.066 117.398 126.067 135.677 144.950 154.560 164.438 175.728 186.278 197.098 208.253 221.424 233.251 245.347 257.779 278.074 291.312 318.595 357.907 388.080 419.597 452.256 521.338 595.258 674.083 773.472 862.982 1,500.374 1,592.640

106.6 116.7 127.2 138.2 150.4 162.3 174.7 187.6 201.9 215.7 230.0 244.7 261.5 277.2 293.3 309.9 329.5 347.1 365.1 383.6 413.8 433.5 474.1 532.6 577.5 624.4 673.0 775.8 885.8 1,003.1 1,151.0 1,284.2 2,232.7 2,370.0

Standard Length: 72" (+3"/- 0")/1,830mm (+76.2mm/-0mm) Bending: 1.125" x 3ft section/2.5mm/m

37

V1 Class 30

V2 Class 40

V3 V4 Class Class 65-45-12 80-55-06

Standard Dimensions

◗ Rectangular Shapes Actual Dimension (inch) 1.250 x 2.250 1.250 x 3.250 1.250 x 4.250 1.250 x 5.250 1.250 x 6.250 1.250 x 10.250 1.500 x 2.250 1.500 x 3.250 1.500 x 4.250 1.500 x 5.250 1.500 x 6.250 1.750 x 2.000 1.750 x 4.250 1.750 x 4.500 1.750 x 6.250 2.000 x 2.500 2.000 x 3.625 2.250 x 3.250 2.250 x 4.250 2.250 x 5.250 2.250 x 6.250 2.250 x 8.250 2.500 x 6.250 2.500 x 7.250 2.500 x 8.250 3.000 x 8.250 3.250 x 4.250 3.250 x 10.250 4.250 x 5.250 5.500 x 6.500 7.000 x 16.000 8.250 x 14.250 12.500 x 18.000 14.000 x 21.000 14.000 x 22.000

(mm) 31.7 x 57.1 31.7 x 82.5 31.7 x 107.9 31.7 x 133.3 31.7 x 158.7 31.7 x 260.3 38.1 x 57.1 38.1 x 82.5 38.1 x 107.9 38.1 x 133.3 38.1 x 158.7 44.4 x 50.8 44.4 x 107.9 44.4 x 114.3 44.4 x 158.7 50.8 x 63.5 50.8 x 92.1 57.1 x 82.5 57.1 x 107.9 57.1 x 133.3 57.1 x 158.7 57.1 x 209.5 63.5 x 158.7 63.5 x 184.1 63.5 x 209.5 76.2 x 209.5 82.5 x 107.9 82.5 x 260.3 107.9 x 133.3 139.7 x 165.1 177.8 x 406.4 209.5 x 361.9 317.5 x 457.2 355.6 x 533.4 355.6 x 558.8

Recommended Machining per face (inch) 0.091 0.102 0.126 0.126 0.189 0.189 0.091 0.102 0.102 0.126 0.126 0.091 0.102 0.102 0.126 0.091 0.091 0.091 0.091 0.102 0.102 0.126 0.102 0.102 0.126 0.189 0.102 0.248 0.110 0.110 0.248 0.126 0.248 0.248 0.248

(mm) 2.3 2.6 3.2 3.2 4.8 4.8 2.3 2.6 2.6 3.2 3.2 2.3 2.6 2.6 3.2 2.3 2.3 2.3 2.3 2.6 2.6 3.2 2.6 2.6 3.2 4.8 2.6 6.3 2.8 2.8 6.3 3.2 6.3 6.3 6.3

Maximum Swelling (inch) 0.114 0.165 0.248 0.248 0.350 0.461 0.114 0.165 0.165 0.248 0.248 0.122 0.173 0.173 0.260 0.122 0.122 0.122 0.122 0.173 0.173 0.260 0.173 0.173 0.260 0.189 0.134 0.283 0.142 0.142 0.232 0.154 0.173 0.173 0.173

* Standard Length: 72" (+3/-0")/1830mm (+76.2mm/-0mm) * Bending: 1.125" x 3ft section/2.5mm/m * Available in all standard grades

