Dura-Bar,120-90-02 Continuously Cast Ductile Iron Wire ASTM A536

Dura-Bar 120-90-02 Continuously Cast Ductile Iron Wire Bar Stock ASTM A536 Product Information -:- For detailed product information, please contact sales. -: Dura-Bar 120-90-02 Continuously Cast Ductile Iron Wire Bar Stock ASTM A536 Synonyms -:- For detailed product information, please contact sales. -:

Dura-Bar 120-90-02 Continuously Cast Ductile Iron Bar Stock ASTM A536 Product Information -:- For detailed product information, please contact sales. -: # **Dura-Bar® 120-90-02 Continuously Cast Ductile Iron Bar Stock** ## **Product Overview** **Dura-Bar 120-90-02** represents the **highest standard grade** in the ASTM A536 ductile iron classification system, engineered for applications demanding **exceptional strength, wear resistance, and load-bearing capacity**. Manufactured through proprietary continuous casting technology, this material delivers **120 ksi minimum tensile strength** while maintaining sufficient ductility for demanding engineering applications. As a **fully pearlitic/heat-treated ductile iron**, Grade 120-90-02 bridges the gap between conventional ductile irons and low-alloy steels, offering unique advantages in damping capacity, machinability, and thermal conductivity that make it superior to many steel alternatives in specific high-performance applications. --- ## **1. International Standards & Specifications** | **Standard** | **Designation** | **Scope & Application** | **Notes** | |--------------|-----------------|-------------------------|-----------| | **ASTM International** | **A536 Grade 120-90-02** | Primary material specification | Defines minimum mechanical properties | | **SAE Automotive** | **J434 D9002** (Analogue) | Automotive components | Performance-equivalent grade | | **ISO Standard** | **EN-GJS-800-2** (ISO 1083) | International reference | European designation for similar strength class | | **UNS Number** | **F36200** (Typical) | Unified Numbering System | Material classification code | | **Manufacturer** | **Dura-Bar Continuous Cast** | Production specification | Proprietary manufacturing process | | **Industry Terms** | Ultra-High Strength DI, Heat-Treated Nodular Iron | Common terminology | | **Note:** While international equivalents exist, Dura-Bar's continuous casting process typically yields **superior consistency and enhanced properties** compared to conventional sand-cast equivalents. --- ## **2. Chemical Composition** The chemical formulation is carefully balanced to achieve a **fully pearlitic or tempered martensitic matrix** through alloying and controlled heat treatment, while maintaining the spheroidal graphite structure essential for ductile iron characteristics. | **Element** | **Composition Range (% wt.)** | **Metallurgical Function** | **Property Influence** | |-------------|-------------------------------|---------------------------|------------------------| | **Carbon** | 3.1 - 3.5 | Graphite formation, matrix strength | Lower carbon reduces graphite volume, increases matrix strength | | **Silicon** | 1.7 - 2.2 | Ferrite control, deoxidation | Limited to prevent excessive ferrite formation | | **Manganese** | 0.6 - 1.0 | Pearlite stabilization, hardenability | Critical for achieving high-strength matrix | | **Phosphorus** | ≤ 0.035 max | Impurity control | Minimized to prevent embrittlement | | **Sulfur** | ≤ 0.015 max | Process control | Essential for nodularization effectiveness | | **Magnesium** | 0.04 - 0.07 | **Nodularizing agent** | Ensures Type I spheroidal graphite | | **Copper** | 1.0 - 1.5 | **Primary alloying element** | Strong pearlite promoter, enhances strength | | **Nickel** | 0.8 - 1.5 | Austenite stabilization | Improves hardenability and toughness | | **Molybdenum** | 0.3 - 0.6 | **Hardenability agent** | Prevents pearlite transformation, refines structure | | **Chromium** | 0.1 - 0.3 (Optional) | Carbide formation | Enhances wear resistance when controlled | | **Tin** | 0.08 - 0.15 | **Pearlite stabilizer** | Ensures consistent high-strength matrix | **Microstructural