Dura-Bar Product & Process
Can I buy direct from Dura-Bar?
If the ductile grade 60-40-18 is easier to machine, why does Dura-Bar offer 65-45-12?
What is Dura-Bar Plus?
What is the "bullseye"?
What is the pressure rating of Dura-Bar?
What is the typical lead time for specials?
What size should I order to make sure I have enough material to clean-up to my major dimension?
Where can I purchase Dura-Bar?
Material Substitution & Advantages
How can I get my customers to specify Dura-Bar on their print?
How can I get started with my application?
How does the price of Dura-Bar compare to steel?
Is Dura-Bar a good alternative for all steel applications?
What are the most popular Dura-Bar grades used in place of steel?
What factor is most often cited for switching to Dura-Bar?
What influences most properties of cast steel?
What is the advantage of Dura-Bar versus other irons?
What is the difference between iron and steel?
What is the single best factor in determining the use of Dura-Bar?
Why is Dura-Bar lighter than steel and by how much?
Machining and Processing of Dura-Bar
Can Dura-Bar be heat-treated?
Can Dura-Bar be plated, coated or painted?
Can Dura-Bar be welded?
Do I need extra filtration to run iron?
How long will inserts and other tooling last with Dura-Bar?
How much faster can Dura-Bar be machined than steel?
Why is iron "dirty" and won't it harm my machine ways and slides?
Dura-Bar Product & Process
Can I buy direct from Dura-Bar?
Dura-Bar is a mill. Our focus is on producing the highest quality product on the market as competitively as possible. We have Sales Engineers that work with the customer to provide the full resources of our organization.
Our network of distributors are the best at cost effectively stocking and serving a varied range of users, close to the customer. It is rare that one of them cannot meet all the customer’s requirements.
Try our convienent Distributor Locator.
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If the ductile grade 60-40-18 is easier to machine, why does Dura-Bar offer 65-45-12?
The heat-treat cost to achieve 60-40-18 is unnecessary in most instances. A well controlled continuous cast process, like Dura-Bar, produces 65-45-12. To achieve 60-40-18, the bars have to be annealed and that adds cost. The actually machinability between a consistently cast 65-45-12 and an annealed 60-40-18 is almost negligible.
Some foundries will add a full anneal to mask or eliminate inconsistencies in their casting process, such as poor rim control, carbides and hard spots.
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What is Dura-Bar Plus?
Several years ago, Dura-Bar did an in-depth study of the continuous casting process and how it affected machinability. The process changes made from that study are what give all grades of Dura-Bar their excellent machining characteristics. When we first introduced the improved product, we called it, Dura-Bar Plus. Since that time, we have dropped the “Plus” addition to the name, but the unique machining benefits remain.
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What is the "bullseye"?
This is the lighter colored area below the rim of the bar, when viewed at a cross-section. This area exhibits equilibrium type(s) of graphite.
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What is the pressure rating of Dura-Bar?
Pressure ratings are dependent on the design of the application. Dura-Bar is often used for pressures between 3,000 and 8,000 psi, but higher pressures have been achieved. Also, the compressive strength of Dura-Bar allows for a smaller product design versus other materials.
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What is the typical lead time for specials?
Dura-Bar can normally respond with runs of special items within 8 weeks. Modifications of standard sizes (lengths, inside diameter of tubes, special grades) are often quicker.
Non-standard sizes or special profiles also fall in this time frame. All specials go through our APQP process to insure we can provide you with quality product. Contact us with any questions or ideas you may have, at sales@dura-bar.com
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What size should I order to make sure I have enough material to clean-up to my major dimension?
Dura-Bar produces all round material to a nominal dimension. Enough clean-up stock has been added to allow finish machining to the listed size. For example, a 3.00” diameter, as-cast bar will actually have .125” stock allowance for clean-up. Stock allowance varies by diameter and grade. To check the size you need, click here.
Rectangles and squares are listed at their as-cast size and clean-up below the listed size. For detail on the size you need, click here.
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Where can I purchase Dura-Bar?
Dura-Bar is distributed across North America through an authorized distributor network. Both national and regional distributors are available to meet your needs. Try our convenient Distributor Locator.
For purchases outside North America, please contact us directly at sales@dura-bar.com.
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Material Substitution & Advantages
How can I get my customers to specify Dura-Bar on their print?
Dura-Bar has been used to offer cost savings to a machine shop’s customer. Most companies are looking for ways to cut component cost. By suggesting Dura-Bar to the end user, the machine shop is able to lower the customer’s part cost without losing profit margin. We will be happy to provide the information needed to support the case for adding Dura-Bar to the print.
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How can I get started with my application?
The easiest way is to give it a try. If you are not ready for that, simply contact us. By answering a few questions, we can quickly determine if it makes sense to consider Dura-Bar. Each case can be different and we are experts at providing the support you need to decide if Dura-Bar is right for you.
