Dura-Bar,G1 Continuously Cast Gray Iron Wire ASTM A48

Dura-Bar G1 Continuously Cast Gray Iron Wire Bar Stock ASTM A48 Product Information -:- For detailed product information, please contact sales. -: Dura-Bar G1 Continuously Cast Gray Iron Wire Bar Stock ASTM A48 Synonyms -:- For detailed product information, please contact sales. -:

Dura-Bar G1 Continuously Cast Gray Iron Bar Stock ASTM A48 Product Information -:- For detailed product information, please contact sales. -: # **Dura-Bar® G1 Continuously Cast Gray Iron Bar Stock** ## **Product Overview** **Dura-Bar G1 Continuously Cast Gray Iron** is a premium **low-to-medium strength gray iron** manufactured through proprietary continuous casting technology, corresponding to **ASTM A48 Class 25B** specification. This material represents the optimal balance of **exceptional machinability, superior damping capacity, and excellent thermal properties**, making it ideal for applications where vibration absorption, dimensional stability, and manufacturing efficiency are prioritized over ultimate tensile strength. The "G1" designation refers to Dura-Bar's internal classification for their ASTM A48 Class 25B equivalent material, distinguished by its continuous casting production that eliminates internal defects and ensures homogeneous properties throughout the bar cross-section. With a minimum tensile strength of 25 ksi, this grade offers the most favorable machining characteristics of all gray iron grades while maintaining adequate mechanical properties for a wide range of industrial applications. --- ## **1. International Standards & Specifications** | **Standard System** | **Designation** | **Equivalent/Reference** | **Key Specification** | |---------------------|-----------------|--------------------------|----------------------| | **ASTM International** | **A48 Class 25B** | Primary material specification | Minimum tensile: 25 ksi (172 MPa) | | **SAE Automotive** | **J431 G2500** | Automotive applications | Similar strength classification | | **ISO Standard** | **ISO 185 Grade 200** | International reference | Brinell hardness correlation | | **DIN Standard** | **GG-20** | German standard | Comparable strength grade | | **UNS Designation** | **F10006** | Unified Numbering System | Gray iron classification | | **Manufacturer** | **Dura-Bar Grade G1** | Proprietary continuous cast | Superior consistency vs. sand cast | | **Common Names** | Class 25 Gray Iron, Grade G1, Machine Grade Gray Iron | Industry terminology | | **Note:** The continuous casting process produces material with **more consistent properties** than sand-cast equivalents, often exceeding minimum specifications while maintaining excellent processability. --- ## **2. Chemical Composition** The chemical composition is optimized to produce a pearlitic-ferritic matrix with well-dispersed Type A graphite flakes, ensuring optimal machinability while meeting strength requirements. | **Element** | **Typical Range (% wt.)** | **Metallurgical Function** | **Property Influence** | |-------------|---------------------------|---------------------------|-----------------------| | **Carbon (C)** | 3.3 - 3.6 | Primary graphite former | Higher carbon improves machinability and damping | | **Silicon (Si)** | 1.9 - 2.4 | Graphitizing agent | Controls graphite formation, promotes ferrite | | **Manganese (Mn)** | 0.5 - 0.8 | Sulfur neutralization | Forms MnS, slight pearlite promotion | | **Phosphorus (P)** | 0.05 - 0.20 | Fluidity enhancer | Improves castability, limited to prevent brittleness | | **Sulfur (S)** | 0.08 - 0.12 | Inoculation control | Combines with Mn to form harmless inclusions | | **Chromium (Cr)** | < 0.15 (optional) | Pearlite promoter | Minimal to maintain machinability | | **Copper (Cu)** | < 0.20 (optional) | Matrix strengthener | Trace amounts for consistency | | **Nickel (Ni)** | < 0.10 (optional) | Structure refiner | Rarely added to this grade | **Microstructural Characteristics:** - **Graphite