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VERSA-BAR


Continuous Cast Iron

Technical Catalogue

CONTINUOUS CAST IRON


Continuous Cast Iron - VERSA-BAR

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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
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INTRODUCTION
CAST IRON DEFINITION

Gray and Ductile Irons are alloys of iron-carbon-silicon, with tenors of carbon
usually above 2,0%, in quantity superior of the one that can be retained in solid
solution 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 the
selection of the most appropriate cast iron grade depends a lot on its
application.

Combinations of different formats of graphite with different structures of


matrix, result in a large variety of grades, and certainly one of them will attend
the necessary performance, assurance and quality requirements.

The constant evolution of the casting technology of the cast irons has
contributed more and more to the development of new applications, allowing
thus, more economical alternatives enabling to obtain quality products.

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


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PRESENTATION OF VERSA-BAR

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

1. Molten Metal
2. Filling Spout
3. Holding Furnace
4. Water Cooled Graphite Die
5. Roller Supports
6. Distribution Panel
7. Drawing Unit
8. Cut-off machine
9. Break-off Unit
10. Stock Size - VERSA-BAR
11. Water inlet and outlet
12. Water Cooling Jacket
13. Cast Bar

Fig. 2 - Production Process by Continuous Casting


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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 of
high responsibility can be produced without the risks or imperfections in service related to
material 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.


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ADVANTAGES OF VERSA-BAR

ABSENCE OF POROSITIES

Porosities are casting defects that occur internally to the piece and present, generally, round shape
and smooth internal surface, also being possible to be presented with elongated aspect and
different 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 does
not discharge gases while submitted to high temperatures. Besides, the gas sources
already mentioned do not exist. in bars produced by continuous casting process, the
presence 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 the
gas 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 the
solidification of the cast irons, certifying, thus a perfect feeding of the piece and as a
consequence the absence of gas holes.

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


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


The density difference of approximately 10% less in VERSA-BAR compared to the steels, is
due 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 (cooling
modulus), 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 fundamental
characteristic 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 casting
process 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 inclusions
or surface defects and the good as cast surface finish, also contribute to the reduction of the over
material for machining.
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SUPERIOR MACHINABILITY

Due to the uniformity of its microstructure, absence of superficial abrasive inclusions (sand
residues), 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 cast
irons.


While compared to the steels, the superior machinability of VERSA-BAR is due mainly to the
presence 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 of
productivity.

ALLOYS OF HIGH RESISTANCE

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

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

The ductile cast irons submitted to heat treatment of austempering are indicated to the
manufacturing of gears, valve guides, pins, bushings, and other components that require a good
tenacity 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 will
eliminate the high expenses with casting toolings and the long time to obtain them, reducing
significantly the final cost of the product specially in what concerns to low demand items as
prototypes, pieces that will be submitted to future alterations, pieces to be used in maintenance
and others.
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SURFACE TREATMENTS


VERSA-BAR admits the application of the most different surface treatments, aiming in each
situation 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), treatment
with 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 conventional
process 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 is
extremely expensive, since there are losing of raw material, labour and machine time to the
productive process.
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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


Manifolds
Plungers
HYDRAULIC AND PNEUMATIC Cylinder Caps
Cylinder Head
Valve Body
Molds
Pins
Punches
GLASS INDUSTRY Neck Rings
Core Boxes
Pulleys
Coupling
Sheaves
Axles
Straightedges
Bushings
MACHINES AND EQUIPMENTS Washers
Nuts
Gears
Pins
Counterweights
Tables
Flanges
Bearings
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MARKET SEGMENT COMPONENTS


Bearing Caps
Distance Rings
Brake Pistons
AUTOPARTS Rings
Valve guides
Command axles
Valve seats
Protector tube for thermocouplings
Matrixes
Retainers
OTHERS Cones
Plugs
Valve Plates
Rollers
Dies


These examples show the versatility of VERSA-BAR that follows an enormous
diversity of segments from simple applications as washers and pulleys to complex
applications 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 our
technical division by the telephone nº (005547) 441-8421 or (005547) 441-8305.

In USA contact is by the telephone 0014145444800 American Iron & Alloys Co. Tool
Free 8005444800.
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GRAY IRON

DESCRIPTION OF GRADES

The gray cast irons produced by continuous casting process, whose dominant structural
characteristic 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 the
graphite.

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

On the other hand, the cast gray iron grades of larger mechanical resistance (FC 300) present
more refined graphite and a matrix essentially pearlitic, providing to these materials a better
surface finish and a higher hardness .
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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 the
toolings, certifying thus strait dimensional tolerances. This material is recommended to
applications 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 predominantly
pearlitic with 5 to 20% of ferrite. The rim consists of type D graphite, size 6-8 and essentially
ferritic matrix with 5% maximum of well dispersed carbides.

