Dura-Bar: An Alternative to Steel

Overview

Dura-Bar is an ideal alternative for many steel applications, particularly for carbon steel grades such as 1010, 1018, 1040, 1045, 1141, 1144, 1212, 1214, 1215, 1218, and 12L14. Depending on the application, even some grades of alloy bar are an excellent fit for Dura-Bar.

Many companies are putting Dura-Bar to work in place of traditional steel grades. They are discovering the benefits of continuous cast ductile iron from Dura-Bar. Usually the switch is made because Dura-Bar lowers the cost to produce their part. However, they also realize Dura-Bar doesn't have other issues that plague the steel market, like spot shortages, allocations and fluctuating prices.

Dura-Bar's consistent material performance, distribution network and commitment to customers are unmatched in the industry.

Dura-Bar Chips

Dura-Bar Chips

Steel Chips

Steel Chips

Dura-Bar results in consistent and controllable chip formation, unlike typical steel stringers.

The following chart depicts how the material properties of Dura-Bar 65-45-12 and 80-55-06 ductile iron compare to those of a few common grades of steel.

Material Property Comparison

Material Property Ductile Iron Hot Rolled Steel
65-45-12 80-55-06 1018 AISI 1045 JSI 45C 1117 1144 12L14
Tensile Strength (psi) 65,000 80,000 58,000 81,900 58,900 102,000 57,300
Yeild Strength (psi) 45,000 55,000 31,900 45,000 31,900 60,900 34,100
Elongation (% in 2") 12 6 25 16 25 21 22
Hardness - Average (BHN) 180 229 116 163 116 212 121
Shear Strength (psi) 54,000 72,000 33,060 46,680 33,060 58,140 32,660
Compressive Strength (psi) 110,000 115,000 58,000 81,900 58,000 102,000 57,300
Material Property 65-45-12 80-55-06 1018 AISI 1045
JIS 45C
1117 1144 12L14
Tensile Strength (psi) 65,000 80,000 58,000 81,900 58,900 102,000 57,300
Yield Strength (psi) 45,000 55,000 31,900 45,000 31,900 60,900 34,100
Elongation (% in 2") 12 6 25 16 25 21 22
Hardness - Average (BHN) 180 229 116 163 116 212 121
Shear Strength (psi) 54,000 72,000 33,060 46,680 33,060 58,140 32,660
Compressive Strength (psi) 110,000 115,000 58,000 81,900 58,900 102,000 57,300
Material Property
Ductile Iron
65-45-12
80-55-06
Hot Rolled Steel
1018
AISI 1045
JIS 45C
1117
1144
12L14
Tensile Strength (psi) Yield Strength (psi) Elongation (% in 2") Hardness - Average (BHN) Shear Strength (psi) Compressive Strength (psi)
65,000 45,000 12 180 54,000 110,000
80,000 55,000 6 229 72,000 115,000
58,000 31,900 25 116 33,060 58,000
81,900 45,000 16 163 46,680 81,900
58,900 31,900 25 116 33,060 58,900
102,000 60,900 21 212 58,140 102,000
57,300 34,100 22 121 32,660 57,300

Browse example applications and additional advantages below, or request a Steel Alternative Kit - the kit (available as a .pdf via e-mail or packet via snailmail) addresses machinability, heat treating, applications and more.

Request A Kit


Example Application: Pulley

Steel's Problems

  • Leaded material requires coolant disposal costs
  • Poor surface finish
  • Poor wear resistance

Solutions and Benefits

  • Lead-free Dura-Bar
  • Superior surface finish
  • Excellent grooving and drilling
  • Extended tool life
  • Lower shipping cost due to lighter weight of Dura-Bar
Pulley Made From Dura-Bar
  • Spot Shortages

    Dura-Bar stocks over 500 sizes, available from our distributor network with over 100 locations. Our network of regional and national distributors is the best in the business for stocking, processing and delivering the Dura-Bar product. From specialty distributors to multi-line service centers, they stock a multitude of sizes and shapes and offer a broad mix of services, to meet your individual production needs.

    We stock a broad selection of sizes:

    Shape Size
    Rounds 5/8" to 26"
    Rectangles 2.150" x 2.930" to 18.500" x 22.000"
    Squares 1.250" to 12.250"
    Tubes ID 1.5" to 7" and OD 2.250" to 16"

    All Dura-Bar products are produced in North America and we maintain a sufficient inventory of all sizes to meet historic and current demands. Custom sizes and shapes can be produced in just a few weeks. We are committed to keeping your machines busy.

    Read more

  • Quality

    Dura-Bar understands there is no substitute for quality when you are efficiently running material. Running machines faster (increased capacity) is where most money is made. That kind of production and profitability is not possible with poor quality material.

    Dura-Bar’s commitment to quality starts with a process registered by UL to ISO 9001.