38

Theoretical Weight (mm) 2.9 4.2 6.3 6.3 8.9 11.7 2.9 4.2 4.2 6.3 6.3 3.1 4.4 4.4 6.6 3.1 3.1 3.1 3.1 4.4 4.4 6.6 4.4 4.4 6.6 4.8 3.4 7.2 3.6 3.6 5.9 3.9 4.4 4.4 4.4

(Ib/ft) 8.736 12.634 16.531 20.429 24.326 39.917 10.550 15.187 19.891 24.595 29.232 10.886 23.184 24.528 34.070 15.590 22.646 22.781 29.837 36.826 43.814 57.859 48.787 56.582 64.378 77.213 43.075 103.891 69.619 111.619 349.642 366.845 702.374 917.750 961.430

(kg/m) 13.0 18.8 24.6 30.4 36.2 59.4 15.7 22.6 29.6 36.6 43.5 16.2 34.5 36.5 50.7 23.2 33.7 33.9 44.4 54.8 65.2 86.1 72.6 84.2 95.8 114.9 64.1 154.6 103.6 166.1 520.3 545.9 1,045.2 1,365.7 1,430.7

Standard Dimensions

◗ Square Shapes Recommended Machining per face

Actual Dimension (inch) 1.250 1.500 1.625 1.750 2.000 2.250 2.500 2.750 3.000 3.250 3.500 3.750 4.250 4.750 5.250 6.250 7.250 8.250 9.250 10.250 12.250 15.000 18.500

(mm) 31.7 38.1 41.3 44.4 50.8 57.1 63.5 69.8 76.2 82.5 88.9 95.2 107.9 120.6 133.3 158.7 184.1 209.5 234.9 260.3 311.1 381.0 469.9

(inch) 0.091 0.091 0.091 0.091 0.091 0.091 0.091 0.091 0.091 0.091 0.102 0.102 0.102 0.102 0.110 0.126 0.142 0.157 0.169 0.185 0.232 0.311 0.311

(mm) 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.3 2.6 2.6 2.6 2.6 2.8 3.2 3.6 4.0 4.3 4.7 5.9 7.9 7.9

Maximum Swelling (inch) 0.114 0.114 0.122 0.122 0.122 0.122 0.122 0.134 0.134 0.134 0.134 0.134 0.142 0.142 0.142 0.154 0.154 0.154 0.161 0.161 0.173 0.196 0.196

Theoretical Weight (mm) 2.9 2.9 3.1 3.1 3.1 3.1 3.1 3.4 3.4 3.4 3.4 3.4 3.6 3.6 3.6 3.9 3.9 3.9 4.1 4.1 4.4 5.0 5.0

(Ib/ft) 4.838 7.056 8.266 9.542 12.499 15.792 19.488 23.587 28.090 32.928 38.237 43.814 56.314 70.358 85.949 121.834 163.968 212.352 266.986 327.802 468.250 698.665 1,068.803

(kg/m) 7.2 10.5 12.3 14.2 18.6 23.5 29.0 35.1 41.8 49.0 56.9 65.2 83.8 104.7 127.9 181.3 244.0 316.0 397.3 487.8 696.8 1,039.7 1,590.5

* Standard Length: 72" (+3/-0")/1830mm (+76.2mm/-0) * Bending: 1.125" x 3ft section/2.5 mm/m * Available in all standard grades

In addition to the products listed above, it is possible to produce Versa-Bar to specific required dimensions, shapes and materials in order to meet special conditions or properties for improved performance in machining, heat, corrosion and wear resistance.

39

Additional Information

◗ Relational Comparison between Versa-Bar Mechanical Properties and Other Properties Usually gray and ductile irons are commercially specified by the Ultimate Tensile Strength and hardness. The requirement for a specific application, strength and other mechanical properties are the basis in selecting the most appropriated material. Table 16 shows the relationship between Ultimate Tensile Strength and hardness in Versa-Bar and various required properties.