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


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

Dimensions Hardness Strength Limit


( mm ) ( HB ) ( MPa ) mín.
Till 27,6 163 – 207 200
27,7 - 43,4 163 – 207 190
43,5 - 63,1 163 – 207 180
63,2 - 79,0 163 – 207 170
79,1 - 92,1 163 – 207 160
92,2 – 111,5 163 – 207 150
111,6 - 124,2 163 – 207 140
124,3 - 143,6 163 – 207 130
143,7 - 254,1 163 - 207 125

CHEMICAL COMPOSITION

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

Element %
C1 2,90 - 3,90
Si 2,20 - 2,60 Note: 1 - The carbon grades are specified to each
Mn 0,40 - 0,60 dimensional group in a way to control the type and
S 0,05 - 0,25 size of the graphite. The variation in the same
P 0,10 máx. grade is approximately 0,20%.
Cr 0,05 máx.
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FC 300 - PEARLITIC GRAY IRON

DESCRIPTION


VERSA-BAR FC 300 is a gray cast iron with totally pearlitic structure that provides to it high
mechanical properties and a good surface finish. Another important characteristic to be
mentioned is the good leaking resistance, that allied to the above mentioned properties, makes
possible its utilization in pieces applied to hydraulic components subjected to high pressures as
manifolds, 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 of
well dispersed carbides.

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


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

Dimensions Hardness Strength Limit


( mm ) ( HB ) ( MPa ) mín.
Till 27,6 229 – 285 270
27,7 – 53,0 197 – 269 250
53,1 – 79,0 197 – 269 240
79,1 – 104,8 197 – 269 230
104,9 – 156,3 197 – 269 205
156,4 – 260,5 179 – 255 185
260,6 – 345,0 179 – 255 170
345,1 – 476,6 179 – 255 160

CHEMICAL COMPOSITION

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

Element %
C1 2,80 - 3,70 Note: 1 - The carbon grades are specified to each
Si 2,20 - 2,60 dimensional group, in a way to control the
S 0,05 - 0,25 type and size of the graphite. The
P 0,10 máx. variation in the same grade is
Cr 0,05 máx. approximately 0,20%.
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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 an
extremely refined graphite, providing to it an excellent surface finish. It is also well known by its
excellent machinability and good heat conductivity.

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

MICROSTRUCTURE


The typical microstructure of VERSA-BAR GMI consists of refined graphite, form VII, Type
D (80% min.), size 6-8, as defined in ASTM A247. The matrix is ferritic with approximately
15% of pearlite with 5% maximum of well dispersed carbides.

Fig. 10 - Typical microstructure of GMI.


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MECHANICAL PROPERTIES


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

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

CHEMICAL COMPOSITION

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

Element %
C1 3,40 – 4,00
Si 2,20 - 2,60 Note: 1 - The carbon grades are specified to each
Mn 0,20 máx. dimensional group and the variation in the same
S 0,02 máx grade is approximately 0,20%.
P 0,10 máx.
Cr 0,05 máx. 2 - Titanium is added to generate Type D graphite.
Ti2 0,30 máx.

TYPICAL APPLICATIONS

- Moulds and accessories to the glass industry


- Brake pistons
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DUCTILE IRON

DESCRIPTION OF GRADES

The ductile cast irons produced by continuous casting process whose dominant structural
characteristic 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 some


chemical elements or specific production conditions that modify the way of its growth. This type
of material is recommended to pieces that require high mechanical properties, high tenacity and
excellent leaking resistance.

Besides of the graphite format, the quantities of ferrite and/or pearlite in the matrix determine the
mechanical 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 700
MPa with elongation from 2% to 15%.
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FE 40015 - FERRITIC DUCTILE IRON

DESCRIPTION


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

This material presents tensile and yield strength limits similar to hot laminated steels SAE 1020
in 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.
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MECHANICAL PROPERTIES


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 taken
from the mid-radius of the bar.

Dimensions Hardness
( mm ) ( HB )
27,6 – 208,0 131 – 207
208,1 – 451,2 121 – 207

Tensile strength limit (MPa) = 400 min.

Yield strength limit (MPa) = 270 min.

Elongation (%) = 15 min.

CHEMICAL COMPOSITION

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

Element %
C1 3,30 – 3,80 Note: 1 - The carbon grades are specified to each
Si 2,60 - 3,00 dimensional group and the variation in the same
Mn 0,20 máx. grade is approximately 0,20%.
S 0,02 máx
P 0,10 máx. 2 - Magnesium is added to generate spheroidal
Mg2 0,04 – 0,07 graphite.
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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 1030
in the as cast condition.

