TABLE OF CONTENTS - TUPY. Referência em tecnologia … · Continuous Cast Iron - VERSA-BAR 3 INTRODUCTION CAST IRON DEFINITION Gray and Ductile Irons are alloys of iron-carbon-silicon,

VERSA-BARContinuous Cast Iron

Technical Catalogue

CONTINUOUS CAST IRON

Continuous Cast Iron - VERSA-BAR2

TABLE OF CONTENTS

INTRODUCTION

Cast Iron Definition ....................................................................................................... 03

Presentation of VERSA-BAR .................................................................................................... 04

The advantages of VERSA- BAR ............................................................................................. 06

Typical applications of VERSA- BAR ..................................................................................... 10

GRAY IRON

Description of grades ...................................................................................................... 12

FC 200 - Pearlitic/Ferritic Gray Iron ............................................................................... 13

FC 300 - Pearlitic Gray Iron ........................................................................................... 15

GMI - (Glass Moulding Iron) - Gray Iron with refined graphite ...................................... 17

DUCTILE IRON

Description of grades ..................................................................................................... 19

FE 40015 - Ferritic Ductile Iron ..................................................................................... 20

FE 45012 - Ferritic/Pearlitic Ductile Iron ....................................................................... 22

FE 55006 - Pearlitic/Ferritic Ductile Iron ....................................................................... 24

FE 70002 - Pearlitic Ductile Iron ................................................................................... 26

STANDARD DIMENSIONS

Round Bars .................................................................................................................... 28

Rectangular Bars ............................................................................................................ 30

Square Bars .................................................................................................................... 31

ADDITIONAL INFORMATION

Other Properties ............................................................................................................. 32

Corresponding Materials according to the norms of other entities ................................... 33

Useful Formulas/Conversion Factors .............................................................................. 34


INTRODUCTION

CAST IRON DEFINITION

Gray and Ductile Irons are alloys of iron-carbon-silicon, with tenors of carbonusually above 2,0%, in quantity superior of the one that can be retained in solidsolution in the austenite, in order to result the formation of graphite, in the vein(lamellas) or nodule (spheres) format, showed by figures 1a and 1b.

The format and distribution of graphite, as well as the structure of the matrix,influences directly in the cast iron properties, this is the reason why theselection of the most appropriate cast iron grade depends a lot on itsapplication.

Combinations of different formats of graphite with different structures ofmatrix, result in a large variety of grades, and certainly one of them will attendthe necessary performance, assurance and quality requirements.

The constant evolution of the casting technology of the cast irons hascontributed more and more to the development of new applications, allowingthus, more economical alternatives enabling to obtain quality products.

Fig. 1a -Gray Iron Fig. 1b - Ductile Iron


PRESENTATION OF VERSA-BAR

Originally developed in Europe just after the World War II, the process of continuouscasting in cast irons was introduced into South America in 1975 by lndústria de FundiçãoTupy, aiming to obtain a more economical method to produce pieces with similar orsuperior quality while compared to the ones obtained from steel bars or conventionalcasting process (sand).

Fig. 2 - Production Process by Continuous Casting

1. Molten Metal2. Filling Spout3. Holding Furnace4. Water Cooled Graphite Die5. Roller Supports6. Distribution Panel7. Drawing Unit8. Cut-off machine9. Break-off Unit10. Stock Size - VERSA-BAR

11. Water inlet and outlet12. Water Cooling Jacket13. Cast Bar


A water cooled graphite die, providing to the bars a high sanity, associated to a uniform

and refined structure delineates geometry of VERSA-BAR . It permits that pieces ofhigh responsibility can be produced without the risks or imperfections in service related tomaterial defects, reaching at the process end a lower machining cost.

The continuous casting process permits to obtain the most different geometrical shapes,such as round, square, rectangular, oval and other ones, which can get closer to the final

geometry of the piece to be manufactured from VERSA-BAR .

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


ADVANTAGES OF VERSA-BAR

ABSENCE OF POROSITIES

Porosities are casting defects that occur internally to the piece and present, generally, round shapeand smooth internal surface, also being possible to be presented with elongated aspect anddifferent sizes.

