United Cast Bar,Unibar 200 Continuously Cast Iron Rod/Bar

United Cast Bar Unibar 200 Continuously Cast Iron Rod Product Information -:- For detailed product information, please contact sales. -: United Cast Bar Unibar 200 Continuously Cast Iron Rod Synonyms -:- For detailed product information, please contact sales. -:

United Cast Bar Unibar 200 Continuously Cast Iron Product Information -:- For detailed product information, please contact sales. -: # **United Cast Bar Unibar 200 Continuously Cast Iron** ## **1. Product Overview** **United Cast Bar Unibar 200** is a premium **continuously cast grey cast iron** material engineered for superior performance in precision machining applications. Produced through United's proprietary continuous casting process, this material represents the entry-level strength grade in their Unibar series, offering exceptional **machinability, vibration damping, and thermal conductivity** with guaranteed material consistency. The continuous casting process transforms molten iron directly into solid bars or tubes through controlled solidification, creating a material with **directional solidification characteristics, minimal internal defects, and exceptional microstructural uniformity**. Unibar 200 is specifically designed for applications requiring dimensional stability, pressure tightness, and reliable performance in mass-production machining environments. ## **2. Chemical Composition** Unibar 200 features a carefully balanced chemical composition optimized for the continuous casting process and designed to produce consistent Type A graphite in a pearlitic-ferritic matrix: | Element | Composition Range (%) | Metallurgical Function | |---------|---------------------|-----------------------| | **Carbon (C)** | 3.3 - 3.7 | Primary graphite former; ensures good castability and thermal properties | | **Silicon (Si)** | 2.0 - 2.5 | Graphitizing agent; controls matrix structure and casting fluidity | | **Manganese (Mn)** | 0.5 - 0.8 | Pearlite stabilizer; improves strength and wear resistance | | **Phosphorus (P)** | ≤ 0.15 | Enhances fluidity and pressure tightness; limited to prevent brittleness | | **Sulfur (S)** | ≤ 0.12 | Controlled impurity; affects graphite formation and machinability | | **Chromium (Cr)** | ≤ 0.10 | Kept minimal to preserve machinability and prevent carbide formation | | **Copper (Cu)** | 0 - 0.3 | Optional addition for improved uniformity and corrosion resistance | **Microstructural Characteristics:** - **Graphite Structure:** **Type A lamellar graphite** with uniform distribution and favorable orientation resulting from directional solidification - **Matrix Structure:** **Pearlitic-ferritic** with approximately 60-80% pearlite depending on cooling rate and section size - **Graphite Size:** ASTM Type II, Size 5-6 (fine to medium flakes) - **Directional Properties:** Enhanced properties in longitudinal direction due to casting orientation ## **3. Physical & Mechanical Properties** ### **Physical Properties:** - **Density:** 7.10 - 7.20 g/cm³ - **Melting Range:** 1150 - 1200°C - **Thermal Conductivity:** 48 - 54 W/m·K (at 20°C) - **Specific Heat Capacity:** 0.46 - 0.50 kJ/kg·K - **Coefficient of Thermal Expansion:** 10.5 - 11.5 × 10⁻⁶/°C (20-200°C) - **Electrical Resistivity:** 70 - 85 μΩ·cm ### **Mechanical Properties (Longitudinal Direction):** - **Tensile Strength:** 200 - 250 MPa - **Yield Strength (0.2%):** Not typically specified for grey iron - **Compressive Strength:** 750 - 850 MPa (3.5-4.0 × tensile strength) - **Transverse Rupture Strength:** 350 - 420 MPa - **Modulus of Elasticity:** 100 - 115 GPa - **Shear Modulus:** 40 - 45 GPa - **Poisson's Ratio:** 0.26 - 0.28 - **Hardness:** 170 - 220 HB - **Elongation:** < 1% (characteristic of grey cast iron) - **Impact Toughness:** 2 - 4 J (Charpy unnotched) ### **Performance Characteristics:** - **Machinability Index:** 80 - 90% (relative to free-machining steel) - **Surface Finish Capability:** 0.8 - 3.2 μm Ra achievable - **Tool Life:** Excellent - graphite provides natural lubrication - **Damping Capacity:** 8-12 × steel (logarithmic decrement: 0.002-0.004) - **Pressure Tightness:** Excellent due to fine, uniformly distributed graphite structure - **Wear Resistance:** Good under lubricated conditions; graphite provides self-lubrication ### **Section Size