This specification is similar to ASTM A536, grade 65 - 45 - 12.

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 with
25% pearlite maximum and 5% maximum of well dispersed carbides.

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


The typical hardness, tensile and yield strength limit and elongation values of VERSA-BAR
FE 45012 are listed below and refer to the results showed by longitudinal test specimen taken
from the mid-radius of the bar.

Dimensions Hardness
( mm ) ( HB )
27,6 – 79,0 156 – 217
79,1 – 156,3 143 – 217
156,4 – 451,2 131 – 217

Tensile strength limit (MPa) = 450 min.


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

CHEMICAL COMPOSITION

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

Element %
C1 3,30 – 3,80 Note: 1 - The carbon grades are specified to each
Si 2,60 - 3,00 dimensional group an the variation in the same
Mn 0,20 máx. grade is approximately 0,20%.
S 0,02 máx
P 0,10 máx. 2 -Magnesium is added to generate spheroidal graphite.
Mg2 0,04 – 0,07
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FE 55006 – PEARLITIC / FERRITIC DUCTILE IRON

DESCRIPTION


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

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

This specification is similar to ASTM A536, grade 80 - 55 - 06.

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 with
approximately 50% of ferrite and 5% maximum of well dispersed carbides.

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


The typical hardness, tensile and yield strength limit and elongation values of VERSA-BAR
FE 55006 are listed below and refer to the results showed by longitudinal test specimen taken
from the mid-radius of the bar.

Dimensions Hardness
( mm ) ( HB )
27,6 – 37,1 229 – 269
37,2 – 79,0 217 – 269
79,1 – 195,3 207 – 255
195,4 – 451,2 187 – 255

Tensile strength limit (MPa) = 550 min.

Yield strength limit (MPa) = 380 min.

Elongation (%) = 6 min.

CHEMICAL COMPOSITION

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

Element %
C1 3,30 – 3,80
Si 2,60 - 3,00 Note: 1 - The carbon grades are specified to each
Mn 0,20 – 0,65 dimensional group and the variation in the same grade
S 0,02 máx is approximately 0,20%.
P 0,10 máx.
Cu 0,10 – 0,25 2 - Magnesium is added to generate spheroidal
Mg2 0,04 – 0,07 graphite.
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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 matrix
provides high temperability, allowing the execution of heat treatments as tempering, normalizing
and 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 the
as cast condition.

This specification is similar to ASTM A536, grade 100 - 70 - 03.

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 predominantly
pearlitic 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.
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MECHANICAL PROPERTIES


The typical hardness, tensile and yield strength limit and elongation values of VERSA-BAR
FE 70002 are listed below and refer to the results showed by longitudinal test specimen taken
from the mid-radius of the bar.

Dimensions Hardness
( mm ) ( HB )
27,6 – 79,0 241 – 302
79,1 – 195,3 241 – 285
195,4 – 451,2 229 – 269

Tensile strength limit (MPa) = 700 min.

Yield strength limit (MPa) = 480 min.

Elongation (%) = 2 min.

CHEMICAL COMPOSITION

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

Element %
C1 3,30 – 3,80
Si 2,60 - 3,00 Note: 1 - The carbon grades are specified to each
Mn 0,20 – 0,65 dimensional group and the variation in the same grade
S 0,02 máx is approximately 0,20%.
P 0,10 máx.
Cu 0,10 – 0,25 2 - Magnesium is added to generate
Mg2 0,04 – 0,07 spheroidal graphite.
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STANDARD DIMENSIONS

ROUND BARS
As Cast Recommended Dimensional Theoretical
Dimension Machining in Tolerance Weight
FC200 FC300 FE45012 FE55006
(mm) the Diameter (mm) (kg/m)
18.0 1.8 •
21.2 2.5 •
22.2 2.8 •
27.6 4.3 • • • •
30.7 5.3 • • •
33.9 2.2 + / - 0.30 6.5 • • • •
37.1 7.8 • • • •
40.3 9.2 • • •
43.4 10.7 • • • •
46.6 12.3 • • • •
49.8 14.0 • • •
53.0 15.9 • • • •
56.8 18.2 • • • •
59.9 20.3 • • •
63.1 22.5 • • • •
66.3 2.8 + / - 0.80 24.9 • • • •
69.5 27.3 • • •
72.6 29.8 • • • •
75.8 32.5 • • •
79.0 35.3 • • • •
82.6 38.5 • • • •
85.7 41.6 • • •
88.9 44.7 • • • •
92.1 3.2 + / - 1.00 47.9 • • • •
95.3 51.3 • • •
98.4 54.8 • • • •
101.6 58.4 • • •
104.8 62.1 • • • •
111.5 70.3 • • • •
113.6 73.0 •
117.9 3.6 + / - 1.10 78.5 • • • •
124.2 87.2 • • • •
130.6 96.4 • • •
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As Cast Recommended Dimensional Theoretical