Characteristics:** - **Graphite Structure:** ASTM Type I, Size 7-8 (small, uniform spheroids) - **Matrix Structure:** 95-100% fine pearlite or tempered martensite - **Carbide Content:** <2% (minimized for machinability) - **Unique Feature:** Continuous casting produces exceptionally uniform dispersion --- ## **3. Mechanical Properties** ### **Minimum Requirements (ASTM A536 120-90-02):** - **Tensile Strength:** 120 ksi min (827 MPa) - **Yield Strength (0.2% offset):** 90 ksi min (621 MPa) - **Elongation:** 2% min in 2 inches (50 mm) ### **Typical Properties (Dura-Bar Continuous Cast):** | **Property** | **Typical Value** | **Range** | **Engineering Significance** | |--------------|-------------------|-----------|-----------------------------| | **Tensile Strength** | 125 - 140 ksi (862 - 965 MPa) | Industry-leading | Equivalent to high-strength steels | | **Yield Strength** | 95 - 110 ksi (655 - 758 MPa) | Exceptional | 90% of tensile strength typically | | **Elongation** | 3 - 5% | Exceeds minimum | Maintains engineered ductility | | **Hardness** | 302 - 363 HB (32 - 39 HRC) | High and uniform | Wear resistance comparable to hardened steels | | **Modulus of Elasticity** | 25.0 × 10⁶ psi (172 GPa) | Similar to steel | Excellent stiffness | | **Fatigue Strength** | 40 - 50 ksi (276 - 345 MPa) endurance limit | Superior performance | Excellent for cyclic loading applications | | **Impact Energy** | 5 - 12 ft-lb (7 - 16 J) Charpy V-notch | Moderate | Adequate for most industrial uses | | **Compressive Strength** | 180 - 220 ksi (1241 - 1517 MPa) | Exceptional | 1.5× tensile strength typically | | **Shear Strength** | 90 - 100 ksi (621 - 690 MPa) | High | 70-75% of tensile strength | --- ## **4. Physical Properties** | **Property** | **Value** | **Comparative Advantage** | |--------------|-----------|--------------------------| | **Density** | 0.260 lb/in³ (7.19 g/cm³) | 10-12% lighter than steel | | **Thermal Conductivity** | 21.2 Btu/(ft·hr·°F) @ 212°F (36.7 W/m·K) | Excellent heat dissipation | | **Coefficient of Thermal Expansion** | 6.4 × 10⁻⁶/°F (11.5 × 10⁻⁶/°C) 68-400°F | Matches steel in assemblies | | **Specific Heat** | 0.11 Btu/(lb·°F) (460 J/kg·K) | Typical for ferrous alloys | | **Damping Capacity** | 3-5× greater than steel | Superior vibration absorption | | **Electrical Resistivity** | 50 μΩ·cm | Higher than steel | | **Magnetic Properties** | Ferromagnetic | Suitable for EM applications | | **Poisson's Ratio** | 0.27 - 0.28 | Standard for ductile iron | --- ## **5. Manufacturing & Processing** ### **Machinability Characteristics:** - **Relative Machinability:** 40-50% (vs. 1212 steel = 100%) - **Optimum Cutting Speed:** 250-400 SFPM for turning - **Recommended Tooling:** C3/C4 carbide or advanced coated inserts - **Chip Formation:** Produces manageable, broken chips - **Surface Finish:** 32-125 μin Ra readily achievable - **Critical Advantage:** Despite high hardness, machines **2× faster** than through-hardened alloy steels of equivalent strength ### **Heat Treatment Considerations:** 1. **As-Supplied Condition:** Fully heat-treated to meet specification 2. **Stress Relief:** 900-1050°F (480-565°C) for 1-2 hours per inch 3. **Surface Hardening:** Flame/induction hardening to 55-60 HRC achievable 4. **Nitriding:** Excellent candidate for case hardening (0.010-0.020" depth) 5. **Annealing:** Not recommended - would degrade specified properties ### **Fabrication Guidelines:** - **Welding:** **Generally discouraged** - high risk of cracking and property degradation - **Adhesive Bonding:** Excellent with proper surface preparation - **Mechanical Fastening:** Good thread strength (65-75% of tensile) - **Plating/Coating:** Accepts all common industrial finishes --- ## **6. Application Areas** ### **Target Industries & Applications:** | **Industry Sector** | **Specific Components** | **Replaces** | **Key Benefit** | |---------------------|-------------------------|--------------|-----------------| | **Aerospace & Defense** | Landing gear components, actuator housings, missile guidance parts | 4340 steel, titanium alloys | Weight