United Cast Bar,Unibar 400-15 As Cast Continuously Cast Spheroidal Graphite Iron Sheet,Plate

United Cast Bar Unibar 400-15 As Cast Continuously Cast Spheroidal Graphite Iron Sheet/Plate Product Information -:- For detailed product information, please contact sales. -: United Cast Bar Unibar 400-15 As Cast Continuously Cast Spheroidal Graphite Iron Sheet/Plate Synonyms -:- For detailed product information, please contact sales. -:

United Cast Bar Unibar 400-15 As Cast Continuously Cast Spheroidal Graphite Iron Product Information -:- For detailed product information, please contact sales. -: # **United Cast Bar Unibar 400-15 As-Cast Continuously Cast Spheroidal Graphite Iron** ## **1. Product Overview** **United Cast Bar Unibar 400-15 As-Cast** is a premium **continuously cast ductile iron** supplied in its as-cast condition, meeting the mechanical requirements of **minimum 400 MPa tensile strength and 15% elongation** without additional heat treatment. This material leverages United's advanced vertical continuous casting technology to produce spheroidal graphite iron with exceptional microstructural consistency and mechanical properties directly from the casting process. The "as-cast" designation indicates that the material achieves its specified properties through controlled solidification and cooling alone, without post-casting annealing or normalizing treatments. This grade represents an optimal balance between manufacturing efficiency and mechanical performance, offering **good strength, adequate ductility, and excellent consistency** for applications where the fully ferritic matrix of annealed material is not required. The continuous casting process ensures superior graphite nodule distribution, minimal internal defects, and excellent dimensional stability compared to conventional sand-cast ductile iron. ## **2. Chemical Composition** The chemical composition of Unibar 400-15 As-Cast is precisely controlled to achieve proper nodularization and desired as-cast microstructure: | Element | Composition Range (%) | Metallurgical Function | |---------|---------------------|-----------------------| | **Carbon (C)** | 3.6 - 3.9 | Primary carbon source; higher content than annealed grades to compensate for pearlite formation | | **Silicon (Si)** | 2.4 - 2.9 | Graphitizing agent; promotes ferrite formation but balanced to achieve mixed matrix | | **Manganese (Mn)** | 0.2 - 0.5 | Controlled to maintain some pearlite for strength while limiting its formation | | **Phosphorus (P)** | ≤ 0.04 | Strictly limited to maintain ductility | | **Sulfur (S)** | ≤ 0.015 | Minimized for effective magnesium treatment | | **Magnesium (Mg)** | 0.035 - 0.065 | Primary spheroidizing agent | | **Cerium (Ce)** | 0.005 - 0.02 | Supplementary nodulizer for improved graphite morphology | | **Copper (Cu)** | 0.05 - 0.30 | Optional addition for pearlite stabilization and strength enhancement | | **Tin (Sn)** | 0.02 - 0.06 | Optional pearlite promoter for consistent as-cast properties | | **Chromium (Cr)** | ≤ 0.10 | Limited to prevent excessive carbide formation | **Microstructural Characteristics:** - **Graphite Structure:** **Type I spheroidal graphite** with uniform distribution - **Nodule Count:** 80-150 nodules/mm² - **Nodule Size:** ASTM Size 4-6 - **Matrix Structure:** **Ferritic-pearlitic** (typically 70-85% ferrite, 15-30% pearlite) - **Nodularity:** >90% (typically 92-96%) - **Carbide Content:** <2% (typically 0-1%) - **Microstructural Uniformity:** Excellent consistency due to controlled continuous casting cooling ## **3. Physical & Mechanical Properties** ### **Physical Properties:** - **Density:** 7.05 - 7.15 g/cm³ - **Melting Range:** 1140 - 1180°C - **Thermal Conductivity:** 35 - 40 W/m·K (at 20°C) - **Specific Heat Capacity:** 0.46 - 0.50 kJ/kg·K - **Coefficient of Thermal Expansion:** 11.5 - 12.5 × 10⁻⁶/°C (20-200°C) - **Electrical Resistivity:** 60 - 70 μΩ·cm - **Damping Capacity:** Moderate (approximately 2-4 × steel) ### **Mechanical Properties (As-Cast Condition):** - **Tensile Strength (Rm):** 400 - 500 MPa - **Yield Strength (Rp0.2):** 250 - 320 MPa - **Elongation (A):** 15 - 