Dimension Machining in Tolerance Weight
FC200 FC300 FE45012 FE55006
(mm) the Diameter (mm) (kg/m)
137.3 106.6 • • • •
143.6 116.7 • • • •
150.0 3.9 + / - 1.40 127.2 • • •
156.3 138.2 • • • •
163.1 150.4 • • • •
169.4 162.3 • • •
175.8 4.3 + / - 1.60 174.7 • • • •
182.1 187.6 • • • •
189.0 201.9 • • •
195.3 215.7 • • • •
201.7 4.8 + / - 2.10 230.0 • • •
208.0 244.7 • • • •
215.0 261.5 • • • •
221.4 277.2 • • •
227.7 5.5 + / - 2.70 293.3 • • • •
234.1 309.9 • • • •
241.4 329.5 • • •
247.8 347.1 • • • •
254.1 6.5 + / - 3.30 365.1 • • • •
260.5 383.6 • • •
270.5 413.8 • • •
276.9 10.2 + / - 3.80 433.5 • • •
289.6 474.1 • • •
306.9 532.6 • • •
319.6 577.5 • • •
332.3 624.4 • • •
345.0 14.8 + / - 5.20 673.0 • • •
370.4 775.8 • • •
395.8 885.8 • • •
421.2 1003.1 • • •
451.2 19.3 + / - 6.60 1151.0 • • •
476.6 1284.2 • • •
Continuous Cast Iron - VERSA-BAR

30

RECTANGULAR BARS - FC 300

As Cast Recommended Machining Maximum Theoretical


Dimension per face Swelling Weight
(mm) (mm) (mm) (kg/m)
31,7 x 57,1 2,3 2,9 13,0
31,7 x 82,5 2,6 4,2 18,8
31,7 x 107,9 3,2 6,3 24,6
31,7 x 133,3 3,2 6,3 30,4
31,7 x 158,7 4,8 8,9 36,2
31,7 x 260,3 4,8 11,7 59,4
38,1 x 57,1 2,3 2,9 15,7
38,1 x 82,5 2,6 4,2 22,6
38,1 x 107,9 2,6 4,2 29,6
38,1 x 133,3 3,2 6,3 36,6
38,1 x 158,7 3,2 6,3 43,5
44,4 x 50,8 2,3 3,1 16,2
44,4 x 107,9 2,6 4,4 34,5
44,4 x 114,3 2,6 4,4 36,5
44,4 x 158,7 3,2 6,7 50,7
50,8 x 63,5 2,3 3,1 23,2
50,8 x 92,1 2,3 3,1 33,7
57,1 x 82,5 2,3 3,1 33,9
57,1 x 107,9 2,3 3,1 44,4
57,1 x 133,3 2,6 4,4 54,8
57,1 x 158,7 2,6 4,4 65,2
57,1 x 209,5 3,2 6,7 86,1
63,5 x 158,7 2,6 4,4 72,6
63,5 x 184,1 2,6 4,4 84,2
63,5 x 209,5 3,2 6,7 95,8
76,2 x 209,5 4,8 4,8 114,9
82,5 x 107,9 2,6 3,4 64,1
82,5 x 260,3 6,3 7,2 154,6
107,9 x 133,3 2,8 3,6 103,6
139,7 x165,1 2,8 3,6 166,1
177,8 x 406,4 6,3 5,9 520,3
209,5 x 361,9 3,2 3,9 545,9
Continuous Cast Iron - VERSA-BAR

31

SQUARE BARS - FC 300

As Cast Recommended Machining Maximum Theoretical


Dimension per face Swelling Weight
(mm) (mm) (mm) (kg/m)
31,7 2,3 2,9 7,2
38,1 2,3 2,9 10,5
41,3 2,3 3,1 12,3
44,4 2,3 3,1 14,2
50,8 2,3 3,1 18,6
57,1 2,3 3,1 23,5
63,5 2,3 3,1 29,0
69,8 2,6 3,4 35,1
76,2 2,6 3,4 41,8
82,5 2,6 3,4 49,0
88,9 2,6 3,4 56,9
95,2 2,6 3,4 65,2
107,9 2,8 3,6 83,8
120,6 2,8 3,6 104,7
133,3 2,8 3,6 127,9
158,7 3,2 3,9 181,3
184,1 3,2 3,9 244,0
209,5 3,2 3,9 316,0
234,9 4,8 4,1 397,3
260,3 4,8 4,1 487,8
311,1 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 special
requested dimensions, shapes and materials in order to attend specific properties required in
some situations as heating, corrosion and wear resistance.