The occurrence of porosities can have various causes, all of them deriving from gas sources.It can be mentioned as probable causes of porosity occurrence:

a) Gases deriving from molding materials, foundry core, paints.b) Mechanical capture of gases

b.1 - Contained in the cavities of the mold;b.2 - Generated by molds and foundry cores;b.3 - Due to the turbulence during the pouring;b.4 - Inadequate systems of conduits.

c) Gases dissolved in the molten metal.

In the production of VERSA-BAR , the mold utilized is a graphite mold, which doesnot discharge gases while submitted to high temperatures. Besides, the gas sourcesalready mentioned do not exist. in bars produced by continuous casting process, thepresence of gases is limited to the only ones contained in the molten metal, what reduces,enormously, the tendency of forming porosities compared to other casting processes.

ABSENCE OF GAS HOLES

The gas holes are cavities caused by the contraction of the molten metal during the solidification.The control of this defect is more difficult as more complex the cast piece geometry is, once thegas holes are always located in the thickest sections in the thermic centers of the pieces.

In the sand casting process there is still an aggravation that is the expansion of the mold,increasing the need of molten metal to compensate the dimensional variety that the piece suffers.

Since they are rigid, the graphite molds do not misshape due to the stress that occur during thesolidification of the cast irons, certifying, thus a perfect feeding of the piece and as aconsequence the absence of gas holes.

The bars produced by the continuous casting process show defined geometry, being able tocontrol the solidification process to each kind of bar in a way to avoid the appearing of cavitiesfrom the solidification.

Therefore, by machining the piece from VERSA-BAR it will not incur in risks of disagreeablesurprises at the end of the machining process as the appearing of gas holes.


LESS DENSITY

The density difference of approximately 10% less in VERSA-BAR compared to the steels, isdue to the presence of graphite in the structure of the cast irons (density = 2,2 g/m3

) .

Density of VERSA-BAR = 7,20 g/cm3

Density of Steel = 7,86 g/cm3

MORE REFINED STRUCTURE

Also due to the utilization of cooled graphites to confer the desirable geometry to the bars,

VERSA-BAR has more refined structures compared to the pieces of same thickness (coolingmodulus), produced in sand molds, conferring better mechanical properties to the material.

Another important aspect attributed to the faster cooling provided by the continuous casting

process is the best leaking resistance of the pieces produced from VERSA-BAR , a fundamentalcharacteristic to the production of hydraulic components (Fig. 4).

Fig 4 - Hydraulic components - manifolds, plungers, caps, valve bodies, etc.

LESS OVER MATERIAL

Due to the large flexibility in what concerns to the geometry of the bars, the continuous castingprocess permits the manufacture of bar shapes close to the final dimension of the piece.The large diversification of dimensions, non existence of outlet angles, exemption of inclusionsor surface defects and the good as cast surface finish, also contribute to the reduction of the overmaterial for machining.


SUPERIOR MACHINABILITY

Due to the uniformity of its microstructure, absence of superficial abrasive inclusions (sandresidues), absence of discarbonated layer and since it is produced in gray and ductile irons of

high quality, VERSA-BAR presents a superior machinability if compared to the sand castirons.

While compared to the steels, the superior machinability of VERSA-BAR is due mainly to thepresence of graphite in its structure , which works as a chip breaker as well as lubricant agents.

It reflects in a superior cutting velocity which can be applied in the VERSA-BAR machining

process and in a lower wear of toolings, avoiding changes for sharpening and due to that waste ofproductivity.

ALLOYS OF HIGH RESISTANCE

In order to produce components that require a high mechanical resistance, there is also availablean alloy that follows the requirements of the class FE 70002, however it is also possible toincrease its resistance and tenacity by heat treatment of austempering to obtain a ductile cast ironof bainitic matrix.

By using this material, values of resistance limits which range from 1000 to 1500 MPa can bereached with values of elongation up to 6%.

The ductile cast irons submitted to heat treatment of austempering are indicated to themanufacturing of gears, valve guides, pins, bushings, and other components that require a goodtenacity associated to high resistance to wear.

Due to its high temperability this material can be also submitted to tempering and normalizing,being possible thus to obtain a wide range of mechanical property combinations.

ELIMINATION OF TOOLING COSTS (MOLDS)

Since different sizes and shapes are available, it will be always possible to select the kind of

VERSA-BAR that can be closer to the final shape of the component to be machined. It willeliminate the high expenses with casting toolings and the long time to obtain them, reducingsignificantly the final cost of the product specially in what concerns to low demand items asprototypes, pieces that will be submitted to future alterations, pieces to be used in maintenanceand others.