22% (in 5× diameter gauge length) - **Reduction of Area:** 15 - 25% - **Hardness:** 150 - 200 HB - **Modulus of Elasticity:** 168 - 172 GPa - **Shear Modulus:** 66 - 69 GPa - **Poisson's Ratio:** 0.27 - 0.29 - **Impact Toughness (Charpy V-notch at 20°C):** 10 - 16 J - **Impact Toughness (Charpy V-notch at -20°C):** 7 - 12 J - **Fatigue Strength (Rotating Bending, R=-1):** 190 - 230 MPa (10⁷ cycles) - **Compressive Strength:** 750 - 900 MPa - **Transverse Rupture Strength:** 600 - 750 MPa ### **Special Properties:** - **Machinability Index:** 65 - 75% (relative to free-machining steel) - **Surface Finish Capability:** 0.8 - 2.0 μm Ra achievable - **Pressure Tightness:** Excellent (superior to grey iron) - **Wear Resistance:** Good (better than fully ferritic grades due to pearlite content) - **Thermal Stability:** Good dimensional stability - **Castability:** Excellent fluidity and feeding characteristics ### **Section-Dependent Properties:** | Bar Diameter (mm) | Typical Hardness (HB) | Tensile Strength (MPa) | Elongation (%) | Pearlite Content (%) | |-------------------|----------------------|----------------------|---------------|---------------------| | 25 - 50 | 170 - 200 | 420 - 500 | 18 - 22 | 20 - 30 | | 51 - 100 | 160 - 190 | 410 - 480 | 16 - 20 | 18 - 28 | | 101 - 200 | 155 - 185 | 400 - 460 | 15 - 18 | 15 - 25 | | 201 - 300 | 150 - 180 | 390 - 450 | 15 - 17 | 12 - 22 | ## **4. As-Cast Condition Advantages** ### **Manufacturing Benefits:** 1. **No Heat Treatment Required:** Eliminates annealing costs and cycle time 2. **Energy Efficiency:** Lower total energy consumption vs. heat-treated grades 3. **Reduced Lead Time:** Directly available from casting to machining 4. **Cost Effectiveness:** Lower total cost compared to annealed material 5. **Surface Quality:** As-cast surface suitable for many applications ### **Material Characteristics:** - **Consistent Properties:** Controlled continuous casting ensures uniform cooling - **Good Machinability:** Balanced ferrite-pearlite matrix offers reasonable tool life - **Adequate Ductility:** Meets minimum 15% elongation for most applications - **Moderate Hardness:** Suitable for general machining operations ## **5. Product Applications** ### **General Engineering Components:** - **Industrial Gear Blanks:** For power transmission applications - **Pump and Compressor Parts:** Casings, housings, impellers - **Valve Bodies and Fittings:** For moderate pressure applications - **Machine Tool Components:** Bases, brackets, housings ### **Automotive & Transportation:** - **Commercial Vehicle Components:** Brake drums, hubs, brackets - **Agricultural Equipment:** Gearbox housings, implement components - **Off-Road Equipment:** Hydraulic component housings - **Railway Components:** Non-critical structural parts ### **Construction & Mining:** - **Equipment Housings:** For crushers, conveyors, processing equipment - **Structural Brackets:** Mounting components, support frames - **Wear Components:** Moderate wear applications ### **Fluid Handling Systems:** - **Pipe Fittings:** Flanges, elbows, tees - **Valve Components:** Gate, globe, check valve bodies - **Pump Housings:** Centrifugal and positive displacement pumps ### **General Manufacturing:** - **Die Casting Machine Components:** Platen supports, tie bar nuts - **Press Components:** Frames, bolsters, slides - **Material Handling:** Conveyor components, rollers, guides ## **6. International & Relevant Standards** ### **Material Specifications:** - **EN 1563:2018:** *Founding — Spheroidal graphite cast irons* - **EN-GJS-400-15:** Minimum tensile strength 400 MPa, minimum elongation 15% - **ISO 1083:2018:** *Spheroidal graphite cast irons* - **JS/ISO 400-15:** Equivalent international designation - **ASTM A536-84 (2020):** *Standard Specification for Ductile Iron Castings* - **Grade 60-40-18:** 60 ksi (414 MPa) tensile, 40 ksi (276 MPa) yield, 18% elongation - Unibar 400-15 As-Cast typically meets or exceeds these requirements - **DIN EN 1563:** *Gusseisen mit Kugelgraphit* - **GGG-40** (historical designation) - **JIS G5502:2022:** *Spheroidal graphite iron castings* - **FCD400-15:** Minimum