Structure:** ASTM Type A, Size 3-4 (medium to coarse, well-distributed flakes) - **Matrix Structure:** 60-80% pearlite with balance ferrite - **Carbide Content:** < 1% (minimized through controlled cooling) - **Unique Feature:** Continuous casting produces more uniform graphite distribution than sand casting - **Graphite Flake Orientation:** Random orientation throughout cross-section --- ## **3. Mechanical Properties** ### **Minimum Requirements (ASTM A48 Class 25B):** - **Tensile Strength:** 25 ksi minimum (172 MPa) - **Test Bar Diameter:** 1.2" (30.5 mm) ### **Typical Properties (Dura-Bar G1 Continuous Cast):** | **Property** | **Typical Value** | **Range** | **Engineering Significance** | |--------------|-------------------|-----------|-----------------------------| | **Tensile Strength** | 27 - 32 ksi (186 - 221 MPa) | Exceeds minimum | Adequate for many non-structural applications | | **Compressive Strength** | 95 - 110 ksi (655 - 758 MPa) | 3.5-4× tensile | Excellent for bearing applications | | **Elongation** | < 0.5% | Essentially zero | Characteristic of all gray irons | | **Hardness** | 174 - 201 HB | Consistent across diameter | Optimal for machining | | **Modulus of Elasticity** | 12 - 14 × 10⁶ psi (83 - 97 GPa) | Lower than steel | Contributes to high damping capacity | | **Shear Strength** | 22 - 26 ksi (152 - 179 MPa) | ~85% of tensile | Adequate for many applications | | **Transverse Strength** | Higher than sand cast | More consistent | Due to uniform microstructure | | **Impact Resistance** | Low | Brittle material | Not suitable for impact loading | ### **Section Sensitivity:** Continuous casting minimizes section sensitivity: - **1" diameter:** 28-31 ksi tensile - **3" diameter:** 27-30 ksi tensile - **6" diameter:** 26-29 ksi tensile --- ## **4. Physical Properties** | **Property** | **Value** | **Comparative Advantage** | |--------------|-----------|--------------------------| | **Density** | 0.260 lb/in³ (7.20 g/cm³) | Standard for gray iron | | **Thermal Conductivity** | 26.0 Btu/(ft·hr·°F) @ 212°F (45.0 W/m·K) | **Excellent** heat dissipation | | **Coefficient of Thermal Expansion** | 6.2 × 10⁻⁶/°F (11.2 × 10⁻⁶/°C) | Lower than steel | | **Specific Heat** | 0.12 Btu/(lb·°F) (500 J/kg·K) | Good thermal capacity | | **Damping Capacity** | **15-25× greater than steel** | **Superior** vibration absorption | | **Electrical Resistivity** | 65 μΩ·cm | Higher than steel | | **Magnetic Properties** | Ferromagnetic | Suitable for all applications | | **Poisson's Ratio** | 0.26 - 0.27 | Typical for gray iron | --- ## **5. Manufacturing & Processing Characteristics** ### **Machinability Characteristics (Primary Advantage):** - **Relative Machinability:** **100-110%** (vs. 1212 steel = 100%) - **Cutting Speed:** 600-900 SFPM for turning operations - **Tool Materials:** C2 carbide or high-speed steel optimal - **Chip Formation:** Excellent - produces fine, broken chips - **Surface Finish:** 16-63 μin Ra readily achievable - **Tool Life:** **4-6× longer** than machining steel - **Power Consumption:** 50-60% lower than steel machining - **Machining Forces:** 40-50% lower than equivalent steel operations ### **Unique Machining Advantages:** 1. **Graphite Flakes** act as natural chip breakers and lubricants 2. **Low hardness** minimizes tool wear 3. **Excellent chip control** reduces cleanup time 4. **Minimal work hardening** during machining 5. **Good dimensional stability** after machining ### **Heat Treatment Capabilities:** 1. **Stress Relieving:** 900-1000°F (480-540°C) for 1 hour/inch 2. **Annealing:** 1550-1650°F (845-900°C) for maximum softness 3. **Surface Hardening:** Flame hardening possible but not common 4. **Normalizing:** Rarely required due to as-cast properties ### **Fabrication Guidelines:** - **Welding:** **Not recommended** - high risk of cracking - **Adhesive Bonding:** Excellent with proper surface preparation - **Mechanical Fastening:** Good for compressive loads only - **Plating/Coating:** Accepts most common surface treatments --- ## **6. Application Areas** ### **Primary Industries & Applications:** | **Industry** | **Specific Components** | **Key Property Utilized** | **Advantage vs. Alternatives** | |--------------|-------------------------|--------------------------|-------------------------------| | **Machine Tool** | Bases, columns, supports, fixtures | Damping, stability | Reduces vibration in precision equipment | | **Electrical** | Motor end bells, transformer bases, switchgear | Damping, EMI shielding | Quieter operation, better heat dissipation | | **General Manufacturing** | Jigs, fixtures, tooling plates, angle plates | Machinability, stability | Faster production, lower tooling costs | | **Automotive** | Non-critical brackets, covers, housings | Damping, thermal properties | Cost-effective for non-structural parts | | **Pump & Compressor** | Bases, covers, non-pressure housings | Vibration absorption | Reduces noise transmission | | **Textile Machinery** | Frames, brackets, supports | Damping, wear resistance | Minimizes vibration in high-speed equipment | ### **Specific Component Examples:** 1. **Machine Tool Bases:** Where maximum vibration damping is required 2. **Electrical Enclosures:** For motors and transformers 3. **Instrument Bases:** For sensitive measurement equipment 4. **Fixture Plates:** For manufacturing and assembly 5. **Non-Structural Housings:** Where appearance and machinability are key 6. **Bearing Blocks:** For compressive load applications only --- ## **7. Comparative Performance** ### **vs. Competitive Materials:** | **Material Comparison** | **Machinability** | **Damping Capacity** | **Thermal Conductivity** | **Cost Efficiency** | |-------------------------|-------------------|----------------------|--------------------------|---------------------| | **Dura-Bar G1 Gray Iron** | **Excellent (5/5)** | **Excellent (5/5)** | **Excellent (5/5)** | **Excellent (5/5)** | | **Steel 1018** | Good (3/5) | Poor (1/5) | Good (3/5) | Good (3/5) | | **Ductile Iron 60-40-18** | Excellent (5/5) | Very Good (4/5) | Excellent (5/5) | Very Good (4/5) | | **Aluminum 6061** | Excellent (5/5) | Good (3/5) | Excellent (5/5) | Good (3/5) | | **Sand Cast Class 25** | Excellent (5/5) | Excellent (5/5) | Good (3/5) | Very Good (4/5) | ### **Economic Advantages:** 1. **Lowest Machining Cost:** Of all ferrous materials 2. **Minimal Tool Wear:** Longest tool life in production 3. **High Production Rates:** Fastest machining speeds 4. **Reduced Energy Use:** Lower power consumption 5. **Minimal Scrap:** 100% material utilization --- ## **8. Design Guidelines** ### **Optimal Application Conditions:** - **Compressive loads only** (avoid tensile stresses) - **Vibration-sensitive** environments - **Thermal management** applications - **Extensive machining** requirements - **Non-structural** components - **Cost-sensitive** production ### **Design Recommendations:** 1. **Avoid Tensile Stresses:** Design for compression loading 2. **Minimum Section:** 0.25" (6 mm) for consistent properties 3. **Fillet Radii:** Minimum 0.06" (1.5 mm) on internal corners 4. **Rib Design:** Use ribs for stiffness rather than thick sections 5. **Bearing Surfaces:** Design with adequate surface area for compressive loads ### **Limitations & Constraints:** - **No ductility** (brittle fracture behavior) - **Low impact resistance** - **Not weldable** for structural purposes - **Limited tensile strength** applications - **Poor fatigue strength** in tension --- ## **9. Quality Assurance & Testing** ### **Production Controls:** - **Chemical Analysis:** Spectroscopic verification of each melt - **Mechanical Testing:** Regular tensile testing from production - **Microstructural Analysis:** Graphite type and matrix verification - **Hardness Testing:** Multiple points per bar for consistency - **Soundness Verification:** Ultrasonic testing available ### **Certification Levels:** 1. **Standard