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How does the price of Dura-Bar compare to steel?
The wide variety of steel offerings makes direct price comparison difficult. In general, Dura-Bar is on the higher end of carbon steel pricing. The cost savings come from the increased machinability and throughput. Most successful users realize the total cost benefit of the finished product. We will be happy to help you compare and see if it makes sense to use Dura-Bar.
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Is Dura-Bar a good alternative for all steel applications?
No, it depends on the form of the product and the needs of the application.
Dura-Bar is a bar product. It is made as rounds, squares, rectangles, cut-plate, tubes and special shapes. It is NOT produced as sheet, coil, strip, structural, wide plate or thin-walled tube product.
In general, it matches up well for applications made from low- and medium-carbon steels; some alloy steels and aluminum. Occasionally it can replace tool steel and stainless steel.
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What are the most popular Dura-Bar grades used in place of steel?
Dura-Bar 65-45-12 is the first choice, because it is the best machining and it can be easily heat treated. Dura-Bar 80-55-06 is second for applications requiring more strength or eliminating a heat treat operation. In fact, 95% of Dura-Bar ductile applications were once made from steel.
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What factor is most often cited for switching to Dura-Bar?
That's easy, it's total cost savings. Most new uses for Dura-Bar come from applications that are heavily machined. Dura-Bar allows the part to be made for less cost and in less time than with alternative materials. Typically there will be several other benefits of using Dura-Bar that also make the switch attractive.
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What influences most properties of cast steel?
The type and distribution of precipitated graphite.
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What is the advantage of Dura-Bar versus other irons?
Machinability. The number one benefit of the Dura-Bar process is the consistency of our product from heat to heat. Anyone concerned with machining parts as quickly as possible, on a repetitive basis, should take a hard look at Dura-Bar.
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What is the difference between iron and steel?
The actual chemistry of steel and iron is similar. Very simply, there is more carbon added to pure iron to produce cast iron. The additional carbon is converted in the microstructure to graphite. This graphite gives iron the natural chip breaking benefits that allow you to machine iron so much faster than steel. It also presents a ready reserve of carbon for heat treating of the part and makes it lighter.
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What is the single best factor in determining the use of Dura-Bar?
Total cost savings. Most new uses for Dura-Bar come from applications that are heavily machined. Dura-Bar allows the part to be made for less cost and in less time than with alternative materials. Typically there will be several other benefits of using Dura-Bar that also make the switch attractive.
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Why is Dura-Bar lighter than steel and by how much?
Dura-Bar is generally 8-10% lighter than steel. This is due to the graphite found in the matrix. The graphite is surrounded by an iron matrix. Steel has similar iron matrices. Since the graphite in iron makes up about 10% of the matrix, iron is that much lighter.
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Machining and Processing of Dura-Bar
Can Dura-Bar be heat-treated?
Yes and often by the same methods as steel. A major benefit of Dura-Bar is that the graphite in the matrix eliminates the need for carburization. Post heat-treat hardness levels are in the Rc50 range with wear properties better than most heat treated steels.
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Can Dura-Bar be plated, coated or painted?
Yes, in fact you can do with Dura-Bar almost anything done to steel. In some cases the process is slightly different, but we can help with that. Daily Dura-Bar parts can handle zinc-oxide, black-oxide, nickel plating, etc.
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Can Dura-Bar be welded?
Yes, but the process is different from steel. Typically you use a nickel based welding rod. Often your current welding supply vendor or the manufacturer can provide additional detail. We also will be glad to assist.
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Do I need extra filtration to run iron?
No, most systems today are fully capable of handling iron. The ductile iron in particular makes a good chip. Some shops that run iron all the time will add a bag filter system. They are relatively inexpensive and seem to improve surface finish and extend coolant life.
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How long will inserts and other tooling last with Dura-Bar?
The answer depends on the current material and how aggressive the machining. In general, inserts used on Dura-Bar 65-45-12 will last up to 2.5 times longer than they did with steel.
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How much faster can Dura-Bar be machined than steel?
The answer depends on the steel being run, but Dura-Bar 65-45-12 can turn up to 3 times faster, mill 1.5 times faster and drill 2.5 times faster. We will be glad to help set up a test to compare. For a quick look at Dura-Bar versus your current material, check out our
Machine Savings Calculator.
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Why is iron "dirty" and won't it harm my machine ways and slides?
Traditionally there are two components to iron that make it appear “dirty”. The first is the graphite found in the matrix. Graphite is a natural lubricant and will not harm machine tools. The other component that creates grittiness actually comes from the static cast process that uses a hard sand mold to form the casting.
Dura-Bar is a continuous cast product and does not use sand in the process. Furthermore, the ductile grades produce a solid chip that helps contain the matrix graphite much better than gray iron.
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