    This total approach to our market allows us to provide our customers with the best, most consistent product possible.

    The only one in the industry backed by a Zero Defect Guarantee

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  • Mill Allocation

    Dura-Bar is committed to long-term relationships. By working closely with our distributors, customers and suppliers, we forecast and plan inventory needs and make sure we have capacity to meet them. This approach to the market has kept us from ever having to resort to any type of mill allocation.

    Our product is made in North America. No waiting for containers to arrive or betting on the fortunes of the overseas markets. We also have a large network of distributors in North America.

    This total approach to our market allows us to provide our customers with the best, most consistent product possible.

    View our Stock Sizes
    View our Distributor Locator

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  • Performance: Mechanical and Physical Properties

    Performance in an application is the ultimate test of a material. There are many grades of steel, generally referred to as low-carbon, medium carbon and alloy steel. Dura-Bar has two primary grades of ductile that can be considered as a replacement for most carbon steel applications and some alloy steel grades.

    Dura-Bar 65-45-12 – An excellent replacement for low-carbon leaded steels as well as rephosphorized and resulfurized free machining grades, including: 1010, 1018, 1020, 1212, 12L14 and 1215. Dura-Bar 80-55-06 – Less machinable than 65-45-12, but has better wear resistance and higher strengths. A good replacement for medium-carbon steels including: 1040, 1045, 1060, 1141 and 1144.

    Dura-Bar excels in applications involving:

    • Wear
    • Compression
    • Shear
    • Thermal Conductivity (Heat transfer)
    • Vibrations and Noise
    • Fatigue Strength
    • Lead Free Material ( No extra chip or coolant disposal costs, environmentally safer)
    • High Pressure

    And in applications where processing includes:

    • Turning
    • Milling
    • Drilling and Tapping
    • Heat treating
    • Surface treatments - plating, oxidizing, etc.

    Most grades of material have differences in some mechanical or physical properties. These attributes are often measured in different ways and many are not important in a given application. All these factors can complicate a material decision.

    Request a Steel Alternative Kit. The kit will contain brochures and tech briefs with product and technical information.

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  • Pricing and Lower Cost Per Part

    Since Dura-Bar is a ferrous-based material, like all steels, it requires steel scrap or pig iron in the manufacturing process. Like all mills, we are not immune to the rise and fall of the raw materials market. To keep the impact of such swings to a minimum, we utilize a monthly raw material surcharge or surcredit that is a straight pass-through of our raw material cost.

    The material cost of Dura-Bar is not where most customers see the real savings. While our product’s in-the-door cost is competitive with many steel grades, the real advantage is Dura-Bar’s excellent machinability. Many customers see a 20 to 50% reduction in machining costs so the out-the-door cost is almost always lower.

    Even if the material cost is higher than carbon steel, the excellent machinability of Dura-Bar can lower your net cost.

    Factor in that iron is 8-10% lighter weight than steel (beneficial for shipping cost and also in certain applications).

    Processes such as carburizing may be eliminated, saving additional time and cost.

    Learn more about our lower price per part.

    Read more

  • Better Machinability

    Dura-Bar is designed with the manufacturer in mind. By producing a product that can be repeatedly machined faster than any other ferrous-based material, you can maximize your production throughput.

    By using Dura-Bar, you will be able to increase your profit margins by machining more parts per hour. You will decrease your cycle time and increase your productivity and capacity...

    • Optimize Your Machining Speeds and Feeds (typical minimum 30% increase), decrease cycle time
    • Increase capacity
    • Lower Your Tooling Costs by Maximizing Tool Life (decrease down time for tooling changes)
    • Reduce Scrap by Using a Defect-Free Material, consistent fine-grained microstructure
    • Chip Control (free machining properties, no complex chip breaker design is required – graphite is a natural chip breaker)
    • Minimal deburring
    • Surface finish similar to steel (easier to achieve and maintain due to nodular graphite structure)

    Together, it all adds up to a lower total cost per part.

    If you are serious about making more parts – and more money, give us a call. It only takes a few minutes with one of our sales engineers to determine if Dura-Bar will work for you.

    Learn more about Machinability

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Applications

Following are examples of parts which originated as steel, but now made from Dura-Bar have gained significant cost-saving and performance benefits.

Hydraulic Manifold

Dura-Bar provided a more machinable material with the needed pressure retention of the application originally manufactured in 1018 steel. The machining cycle time was cut in half and time changing inserts was also reduced.

Download Application Brief >

Compressor Rotor

Dura-Bar 65-45-12 properties and superior quality resulted in reduced machining cycle times, lowered tooling costs and improved balance over steel.

Download Application Brief >

Dura-Bar®
1800 West Lake Shore Drive
Woodstock, IL 60098

815-338-7800

800-BAR-MILL (227-6455)

Fax: 815-338-1549 Sales

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