Certification:** Full chemical and mechanical data 2. **Special Testing:** Customer-specified requirements 3. **Traceability:** Complete heat and production tracking 4. **Dimensional Reports:** As-requested dimensional verification --- ## **10. Availability & Specifications** ### **Standard Stock Sizes:** - **Round Bars:** 0.5" to 20" diameter - **Square Bars:** Up to 16" × 16" - **Rectangular Bars:** Various dimensions to 20" width - **Tube Stock:** Available in select sizes - **Lengths:** Standard 12' lengths, custom available ### **Special Services:** - **Stress Relieving:** Available as requested - **Rough Machining:** To customer specifications - **Cut-to-Length:** Precision cutting services - **Surface Preparation:** As-specified surface conditions - **Special Packaging:** For sensitive applications --- ## **Technical Summary** **Dura-Bar G1 (ASTM A48 Class 25B) Continuously Cast Gray Iron** represents the **optimal choice for applications** where: ### **Primary Advantages are Required:** 1. **Maximum Machinability:** Fastest machining of any ferrous material 2. **Superior Damping:** Best vibration absorption available 3. **Excellent Thermal Conductivity:** Efficient heat dissipation 4. **Dimensional Stability:** Minimal distortion after machining 5. **Cost-Effective Production:** Lowest total manufacturing cost ### **Economic Benefits:** - **Reduced Machining Costs:** 50-70% less than equivalent steel parts - **Extended Tool Life:** 4-6× longer than machining steel - **Higher Production Rates:** Faster cycle times - **Lower Capital Investment:** Lighter machine tools required - **Minimal Material Waste:** 100% usable material ### **Application Selection Criteria:** **Choose G1 Gray Iron when:** - Vibration damping is the primary design requirement - Component is loaded exclusively in compression - Extensive machining operations are required - Thermal management is important - Manufacturing cost minimization is critical - Component is non-structural **Consider alternatives when:** - Tensile strength > 30 ksi is required - Impact resistance is necessary - Welding is required for assembly - High fatigue resistance is needed - Component is structurally critical --- ## **Engineering Support & Resources** Dura-Bar provides comprehensive technical support: - **Application Engineering:** Component design consultation - **Machining Guidelines:** Optimized cutting parameters - **Design Review:** Material selection assistance - **Troubleshooting:** Production issue resolution - **Testing Services:** Material verification and validation *For specific application requirements or technical consultations, contact Dura-Bar engineering services for material selection guidance and performance data.* --- **Important Note:** Gray iron is a brittle material with essentially no ductility. Proper engineering design must account for this characteristic by avoiding tensile stresses and stress concentrations. All load-bearing applications should be carefully analyzed to ensure compressive loading conditions. Consultation with materials engineering specialists is recommended for critical applications. -:- For detailed product information, please contact sales. -: Dura-Bar G1 Continuously Cast Gray Iron Bar Stock ASTM A48 Specification Dimensions Size： Diameter 20-1000 mm Length <6609 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 G1 Continuously Cast Gray Iron Bar Stock ASTM A48 Properties -:- For detailed product information, please contact sales. -:

Applications of Dura-Bar G1 Continuously Cast Gray Iron Wire Bar Stock ASTM A48 -:- For detailed product information, please contact sales. -: Chemical Identifiers Dura-Bar G1 Continuously Cast Gray Iron Wire Bar Stock ASTM A48 -:- For detailed product information, please contact sales. -:

Packing of Dura-Bar G1 Continuously Cast Gray Iron Wire Bar Stock ASTM A48 -:- 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 3080 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