SURFACE TREATMENTS

VERSA-BAR admits the application of the most different surface treatments, aiming in eachsituation specific benefits, as the increase of the resistance to fatigue, wear or corrosion.

It is also possible to mention as examples, the chrome finish in glass molds (Fig. 5), treatmentwith nitride and shot peening in gears and surface tempering in valve guides.

Fig 5 - Shapes and accessories applied to the glass industry.

LESS SCRAP AFTER THE MACHINING

The non existence of characteristic defects noticed in pieces produced by the conventionalprocess as porosities, gas holes, inclusions of sand and scoria, make practically null the after

machining scrap in pieces produced from VERSA-BAR . The after machining scrap cost isextremely expensive, since there are losing of raw material, labour and machine time to theproductive process.


TYPICAL APPLICATIONS OF VERSA-BAR

Initially, any kind of component currently produced in gray and ductile cast iron and in

some steel grades can be produced from VERSA-BAR .

As example, see below some already well known applications where VERSA-BAR

replaces the conventional casting process and the steel shapes.

MARKET SEGMENT COMPONENTS

HYDRAULIC AND PNEUMATIC

ManifoldsPlungersCylinder CapsCylinder HeadValve Body

GLASS INDUSTRY

MoldsPinsPunchesNeck RingsCore BoxesPulleys

MACHINES AND EQUIPMENTS

CouplingSheavesAxlesStraightedgesBushingsWashersNutsGearsPinsCounterweightsTablesFlangesBearings


MARKET SEGMENT COMPONENTS

AUTOPARTS

Bearing CapsDistance RingsBrake PistonsRingsValve guidesCommand axlesValve seats

OTHERS

Protector tube for thermocouplingsMatrixesRetainersConesPlugsValve PlatesRollersDies

These examples show the versatility of VERSA-BAR that follows an enormousdiversity of segments from simple applications as washers and pulleys to complexapplications as molds to the glass industry and valve bodies to hydraulic components.

In order to help you making the best choice we offer at your disposal the service of ourtechnical division by the telephone nº (005547) 441-8421 or (005547) 441-8305.

In USA contact is by the telephone 0014145444800 American Iron & Alloys Co. ToolFree 8005444800.


GRAY IRON

DESCRIPTION OF GRADES

The gray cast irons produced by continuous casting process, whose dominant structuralcharacteristic is to present carbon in vein (lamellas) format of graphite, are available in FC 200,FC 300 and GMI grades.

The mechanical properties of the gray cast iron are conditioned to the final structure obtained.That means they depend on the metal matrix as well as on the format and quantity of thegraphite.

The cast gray iron grades of less mechanical resistance (FC 200) usually present larger quantitiesof ferrite, conferring a better machinability to these materials.

On the other hand, the cast gray iron grades of larger mechanical resistance (FC 300) presentmore refined graphite and a matrix essentially pearlitic, providing to these materials a bettersurface finish and a higher hardness .


FC 200 – PEARLITIC / FERRITIC GRAY IRON

DESCRIPTION

VERSA-BAR FC 200 is a gray iron that has as main characteristic an excellent machinability,allowing the increase of the cutting velocity and the reduction of the premature wear of thetoolings, certifying thus strait dimensional tolerances. This material is recommended toapplications that require moderate mechanical properties.

This specification is similar to ASTM A48, class 30.

MICROSTRUCTURE

The typical microstructure of VERSA-BAR FC 200 consists of graphite in vein (lamellas)format, form VII, Type A, size 3-6, as defined in ASTM A48. The matrix is predominantlypearlitic with 5 to 20% of ferrite. The rim consists of type D graphite, size 6-8 and essentiallyferritic matrix with 5% maximum of well dispersed carbides.

Fig. 6 - Typical microstructure in the center Fig. 7 - Typical microstructure in the rim.


MECHANICAL PROPERTIES

The typical values of hardness and tensile strength limits of VERSA-BAR FC 200 are listedbelow and refer to the results showed by a longitudinal test specimen taken from the mid-radiusof the bar. These values are only orientative and were adequate to make possible the obtainmentof the tensile strength limit in standard test samples as per ASTM A48 norm.