Dependence:** | Bar Diameter (mm) | Typical Hardness (HB) | Tensile Strength (MPa) | |-------------------|----------------------|----------------------| | 25 - 50 | 190 - 220 | 230 - 250 | | 51 - 100 | 180 - 210 | 210 - 230 | | 101 - 200 | 170 - 200 | 200 - 220 | ## **4. Product Applications** ### **Hydraulic & Pneumatic Components:** - **Cylinder Barrels and Tubes:** For hydraulic and pneumatic systems requiring pressure tightness - **Valve Bodies and Manifolds:** Where complex internal passages must be machined - **Pump Housings and Casings:** For gear pumps and vane pumps - **Compressor Cylinders:** For air and gas compressors ### **Automotive & Transportation:** - **Brake Components:** Discs, drums, and caliper housings - **Engine Parts:** Flywheels, clutch housings, and timing covers - **Suspension Components:** Bushings and mounting brackets - **Transmission Cases:** For light-duty applications ### **Industrial Machinery:** - **Machine Tool Components:** Bases, slides, and columns requiring vibration damping - **Gears and Sprockets:** For light to moderate power transmission - **Rollers and Guides:** In material handling equipment - **Press Frames and Platens:** Where damping is critical ### **General Engineering:** - **Pump and Compressor Parts:** Impellers, casings, and wear rings - **Electrical Enclosures:** Motor housings and switchgear bases - **Food Processing Equipment:** Where corrosion resistance and cleanability are required - **Textile Machinery:** Guides, rollers, and frames ## **5. International & Relevant Standards** ### **Material Specifications:** - **EN 1561:2011:** *Founding — Grey cast irons* - **EN-GJL-200:** Minimum tensile strength 200 MPa - **ISO 185:2019:** *Grey cast irons — Classification* - **Grade 200:** Minimum tensile strength 200 MPa - **ASTM A48/A48M-22:** *Standard Specification for Gray Iron Castings* - **Class 20:** Minimum tensile strength 138 MPa (145 MPa) - **Class 25:** Minimum tensile strength 172 MPa (179 MPa) - Unibar 200 typically exceeds Class 25 requirements - **DIN 1691:** *Grey cast iron* - **GG-20:** Minimum tensile strength 196 MPa - **JIS G5501:2022:** *Grey iron castings* - **FC200:** Minimum tensile strength 196 MPa ### **Continuous Casting Standards:** - **DIN EN 16079:2011:** *Continuous cast iron bars* - Specifies requirements for continuously cast grey and spheroidal graphite iron bars - **United Cast Bar Internal Specifications:** - UCB-QS-200: Quality specification for Unibar 200 material - UCB-PS-001: Process standard for continuous casting ### **Testing Standards:** - **ASTM A247:** *Evaluating the Microstructure of Graphite in Iron Castings* - **ISO 945-1:** *Microstructure of cast irons — Part 1: Graphite classification* - **ASTM E8/E8M:** *Tension Testing of Metallic Materials* - **ASTM E10:** *Brinell Hardness of Metallic Materials* - **ISO 6506-1:** *Brinell hardness test* ## **6. Manufacturing Advantages** ### **Continuous Casting Benefits:** 1. **Consistent Quality:** Uniform microstructure and properties throughout bar length 2. **Reduced Defects:** Minimal shrinkage, gas porosity, and inclusions 3. **Directional Solidification:** Enhanced properties in longitudinal direction 4. **Material Efficiency:** Near-net shape production reduces machining waste 5. **Surface Quality:** Excellent as-cast surface finish (typically 6.3-12.5 μm Ra) ### **Available Forms & Sizes:** - **Solid Bars:** 20mm to 400mm diameter - **Hollow Bars (Tubes):** 50mm to 300mm OD with various wall thicknesses - **Lengths:** Standard 3-6 meters; custom lengths available - **Tolerances:** Typically ±1% on diameter; straightness within 2mm/meter ## **7. Machining Guidelines** ### **Recommended Cutting Parameters:** | Operation | Speed (m/min) | Feed (mm/rev) | Depth of Cut (mm) | |-----------|--------------|---------------|-------------------| | Turning | 80 - 120 | 0.15 - 0.30 | 1.0 - 3.0 | | Drilling | 20 - 30 | 0.10 - 0.20 | - | | Milling | 60 - 100 | 0.10 - 0.25 | 1.0 - 2.0 | | Tapping | 5 - 10 | - | - | ### **Tooling Recommendations:** - **Inserts:** C2-C6 grade carbide with positive rake geometry - **Coating:** TiN or Al₂O₃ for improved tool life - **Coolant:** Soluble oil or synthetic coolant recommended - **Chip Control:** Graphite promotes good chip breaking ### **Special Considerations:** - **Graphite