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

32

ADDITIONAL INFORMATION

OTHER PROPERTIES

Usually the gray and ductile cast irons are commercially specified by the Tensile Strength and
Hardness 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 most
adequate material and in most of the time, it is possible to bring them into relation with the
Tensile Strength (SL) and / or Hardness Limits.

PROPERTIES GRAY IRON DUCTILE IRON


(1)
Shear Resistance (MPa) 1,15 x LR 0,90 x LR ( 3;5 )
Torsion Resistance (MPa) 1,15 x LR (1) 0,90 x LR ( 3;5 )
FE 40015 = 0,50 x LR ( 3 )
Fatigue Resistance (MPa) 0,40 x LR ( 4;5 ) FE 45012 = 0,45 x LR ( 3 )
(without notch) FE 55006 = 0,40 x LR ( 3 )
FE 70002 = 0,40 x LR ( 3 )
LR de 140-175 x 4,02 ( 5 )
Compression Strength (MPa) LR de 176-200 x 3,68 ( 5 ) ----------
LR de 211-245 x 3,61 ( 5 )
LR de 246-280 x 3,39 ( 5 )
FE 40015 = 15 – 13 ( 2 )
Impact Resistance FE 45012 = 10 - 5 ( 2 )
(with notch 20ºC) ---------- FE 55006 = 5 - 2 ( 2 )
FE 70002 = 5 - 2 ( 2 )
FC 200 = 88 – 113 ( 1 ) FE 40015 = 169 ( 2 )
Elasticity Modulus (GPa) FC 300 = 108 – 137 ( 1 ) FE 45012 = 169 ( 2 )
GMI = 78 – 107 ( 1 ) FE 55006 = 169 ( 2 )
FE 70002 = 172 – 176 ( 2 )
FC 200 = 51 – 48 ( 2 ) FE 40015 = 37 – 36 ( 2 )
Heat Conductivity FC 300 = 47 – 44 ( 2 ) FE 45012 = 37 – 36 ( 2 )
W / m.K 100ºC / 400ºC GMI = 44 – 41 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
Continuous Cast Iron - VERSA-BAR

33

CORRESPONDING MATERIALS ACCORDING TO THE


NORMS OF OTHER ENTITIES


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

GRAY CAST IRON

TUPY MATERIALS ACCORDING TO THE NORMS


MATERIALS OF OTHER ENTITIES
ABNT ASTM DIN ISO SAE
NBR 6589 A 48 A 159 1691 R 185 J 434c
FC 200* FC 200 30 G3000 GG 20 GR 20 G3000
FC 300 FC 300 40 G4000 GG 30 GR 30 G4000
GMI -- -- -- -- -- --

* without painting

DUCTILE CAST IRON

TUPY MATERIALS ACCORDING TO THE NORMS


MATERIALS OF OTHER ENTITIES
ABNT ASTM DIN ISO SAE
NBR 6916 A 536 A 897 M 1693 1693 J 431c
FE 40015 FE 38017 60-40-18 -- GGG 40 400-15 D 4018
FE 45012 FE 42012 65-45-12 -- -- 450-12 D 4512
FE 55006 FE 50007 80-55-06 -- GGG 50 500-7 D 5506
FE 70002 FE 70002 100-70-03 -- GGG 70 700-2 D 7003
BAINÍTICO -- -- 850/555/10 -- -- --
ADI 1 1050/700/7
BAINÍTICO -- -- 1200/850/4 -- -- --
ADI 2 1400/1100/1
Continuous Cast Iron - VERSA-BAR

34

USEFUL FORMULAS/CONVERSION FACTORS

To calculate the weight/meter in sections:

ROUND

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

SQUARE

kg/m = W x W x 0,0072
where: 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 OBTAIN


2
PSI x 0,00694 N / mm or MPa
N / mm2 or MPa x l44 PSI
kgf / mm2 x 9,80665 N / mm2 or MPa
N / mm2 or MPa x 0,10197 kgf / mm2
Mm x 0,03937 pol.
pol. x 25,4 mm
Mm x 0,00328 pés
Pés x 304,8 mm
Lb x 0,4536 kg
Kg x 2,2046 lb
ºC (ºC x 1,8) + 32 ºF
ºF (ºF - 32 ) x 0,556 ºC
ºC ºC + 273,15 K
K K - 273,15 ºC

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