Dimensions( mm )

Hardness( HB )

Strength Limit( MPa ) mín.

Till 27,627,7 - 43,443,5 - 63,163,2 - 79,079,1 - 92,1

92,2 – 111,5111,6 - 124,2124,3 - 143,6143,7 - 254,1

163 – 207163 – 207163 – 207163 – 207163 – 207163 – 207163 – 207163 – 207163 - 207

200190180170160150140130125

CHEMICAL COMPOSITION

The general chemical composition applied to this material is showed by the table below:

Element %C1

SiMnSPCr

2,90 - 3,902,20 - 2,600,40 - 0,600,05 - 0,250,10 máx.0,05 máx.

Note: 1 - The carbon grades are specified to eachdimensional group in a way to control the type andsize of the graphite. The variation in the samegrade is approximately 0,20%.


FC 300 - PEARLITIC GRAY IRON

DESCRIPTION

VERSA-BAR FC 300 is a gray cast iron with totally pearlitic structure that provides to it highmechanical properties and a good surface finish. Another important characteristic to bementioned is the good leaking resistance, that allied to the above mentioned properties, makespossible its utilization in pieces applied to hydraulic components subjected to high pressures asmanifolds, valve bodies, heads, caps and plungers.

This specification is similar to ASTM A48, class 40.

MICROSTRUCTURE

The typical microstructure of VERSA-BAR consists of graphite in vein (lamellas) format,form VII, type A, size 3-6, as defined in ASTM A247. The matrix is predominantly pearlitic,with 10% ferrite maximum. The rim consists of type D graphite size 6 - 8 with 5% maximum ofwell dispersed carbides.

Fig. 8 - Typical microstructure in the center. Fig. 9 - Typical microstructure in the rim.



The typical values of hardness and tensile strength limits of VERSA-BAR FC 300 are listedbelow and refer to the results showed by a longitudinal test specimen taken from the mid-radiusof the bar. These values are only orientative and were adequate to make possible the obtainmentof the tensile strength limit in standard test samples as per ASTM A48 norm.

Dimensions( mm )

Hardness( HB )

Strength Limit( MPa ) mín.

Till 27,627,7 – 53,053,1 – 79,079,1 – 104,8104,9 – 156,3156,4 – 260,5260,6 – 345,0345,1 – 476,6

229 – 285197 – 269197 – 269197 – 269197 – 269179 – 255179 – 255179 – 255

270250240230205185170160



Element %C1

SiSPCr

2,80 - 3,702,20 - 2,600,05 - 0,250,10 máx.0,05 máx.

Note: 1 - The carbon grades are specified to eachdimensional group, in a way to control thetype and size of the graphite. Thevariation in the same grade isapproximately 0,20%.


GMI - (GLASS MOULDING IRON)GRAY IRON WITH REFINED GRAPHITE

DESCRIPTION

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

Originally developed to the production of glass moulds to the glass industry, the GMI has anextremely refined graphite, providing to it an excellent surface finish. It is also well known by itsexcellent machinability and good heat conductivity.

While submitted to repetitive heat cycles of heating/cooling, shows a good dimensional stabilitydue to the small graphite size and the essentially ferritic matrix.

MICROSTRUCTURE

The typical microstructure of VERSA-BAR GMI consists of refined graphite, form VII, TypeD (80% min.), size 6-8, as defined in ASTM A247. The matrix is ferritic with approximately15% of pearlite with 5% maximum of well dispersed carbides.

Fig. 10 - Typical microstructure of GMI.



The typical hardness values and tensile strength limits of VERSA-BAR GMI are listed belowand refer to the results showed by longitudinal test specimen taken from the mid-radius of thebar.

Tensile Strength Limit (MPa) = 180 min.Hardness (HB) = 131 - 207

PHYSICAL PROPERTIES

Heat Conductivity (W/m.K) 100 to 400ºC = 41 to 44

Heat Expansion Coefficient (10-6/K) 20ºC / 20 to 400ºC = 10 to 12,5



Element %C1

SiMnSPCrTi2

3,40 – 4,002,20 - 2,600,20 máx.0,02 máx0,10 máx.0,05 máx.0,30 máx.

Note: 1 - The carbon grades are specified to eachdimensional group and the variation in the samegrade is approximately 0,20%.