Properties

Gray Iron

Shear Strength (MPa) Torsion Strength (MPa)

1.5 x UTS 1.5 x UTS (1)

Fatigue Strength (MPa) (Without notch)

0.40 x UTS (4;5)

Compressive Strength (MPa)

Ductile Iron

(1)

0.90 x UTS (3;5) 0.90 x UTS (3;5) V3 (60-40-18) = 0.50 x UTS(3) V3 (65-45-12) = 0.45 x UTS(3) V4 = 0.40 x UTS(3) V5 = 0.40 x UTS(3)

UTS of 140 - 175 x 4.02 (5) UTS of 176 - 210 x 3.68 (5) UTS of 211 - 245 x 3.61 (5) UTS of 246 - 280 x 3.39 (5)

Impact Strength ( j ) (With notch 20 C)

V3 (60-40-18) = 15 - 13 (2) V3 (65-45-12) = 10 - 5 (2) (2) V4 = 5 - 2 V5 = 5 - 2 (2) V3 (60-40-18) = 169 (2) V3 (65-45-12) = 169 (2) V4 = 169 (2) V5 = 172 - 176 (2) V3 (60-40-18) = 37 - 36 (2) V3 (65-45-12) = 37 - 36 (2) V4 = 35 - 34 (2) V5 = 32 - 31 (2)

-

Modulus of Elasticity (GPa)

V1 = 88 - 113 (1) V2 = 108 - 137 (1) GMI = 78 - 107 (1)

Thermal Conductivity (W/m.K) 100 to 400ºC

V1 = 51 - 48 (2) V2 = 47 - 44 (2) GMI = 44 - 41

-

Table 16 - Relational Comparison between Versa-Bar Mechanical Properties and Other Properties

Sources: ( 1 ) DIN 1691 ( 2 ) BCIRA BROADSHEET 1 ( 3 ) Engineering Data on Nodular Cast Irons ( 4 ) High Quality Gray Cast Irons ( 5 ) Mettalurgy of Gray and Nodular Cast Irons

40

Additional Information

◗ Versa-Bar Grades Compared to Other Standards Versa-Bar is produced according to TUPY standards and its properties are similar to the materials specified by the standards of the entities mentioned in Tables 17 and 18:

Gray Iron

Versa-Bar Grades

ASTM A 48 30 40 -

V1 V2 GMI

A 159 G2500 G4000 -

DIN EN 1561 EN EN

SAE J 431 G2500 G4000 -

DIN EN 1563 EN-GJS-400-15 EN-GJS-500-7 EN-GJS-700-2 -

SAE J 434 D 4018 D 4512 D 5506 D 7003 -

Table 17 - Standards for Gray Iron

Ductile Iron

Versa-Bar Grades V3H V3 V4 V5 ADI 1 ADI 2 ADI 3 ADI 4

ASTM A 536 60-40-18 65-45-12 80-55-06 100-70-03 -

A 897 125-800-10 (*) 150-100-7 (*) 175-125-4 (*) 200-155-1 (*)

Table 18 - Standards for Ductile Iron (*) Ultimate Tensile Strength, Yield Strength and Elongation after austempering process

41

Additional Information

◗ Useful Formulas/Conversion Factors To calculate the weight/meter in sections:

◗ Round lbs/in = D2 x 0.2043 kg/m = D2 x 0.005655 where: D = Rough Diameter ◗ Square lbs/in = W2 x 0.26011 kg/m = W2 x 0.0072 where: W = Rough Width ◗ Rectangle lbs/in = W x H x 0.26011 kg/m = W x H x 0.0072 where: W = Rough Width H = Rough Height

To Convert

Operation

psi N/mm2 or MPa kgf/mm2 N/mm2 or MPa mm in mm feet Ib kg ºC ºF ºC K

x 0.00690 x 144.929 x 9.80665 x 0.10197 x 0.03937 x 25.4 x 0.00328 x 304.8 x 0.4536 x 2.2046 ( ºC x 1,8 ) + 32 ( ºF - 32 ) x 0.556 ºC + 273.15 k - 273.15

To Obtain N/mm2 or MPa psi N/mm2 or MPa kgf/mm2 in mm feet mm kg Ib ºF ºC K ºC

42

43

Tupy Fundições Ltda. Rua Albano Schmidt, 3400 89227-901 - Joinville - SC - Brazil Telephone: +55 47 4009-8434 Fax: +55 47 4009-8500 E-mail: [email protected]

Tupy American Iron & Alloys Corporation - TAIA

Maio/2007

1700 Airport Road - Waukesha - Wi 53188 - USA Telephone: 262-544-4830 - Fax: 248-324-1436 e-mail: [email protected]

44