tensile strength 400 MPa, minimum elongation 15% - **GB/T 1348-2019:** *Spheroidal graphite iron castings* (Chinese Standard) - **QT400-15:** Minimum tensile strength 400 MPa, minimum elongation 15% ### **Continuous Casting Standards:** - **DIN EN 16079:2011:** *Continuous cast iron bars* - **ISO 16112:2017:** *Compacted graphite cast irons* (reference only) - **United Cast Bar Internal Specifications:** - UCB-QS-400-15-AC: As-cast ductile iron specification - UCB-CC-002: Continuous casting process standard ### **Testing & Certification 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* - **EN 10204:** *Metallic products — Types of inspection documents* - Type 3.1 certificate standard - **ISO 6892-1:** *Metallic materials — Tensile testing* ## **7. Manufacturing & Processing** ### **Continuous Casting Process:** 1. **Melting:** Electric induction furnace with precise temperature control 2. **Treatment:** Magnesium treatment in tundish or converter 3. **Casting:** Vertical continuous casting with controlled solidification 4. **Cooling:** Controlled air cooling to achieve target microstructure 5. **Cutting:** Precision cut-to-length 6. **Inspection:** Comprehensive quality verification ### **Available Forms & Specifications:** - **Solid Bars:** 30mm to 350mm diameter - **Hollow Bars (Tubes):** 50mm to 250mm OD - **Standard Lengths:** 3-6 meters - **Tolerances:** Diameter ±0.5% to ±1.0% - **Surface Condition:** As-cast or rough turned - **Straightness:** Within 1.5mm/meter ### **Optional Post-Casting Treatments:** - **Stress Relieving:** 550-580°C for dimensional stability - **Surface Machining:** Rough turning for improved surface finish - **Shot Blasting:** For surface cleaning and stress relief ## **8. Machining & Fabrication Guidelines** ### **Recommended Cutting Parameters:** | Operation | Speed (m/min) | Feed (mm/rev) | Depth of Cut (mm) | Tool Material | |-----------|--------------|---------------|-------------------|--------------| | Turning | 100 - 160 | 0.18 - 0.35 | 2.0 - 4.0 | C3-C6 Carbide | | Drilling | 20 - 30 | 0.12 - 0.22 | - | HSS or Carbide | | Milling | 70 - 110 | 0.12 - 0.25 | 1.5 - 3.0 | Carbide | | Tapping | 6 - 12 | - | - | HSS with coating | | Boring | 80 - 130 | 0.08 - 0.20 | 1.5 - 3.0 | Carbide | ### **Tooling Recommendations:** - **Insert Grades:** C3-C6 carbide for general machining - **Tool Geometry:** Positive to neutral rake angles - **Coatings:** TiN or TiCN for improved tool life - **Coolant:** Water-soluble oils recommended - **Chip Control:** Moderate chip breaking characteristics ### **Special Considerations:** 1. **Variable Hardness:** Slight hardness variations may occur due to mixed matrix 2. **Tool Wear:** Monitor for increased wear in pearlitic areas 3. **Surface Finish:** Good finish achievable with proper parameters 4. **Thread Quality:** Good thread formation with sharp tools ### **Fabrication Methods:** - **Welding:** Possible with proper pre-heat and post-heat treatments - **Machining:** Good overall machinability - **Joining:** Excellent for mechanical fastening - **Surface Treatment:** Responds well to various coatings and platings ## **9. Quality Assurance** ### **Quality Control Protocol:** 1. **Chemical Control:** Spectroscopic analysis for each melt 2. **Microstructural Check:** Regular nodularity and matrix evaluation 3. **Mechanical Testing:** Tensile tests from each casting run 4. **Hardness Testing:** Systematic hardness mapping 5. **Dimensional Check:** Full geometric inspection 6. **Surface Inspection:** Visual and non-destructive examination ### **Certification:** - **Material Certificates:** EN 10204 3.1 provided - **Traceability:** Full batch traceability maintained - **Test Reports:** Comprehensive mechanical test data - **Process Records:** Complete casting parameter documentation ## **10. Comparative Analysis** ### **vs. Annealed Unibar 400-15:** | Parameter | As-Cast 400-15 | Annealed 400-15 | Considerations | |-----------|---------------|-----------------|----------------| | **Tensile Strength** | 400-500 MPa | 400-480 MPa | Similar minimum, higher potential in as-cast | | **Elongation** | 15-22% | 