2 - Titanium is added to generate Type D graphite.

TYPICAL APPLICATIONS

- Moulds and accessories to the glass industry- Brake pistons


DUCTILE IRON

DESCRIPTION OF GRADES

The ductile cast irons produced by continuous casting process whose dominant structuralcharacteristic is to present carbon in nodule (spheres) graphite format, are available in FE 40015,FE 45012, FE 55006 and FE 70002 grades.

The obtainment of nodular (spherical) graphite is a consequence of the addition of somechemical elements or specific production conditions that modify the way of its growth. This typeof material is recommended to pieces that require high mechanical properties, high tenacity andexcellent leaking resistance.

Besides of the graphite format, the quantities of ferrite and/or pearlite in the matrix determine themechanical properties of the material and consequently its grade.

The tensile strength limit of VERSA-BAR in the as cast condition can range from 400 to 700MPa with elongation from 2% to 15%.


FE 40015 - FERRITIC DUCTILE IRON

DESCRIPTION

VERSA-BAR FE 40015 is a ductile iron with Type I and II graphite, in a totally ferritic matrixobtained by heat treatment. Besides of the excellent machinability, the ferritic matrix provides ahigh tenacity and a high magnetic permeability.

This material presents tensile and yield strength limits similar to hot laminated steels SAE 1020in the as cast condition.

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

MICROSTRUCTURE

The typical microstructure of VERSA-BAR FE 40015 consists of graphite in nodule (spheres)format, form I and II, size 6 - 8, as defined in ASTM A247. The matrix is totally ferritic.

Fig.11 - Typical microstructure in the center Fig. 12 - Typical microstructure in the rim.



The typical hardness, tensile and yield strength limit and elongation values of VERSA-BAR

FE 40015 are listed below and refer to the results showed by longitudinal test specimen takenfrom the mid-radius of the bar.

Dimensions( mm )

Hardness( HB )

27,6 – 208,0208,1 – 451,2

131 – 207121 – 207

Tensile strength limit (MPa) = 400 min.

Yield strength limit (MPa) = 270 min.

Elongation (%) = 15 min.



Element %C1

SiMnSP

Mg2

3,30 – 3,802,60 - 3,000,20 máx.0,02 máx0,10 máx.

0,04 – 0,07

Note: 1 - The carbon grades are specified to eachdimensional group and the variation in the samegrade is approximately 0,20%.

2 - Magnesium is added to generate spheroidalgraphite.


FE 45012 – FERRITIC / PEARLITIC DUCTILE IRON

DESCRIPTION

VERSA-BAR FE 45012 is a ductile iron with Type I and II graphite, in a ferritic/pearlitic

matrix obtained as cast or by heat treatment.

Its main characteristics is a good machinability, surface finish and leaking resistance.

This material presents tensile and yield strength limits similar to hot laminated steels SAE 1030in the as cast condition.


MICROSTRUCTURE

The typical microstructure of VERSA-BAR FE 45012 consists of graphite in nodule (spheres)format, form I and II, size 6 - 8, as defined in ASTM A247. The matrix is essentially ferritic with25% pearlite maximum and 5% maximum of well dispersed carbides.

Fig. 13 - Typical microstructure in the center. Fig.14 - Typical microstructure in the rim.





Dimensions( mm )

Hardness( HB )

27,6 – 79,079,1 – 156,3156,4 – 451,2

156 – 217143 – 217131 – 217

Tensile strength limit (MPa) = 450 min.Yield strength limit (MPa) = 310 min.Elongation ( % ) = 12 min.



Element %C1

SiMnSP

Mg2

3,30 – 3,802,60 - 3,000,20 máx.0,02 máx0,10 máx.

0,04 – 0,07

Note: 1 - The carbon grades are specified to eachdimensional group an the variation in the samegrade is approximately 0,20%.

2 -Magnesium is added to generate spheroidal graphite.


FE 55006 – PEARLITIC / FERRITIC DUCTILE IRON

DESCRIPTION

VERSA-BAR FE 55006 is a ductile iron with Type I and II graphite, in a pearlitic/ ferriticmatrix. This pearlitic/ferritic matrix provides high mechanical properties, good surface finishand good temperability, making able to apply this material in pieces that require high tensilestrength and wearing resistance.