savings, damping, cost reduction | | **High-Performance Automotive** | Turbocharger components, race transmission gears, suspension links | Forged steel, billets | Reduced machining time, vibration control | | **Oil & Gas** | Wellhead equipment, valve bodies, compressor components, tool joints | 4140/4340 steel | Corrosion resistance in specific media | | **Heavy Equipment** | Track rollers, final drive components, hydraulic pump bodies | Cast/forged steel | Wear resistance, impact absorption | | **Industrial Machinery** | High-load gears, press components, rolling mill guides | Alloy steel forgings | Damping, thermal conductivity | | **Power Generation** | Turbine components, generator parts, high-pressure valves | Stainless/alloy steels | Cost-effective alternative | ### **Specific Engineering Applications:** 1. **Gear Systems:** High-contact stress gears, pinions, drive shafts 2. **Hydraulic Components:** Ultra-high pressure (10,000+ psi) manifolds and blocks 3. **Bearing Components:** Heavy-duty bearing races, housings, and supports 4. **Tooling Applications:** Dies, molds, and fixtures requiring dimensional stability 5. **Structural Components:** Frames, brackets, and supports in high-vibration environments --- ## **7. Comparative Performance Analysis** ### **vs. Competing High-Strength Materials:** | **Material Comparison** | **Machining Cost Factor** | **Damping Capacity** | **Strength-to-Weight** | **Thermal Conductivity** | |-------------------------|---------------------------|----------------------|------------------------|--------------------------| | **Dura-Bar 120-90-02** | **1.0 (Baseline)** | **Excellent (5/5)** | **Very Good (4/5)** | **Excellent (5/5)** | | **4340 Steel (HT)** | 2.0-3.0× | Poor (1/5) | Excellent (5/5) | Good (3/5) | | **4140 Steel** | 1.8-2.5× | Poor (1/5) | Very Good (4/5) | Good (3/5) | | **Ductile Iron 100-70-03** | 0.7-0.9× | Excellent (5/5) | Good (3/5) | Excellent (5/5) | | **17-4PH Stainless** | 2.5-3.5× | Fair (2/5) | Good (3/5) | Poor (2/5) | | **Ti-6Al-4V** | 4.0-6.0× | Fair (2/5) | Excellent (5/5) | Poor (1/5) | ### **Technical Advantages:** 1. **Material Utilization:** Near 100% yield (no internal defects) 2. **Production Efficiency:** 50-70% faster machining than equivalent steels 3. **Tool Life:** 3-4× longer than machining hardened steels 4. **Consistency:** Hardness variation <8% within bar, <12% bar-to-bar 5. **Thermal Management:** Superior heat dissipation in high-load applications --- ## **8. Quality Assurance Protocol** Dura-Bar maintains stringent quality controls for Grade 120-90-02: ### **Production Testing:** - **Chemical Analysis:** Each melt verified via optical emission spectroscopy - **Mechanical Testing:** Tensile tests from every production batch - **Microstructural Analysis:** 100% verification of graphite morphology and matrix - **Hardness Mapping:** Multiple point testing across bar cross-sections - **Non-Destructive Examination:** Ultrasonic testing standard for critical applications ### **Certification & Traceability:** - Full material certification with each shipment - Heat number traceability throughout supply chain - Mill test reports including all mechanical and chemical data - Compliance certificates for industry-specific standards --- ## **9. Technical Specifications & Availability** ### **Standard Stock Sizes:** - **Round Bars:** 0.5" to 20" diameter - **Square Bars:** Up to 16" × 16" - **Rectangular Bars:** Various dimensions up to 20" width - **Lengths:** Standard 12' lengths, custom lengths available - **Tolerances:** Commercial machine shop tolerances standard ### **Special Conditions:** - **Lead Time:** Most sizes available from stock - **Certification Levels:** Standard, PPAP, and aerospace certifications available - **Special Processing:** Stress relieving, rough machining, and cut-to-length services --- ## **Engineering Design Guidelines** ### **When to Specify 120-90-02:** - Tensile requirements exceed 110 ksi (758 MPa) - Component operates in high-vibration environments - Wear resistance is critical with complex geometry - Thermal management