15-25% | Slightly lower but meets specification | | **Hardness** | 150-200 HB | 130-180 HB | Higher due to pearlite content | | **Machinability** | Good | Excellent | Annealed material machines more easily | | **Cost** | Lower | Higher | No annealing cost | | **Lead Time** | Shorter | Longer | Eliminates heat treatment cycle | | **Impact Toughness** | 10-16 J | 12-20 J | Adequate for most applications | ### **vs. Sand-Cast Equivalent:** | Parameter | Unibar As-Cast | Conventional Sand-Cast | Advantage | |-----------|---------------|----------------------|-----------| | **Consistency** | ±5% variation | ±15-25% variation | Superior | | **Internal Quality** | >99% dense | 92-96% dense | Better | | **Surface Finish** | 6-12 μm Ra | 25-100 μm Ra | Superior | | **Dimensional Accuracy** | ±0.5-1.0% | ±1.5-3.0% | Better | | **Production Lead Time** | Stock/1-2 weeks | 4-8 weeks | Faster | ## **11. Economic Benefits** ### **Cost Advantages:** 1. **No Annealing Cost:** Eliminates heat treatment expense 2. **Reduced Energy:** Lower total energy consumption 3. **Faster Delivery:** Shorter lead times 4. **Lower Inventory:** Can be supplied from stock 5. **Competitive Pricing:** 15-25% lower cost than annealed equivalent ### **Production Efficiency:** - **Direct Machining:** Ready for machining after casting - **Consistent Supply:** Reliable material availability - **Reduced Processing:** Fewer production steps - **Predictable Performance:** Consistent properties batch-to-batch ## **12. Sustainability** ### **Environmental Benefits:** 1. **Energy Efficiency:** No additional heat treatment energy required 2. **Material Efficiency:** Continuous casting yields high material utilization 3. **Reduced Emissions:** Lower carbon footprint vs. heat-treated grades 4. **Recyclability:** 100% recyclable material 5. **Long Service Life:** Durable material reduces replacement frequency ## **Conclusion** **United Cast Bar Unibar 400-15 As-Cast** offers a cost-effective, high-performance solution for applications requiring the strength and ductility of ductile iron without the additional expense of heat treatment. Its balanced ferritic-pearlitic matrix provides adequate mechanical properties for a wide range of engineering applications while maintaining the manufacturing advantages of continuous casting technology. **Key Benefits:** - Meets EN-GJS-400-15 specifications without heat treatment - Excellent consistency and dimensional accuracy - Good machinability and surface finish capability - Cost-effective alternative to annealed material - Shorter lead times and reliable availability - Suitable for pressure-containing applications **Ideal Applications:** - General engineering components - Automotive and transportation parts - Industrial machinery components - Fluid handling systems - Applications where cost-effectiveness is prioritized over maximum ductility For manufacturers seeking a reliable, cost-efficient ductile iron material with guaranteed properties and excellent manufacturing characteristics, Unibar 400-15 As-Cast provides an optimal balance of performance, consistency, and value. -:- For detailed product information, please contact sales. -: United Cast Bar Unibar 400-15 As Cast Continuously Cast Spheroidal Graphite Iron Specification Dimensions Size： Diameter 20-1000 mm Length <6653 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 400-15 As Cast Continuously Cast Spheroidal Graphite Iron Properties -:- For detailed product information, please contact sales. -:

Applications of United Cast Bar Unibar 400-15 As Cast Continuously Cast Spheroidal Graphite Iron Sheet,Plate -:- For detailed product information, please contact sales. -: Chemical Identifiers United Cast Bar Unibar 400-15 As Cast Continuously Cast Spheroidal Graphite Iron Sheet,Plate -:- For detailed product information, please contact sales. -:

Packing of United Cast Bar Unibar 400-15 As Cast Continuously Cast Spheroidal Graphite Iron Sheet/Plate -:- 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 Sheet/Plate 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 3124 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