This material presents tensile and yield strength limits similar to hot laminated steels SAE 1040,in the as cast condition.


MICROSTRUCTURE

The typical microstructure of VERSA-BAR FE 55006 consists of graphite in nodule (spheres)format, form I and II, size 6 - 8, defined in ASTM A247. The matrix is pearlitic/ferritic withapproximately 50% of ferrite and 5% maximum of well dispersed carbides.

Fig. 15 - Typical microstructure in the center. Fig. 16 – Typical microstructure in the rim.





Dimensions( mm )

Hardness( HB )

27,6 – 37,137,2 – 79,079,1 – 195,3195,4 – 451,2

229 – 269217 – 269207 – 255187 – 255






Element %C1

SiMnSP

CuMg2

3,30 – 3,802,60 - 3,000,20 – 0,650,02 máx0,10 máx.

0,10 – 0,250,04 – 0,07

Note: 1 - The carbon grades are specified to eachdimensional group and the variation in the same gradeis approximately 0,20%.

2 - Magnesium is added to generate spheroidalgraphite.


FE 70002 - PEARLITIC DUCTILE IRON

DESCRIPTION

VERSA-BAR FE 70002 is a ductile iron with Type I and II graphite, in a predominantly

pearlitic matrix obtained as cast or by the addition of pearlitizing alloy elements. This matrixprovides high temperability, allowing the execution of heat treatments as tempering, normalizingand surface tempering, obtaining, thus, a large grade of mechanical property combinations.

This material has tensile and yield strength limits similar to hot laminated steels SAE 1045 in theas cast condition.


MICROSTRUCTURE

The typical microstructure of VERSA-BAR FE 70002 consists of graphite in nodule (spheres)format, form I and II, size 6 - 8, as defined in ASTM A247. The matrix is predominantlypearlitic with 25% of ferrite and 5% maximum of well dispersed carbides.

Fig. 17 - Typical microstructure in the center. Fig. 18 - Typical microstructure in the rim.





Dimensions( mm )

Hardness( HB )

27,6 – 79,079,1 – 195,3195,4 – 451,2

241 – 302241 – 285229 – 269






Element %C1

SiMnSP

CuMg2

3,30 – 3,802,60 - 3,000,20 – 0,650,02 máx0,10 máx.

0,10 – 0,250,04 – 0,07

Note: 1 - The carbon grades are specified to eachdimensional group and the variation in the same gradeis approximately 0,20%.

2 - Magnesium is added to generatespheroidal graphite.


STANDARD DIMENSIONS

ROUND BARS

As CastDimension

(mm)

RecommendedMachining inthe Diameter

DimensionalTolerance

(mm)

TheoreticalWeight(kg/m) FC200 FC300 FE45012 FE55006

18.021.222.227.630.733.937.140.343.446.649.853.0

2.2 + / - 0.30

1.82.52.84.35.36.57.89.210.712.314.015.9

••

••

••

•

••

•••••••••

•••••••••

•••••••••

56.859.963.166.369.572.675.879.0

2.8 + / - 0.80

18.220.322.524.927.329.832.535.3

•

••

•

•

••••••••

••••••••

••••••••

82.685.788.992.195.398.4101.6104.8

3.2 + / - 1.00

38.541.644.747.951.354.858.462.1

•

••

•

•

••••••••

••••••••

••••••••

111.5113.6117.9124.2130.6

3.6 + / - 1.10

70.373.078.587.296.4

••••

•

•••

•

•••

•

•••


As CastDimension

(mm)

RecommendedMachining inthe Diameter

DimensionalTolerance

(mm)

TheoreticalWeight(kg/m) FC200 FC300 FE45012 FE55006

137.3143.6150.0156.3

3.9 + / - 1.40

106.6116.7127.2138.2

••

•

••••

••••

••••

163.1169.4175.8182.1

4.3 + / - 1.60

150.4162.3174.7187.6

•

••

••••

••••

••••

189.0195.3201.7208.0

4.8 + / - 2.10

201.9215.7230.0244.7

•

•

••••

••••

••••

215.0221.4227.7234.1

5.5 + / - 2.70

261.5277.2293.3309.9

•

••

••••

••••

••••

241.4247.8254.1260.5

6.5 + / - 3.30

329.5347.1365.1383.6

••

••••

••••

••••

270.5276.9289.6

10.2 + / - 3.80413.8433.5474.1

•••

•••

•••

306.9319.6332.3345.0370.4395.8421.2

14.8 + / - 5.20

532.6577.5624.4673.0775.8885.81003.1

•••••••

•••••••

•••••••

451.2476.6

19.3 + / - 6.60 1151.01284.2

••

••

••


RECTANGULAR BARS - FC 300

As CastDimension

(mm)