Dust:** Use appropriate dust collection during dry machining - **Tool Wear:** Even wear pattern; no built-up edge issues - **Surface Finish:** Excellent achievable finish without special operations - **Dimensional Stability:** Minimal distortion during machining ## **8. Comparative Analysis** | Property | Unibar 200 | Sand Cast EN-GJL-200 | Advantage | |----------|------------|----------------------|-----------| | **Tensile Strength Consistency** | ±5% variation | ±15-20% variation | Superior | | **Internal Soundness** | >99% dense | 95-98% dense | Better | | **Machining Yield** | 85-90% | 70-80% | Higher | | **Surface Finish (as-cast)** | 6.3-12.5 μm Ra | 25-50 μm Ra | Superior | | **Production Lead Time** | Stock/1-2 weeks | 4-8 weeks | Faster | | **Material Cost/kg** | Higher | Lower | - | | **Total Cost/Part** | Often lower | Often higher | Better value | ## **9. Quality Assurance** ### **Standard Testing Protocol:** 1. **Chemical Analysis:** Spectroscopic analysis for each melt 2. **Tensile Testing:** Every production lot (3 bars minimum) 3. **Hardness Testing:** Multiple points along bar length 4. **Microstructural Analysis:** Graphite form and matrix evaluation 5. **Ultrasonic Testing:** For bars >100mm diameter 6. **Surface Inspection:** Visual and dimensional checks ### **Certification:** - **Material Test Certificate 3.1:** Per EN 10204 - **Traceability:** Full melt-to-bar traceability - **Statistical Process Control:** Real-time monitoring of all critical parameters ## **10. Environmental & Sustainability** ### **Environmental Benefits:** 1. **Material Efficiency:** 90-95% utilization vs. 60-70% for conventional machining 2. **Energy Efficiency:** Continuous casting uses 20-30% less energy than conventional foundry processes 3. **Recyclability:** 100% recyclable material 4. **Waste Reduction:** Minimal sand waste (no sand molds) 5. **Emissions:** Reduced CO₂ footprint compared to steel production ### **Life Cycle Advantages:** - **Long Service Life:** Excellent wear and corrosion resistance - **Low Maintenance:** Stable dimensions and properties - **End-of-Life Recovery:** Easy separation and recycling ## **Conclusion** **United Cast Bar Unibar 200** represents a sophisticated engineering material that combines the traditional benefits of grey cast iron with the modern advantages of continuous casting technology. Its exceptional consistency, superior machinability, and reliable performance make it an ideal choice for precision components across multiple industries. For applications requiring guaranteed material properties, pressure tightness, vibration damping, and production efficiency, Unibar 200 offers significant advantages over conventional cast materials. The material's compliance with international standards (EN-GJL-200, ASTM Class 25+) ensures global acceptance and simplifies specification processes. **Application Recommendation:** Unibar 200 is particularly recommended for: - High-volume machining applications where consistency is critical - Hydraulic components requiring pressure tightness - Applications where vibration damping improves performance - Situations where total manufacturing cost is more important than raw material cost - Components requiring complex internal passages or precise dimensions United's technical support team provides comprehensive application engineering assistance to ensure optimal material selection and manufacturing process design for each specific application. -:- For detailed product information, please contact sales. -: United Cast Bar Unibar 200 Continuously Cast Iron Specification Dimensions Size： Diameter 20-1000 mm Length <6648 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. -: United Cast Bar Unibar 200 Continuously Cast Iron Properties -:- For detailed product information, please contact sales. -:

Applications of United Cast Bar Unibar 200 Continuously Cast Iron Rod -:- For detailed product information, please contact sales. -: Chemical Identifiers United Cast Bar Unibar 200 Continuously Cast Iron Rod -:- For detailed product information, please contact sales. -:

Packing of United Cast Bar Unibar 200 Continuously Cast Iron Rod -:- 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 Rod 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 3119 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