Recent problems with the availability and pricing of steel have had an upside for some fluid power engineers. Forced to look for every means to cut costs, they have discovered an alternative that not only improves profitability by increasing throughput, but also reduces cost with longer tool life. They have accomplished this feat by simply…replacing carbon steel with Dura-Bar.
This high quality continuous cast ductile iron is ideal for use in the production of manifolds, cylinders, pistons, and other fluid power components. Many component manufacturers have been able to reduce the out-the-door cost of a part by as much as 50%. The savings stem from Dura-Bar's superior machinability that dramatically reduces cycle time, extends tool life, and reduces the cost of heat-treating and secondary operations.
Such savings are not limited to fluid power applications. Manufacturers of metal components used in the power transmission, transportation, machinery, pump and compressor, steel mill, and other industries can all benefit from using Dura-Bar as an alternative to steel.
To get lower out-the-door cost on a per piece basis, the first step is overcoming some common misconceptions about steel versus iron.
The most common misconception that most users of steel have regarding iron comes from comparing steel to sand cast iron with its associated weakness and porosity. Continuous cast ductile iron bar stock is highly machinable, does not have the defects associated with sand castings, and even has lower defects than steel bar stock. In fact, the performance of Dura-Bar iron is comparable to many steels, especially when considering the critical mechanical properties for a specific application.
Domestically manufactured Dura-Bar provides a relative tool life that exceeds steel and allows operation at higher machine speeds. The key to Dura-Bar's edge in machinability is the unique continuous casting process used to produce it. This tightly controlled production process eliminates the porosity, inclusions, and other defects commonly associated with sand castings making it a consistent material, heat after heat.
Make the Transition:
So confident is Dura-Bar about its improved quality over other materials that all Dura-Bar products come with the company’s Defect-Free Guarantee. This unique guarantee covers not just the material, but also direct labor costs incurred when machining if a foundry defect is found. In most cases, switching to Dura-Bar requires relatively minor changes to existing machining and procurement processes.