Recommended Machiningper face (mm)

MaximumSwelling

(mm)

TheoreticalWeight(kg/m)

31,7 x 57,1 2,3 2,9 13,031,7 x 82,5 2,6 4,2 18,831,7 x 107,9 3,2 6,3 24,631,7 x 133,3 3,2 6,3 30,431,7 x 158,7 4,8 8,9 36,231,7 x 260,3 4,8 11,7 59,438,1 x 57,1 2,3 2,9 15,738,1 x 82,5 2,6 4,2 22,638,1 x 107,9 2,6 4,2 29,638,1 x 133,3 3,2 6,3 36,638,1 x 158,7 3,2 6,3 43,544,4 x 50,8 2,3 3,1 16,244,4 x 107,9 2,6 4,4 34,544,4 x 114,3 2,6 4,4 36,544,4 x 158,7 3,2 6,7 50,750,8 x 63,5 2,3 3,1 23,250,8 x 92,1 2,3 3,1 33,757,1 x 82,5 2,3 3,1 33,957,1 x 107,9 2,3 3,1 44,457,1 x 133,3 2,6 4,4 54,857,1 x 158,7 2,6 4,4 65,257,1 x 209,5 3,2 6,7 86,163,5 x 158,7 2,6 4,4 72,663,5 x 184,1 2,6 4,4 84,263,5 x 209,5 3,2 6,7 95,876,2 x 209,5 4,8 4,8 114,982,5 x 107,9 2,6 3,4 64,182,5 x 260,3 6,3 7,2 154,6107,9 x 133,3 2,8 3,6 103,6139,7 x165,1 2,8 3,6 166,1177,8 x 406,4 6,3 5,9 520,3209,5 x 361,9 3,2 3,9 545,9


SQUARE BARS - FC 300

As CastDimension

(mm)

Recommended Machiningper face (mm)

MaximumSwelling

(mm)

TheoreticalWeight(kg/m)

31,7 2,3 2,9 7,238,1 2,3 2,9 10,541,3 2,3 3,1 12,344,4 2,3 3,1 14,250,8 2,3 3,1 18,657,1 2,3 3,1 23,563,5 2,3 3,1 29,069,8 2,6 3,4 35,176,2 2,6 3,4 41,882,5 2,6 3,4 49,088,9 2,6 3,4 56,995,2 2,6 3,4 65,2107,9 2,8 3,6 83,8120,6 2,8 3,6 104,7133,3 2,8 3,6 127,9158,7 3,2 3,9 181,3184,1 3,2 3,9 244,0209,5 3,2 3,9 316,0234,9 4,8 4,1 397,3260,3 4,8 4,1 487,8311,1 6,3 4,4 696,8

Standard Length = 1880 mm (+ 25 / - 50 mm)

Bending = 2,5 mm / m.

Further to the products above listed, it is possible to produce VERSA-BAR under specialrequested dimensions, shapes and materials in order to attend specific properties required insome situations as heating, corrosion and wear resistance.

VERSA-BAR has a great flexibility in what concerns the chemical composition, being possibleto add all the alloy elements applied by the conventional casting process (sand) in order to raisethe mechanical properties of the gray and ductile cast irons.


ADDITIONAL INFORMATION

OTHER PROPERTIES

Usually the gray and ductile cast irons are commercially specified by the Tensile Strength andHardness Limits. The main reason of that is the relative facility to determine them.

Depending on the application, other properties can be also decisive in the selection of the mostadequate material and in most of the time, it is possible to bring them into relation with theTensile Strength (SL) and / or Hardness Limits.