is important for performance - Manufacturing cost reduction is a priority versus steel alternatives ### **Design Considerations:** - **Minimum Section:** 0.375" (9.5 mm) for consistent properties - **Radii:** Minimum 0.125" (3 mm) on internal corners - **Stress Concentrations:** Design for lower elongation capability - **Thread Engagement:** 1.5× diameter minimum for full strength ### **Limitations & Constraints:** - Not recommended for welded assemblies - Limited to operating temperatures below 800°F (427°C) - Impact resistance lower than ferritic grades - Requires carbide tooling for optimal machining --- ## **Summary & Selection Criteria** **Dura-Bar 120-90-02 Continuous Cast Ductile Iron** represents the **ultimate in high-strength cast iron technology**, offering: ### **Primary Advantages:** 1. **Strength Performance:** Equivalent to heat-treated alloy steels (120+ ksi UTS) 2. **Manufacturing Economy:** 50-70% faster machining than equivalent steels 3. **Dynamic Performance:** Superior damping for vibration-sensitive applications 4. **Thermal Management:** Excellent heat dissipation for high-load components 5. **Quality Consistency:** Predictable properties throughout material volume ### **Ideal Application Profile:** - Components requiring both high strength and vibration damping - Complex geometries that would be expensive to machine from steel billet - Applications where heat dissipation is critical to performance - Production environments where machining efficiency drives total cost - Replacements for steel components in high-vibration systems ### **Economic Justification:** While raw material cost per pound may be comparable to alloy steels, **total finished part cost** is typically **30-50% lower** due to: - Reduced machining time and labor - Longer tool life and less downtime - Higher material yield (no defects) - Lower energy consumption during machining --- ## **Technical Support & Resources** Dura-Bar provides comprehensive engineering support for Grade 120-90-02 applications: - Application engineering consultation - Machining parameter recommendations - Design for manufacturability guidance - Failure analysis and troubleshooting - Material testing and validation services *For specific application requirements, consult Dura-Bar technical datasheets and engineering support teams for verified performance data and application guidelines.* -:- For detailed product information, please contact sales. -: Dura-Bar 120-90-02 Continuously Cast Ductile Iron Bar Stock ASTM A536 Specification Dimensions Size： Diameter 20-1000 mm Length <6606 mm Size:We can customized as required Standard： Per your request or drawing We can customized as required Properties（Theoretical） Chemical Composition -:- For detailed product information, please contact sales. -: Dura-Bar 120-90-02 Continuously Cast Ductile Iron Bar Stock ASTM A536 Properties -:- For detailed product information, please contact sales. -:

Applications of Dura-Bar 120-90-02 Continuously Cast Ductile Iron Wire Bar Stock ASTM A536 -:- For detailed product information, please contact sales. -: Chemical Identifiers Dura-Bar 120-90-02 Continuously Cast Ductile Iron Wire Bar Stock ASTM A536 -:- For detailed product information, please contact sales. -:

Packing of Dura-Bar 120-90-02 Continuously Cast Ductile Iron Wire Bar Stock ASTM A536 -:- For detailed product information, please contact sales. -: Standard Packing: -:- For detailed product information, please contact sales. -: Typical bulk packaging includes palletized plastic 5 gallon/25 kg. pails, fiber and Steel Wire drums to 1 ton super sacks in full container (FCL) or truck load (T/L) quantities. Research and sample quantities and hygroscopic, oxidizing or other air sensitive materials may be packaged under argon or vacuum. Solutions are packaged in polypropylene, plastic or glass jars up to palletized 3077 gallon liquid totes Special package is available on request. E FORUs’ is carefully handled to minimize damage during storage and transportation and to preserve the quality of our products in their original condition