PROPERTIES GRAY IRON DUCTILE IRONShear Resistance (MPa) 1,15 x LR (1) 0,90 x LR ( 3;5 )

Torsion Resistance (MPa) 1,15 x LR (1) 0,90 x LR ( 3;5 )

Fatigue Resistance (MPa)(without notch)

0,40 x LR ( 4;5 )FE 40015 = 0,50 x LR ( 3 )

FE 45012 = 0,45 x LR ( 3 )

FE 55006 = 0,40 x LR ( 3 )

FE 70002 = 0,40 x LR ( 3 )

Compression Strength (MPa)LR de 140-175 x 4,02 ( 5 )

LR de 176-200 x 3,68 ( 5 )

LR de 211-245 x 3,61 ( 5 )

LR de 246-280 x 3,39 ( 5 )

----------

Impact Resistance(with notch 20ºC) ----------

FE 40015 = 15 – 13 ( 2 )

FE 45012 = 10 - 5 ( 2 )

FE 55006 = 5 - 2 ( 2 )

FE 70002 = 5 - 2 ( 2 )

Elasticity Modulus (GPa)FC 200 = 88 – 113 ( 1 )

FC 300 = 108 – 137 ( 1 )

GMI = 78 – 107 ( 1 )

FE 40015 = 169 ( 2 )

FE 45012 = 169 ( 2 )

FE 55006 = 169 ( 2 )

FE 70002 = 172 – 176 ( 2 )

Heat ConductivityW / m.K 100ºC / 400ºC

FC 200 = 51 – 48 ( 2 )

FC 300 = 47 – 44 ( 2 )

GMI = 44 – 41

FE 40015 = 37 – 36 ( 2 )

FE 45012 = 37 – 36 ( 2 )

FE 55006 = 35 – 34 ( 2 )

FE 70002 = 32 – 31 ( 2 )

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


CORRESPONDING MATERIALS ACCORDING TO THENORMS OF OTHER ENTITIES

VERSA-BAR is produced according TUPY own norms and its properties are similar to thematerials specified by the norms of the below mentioned entities:

GRAY CAST IRON

TUPYMATERIALS

MATERIALS ACCORDING TO THE NORMSOF OTHER ENTITIES

ABNT ASTM DIN ISO SAENBR 6589 A 48 A 159 1691 R 185 J 434c

FC 200* FC 200 30 G3000 GG 20 GR 20 G3000FC 300 FC 300 40 G4000 GG 30 GR 30 G4000

GMI -- -- -- -- -- --

* without painting

DUCTILE CAST IRON

TUPYMATERIALS

MATERIALS ACCORDING TO THE NORMSOF OTHER ENTITIES

ABNT ASTM DIN ISO SAENBR 6916 A 536 A 897 M 1693 1693 J 431c

FE 40015 FE 38017 60-40-18 -- GGG 40 400-15 D 4018FE 45012 FE 42012 65-45-12 -- -- 450-12 D 4512FE 55006 FE 50007 80-55-06 -- GGG 50 500-7 D 5506FE 70002 FE 70002 100-70-03 -- GGG 70 700-2 D 7003

BAINÍTICOADI 1

-- -- 850/555/101050/700/7

-- -- --

BAINÍTICOADI 2

-- -- 1200/850/41400/1100/1

-- -- --


USEFUL FORMULAS/CONVERSION FACTORS

To calculate the weight/meter in sections:

ROUND

kg/m = D2 x 0,005655where: D = Diameter in millimeter

SQUARE

kg/m = W x W x 0,0072where: W =Width in millimeter

RECTANGULAR

kg/m = W x H x 0,0072

where: W =Width in millimeter

H = Height in millimeter

TO CONVERT OPERATION TO OBTAINPSI x 0,00694 N / mm2

or MPaN / mm2

or MPa x l44 PSIkgf / mm2 x 9,80665 N / mm2

or MPaN / mm2

or MPa x 0,10197 kgf / mm2

Mm x 0,03937 pol.pol. x 25,4 mmMm x 0,00328 pésPés x 304,8 mmLb x 0,4536 kgKg x 2,2046 lbºC (ºC x 1,8) + 32 ºFºF (ºF - 32 ) x 0,556 ºCºC ºC + 273,15 KK K - 273,15 ºC

Documents

TABLE OF CONTENTS - TUPY. Referência em tecnologia … · Continuous Cast Iron - VERSA-BAR 3 INTRODUCTION CAST IRON DEFINITION Gray and Ductile Irons are alloys of iron-carbon-silicon,