1．General Introduction

There are more than 30 years history for horizontal continuous casting iron, which is called dense bars abroad. Continuous cast iron is an engineered metal produced with advanced technical processes making it not only the finest cast iron in the world but a superior alternative to steel, castings and aluminum. Both the cast iron bars process and the unique metallurgical properties inherent to the material can provide many cost saving advantages for the production of your metal components。

2．Producing characteristic of continuous casting iron bar material

The manufacturing methods of horizontal continuous casting i is the following. A water-cooled graphite die that is machined to form the shape of the bar is mounted on a bar machine crucible. As the bar is pulled horizontally from the crucible, the ferrostatic head pressure feeds the molten iron core producing a fine-grained cast iron.

3．Advantages of Continual Casting Iron Bars

Continuous iron casting process typically equates to unparalleled value for those needing an engineered metal for their component production. Continuous cast iron bars offers numerous physical and structural advantages over steel, sand castings and aluminum because of the unique manufacturing methods. The ability to combine various graphite structures with different matrix structures (ferritic versus pearlitic) results in a variety of grades with several properties. That means cast iron bars can be tailored in a way that best meets your needs. In addition, cast iron bars process enables the material's microstructure to be free from shrinkage, gas holes, sand and other tool-wearing inclusions.

So how is all this beneficial to the customer? With cast iron bars, you can lower your overall costs and improve part performance. Making your parts run quieter, increasing your tool life and saving you money are just a few of the many benefits you can realize by using cast iron bars. Please look below at the additional advantages cast iron bars offers.

Additional cast iron bars advantages:

Corrosion Resistance:

Corrosion resistance is not a specific property of a metal but a characteristic that depends on the conditions of exposure and the quality of performance that is required. All cast iron bars have two constituents in their microstructure, graphite and the matrix structure. Graphite will withstand a wide variety of chemical and atmospheric conditions and the matrix structure will behave similar to non-alloyed steel under the same conditions.

cast iron bars ni-resist, having an austenitic matrix, is the most corrosion resistant grade, although even standard grades of cast iron bars may be suitable depending on the environment.

Fatigue Strength:

Fatigue strength is primarily influenced by the graphite size and shape and will also be affected by the matrix structure. Cast iron bars continuous casting process and strict metallurgical controls result in a uniformly dense, fine-grained microstructure essentially free of porosity, sand and other inclusions, that can affect the endurance ratio severely lowering fatigue life. Cast iron bars has optimal strength in tension, compression and fatigue versus sand castings. Ductile irons having nodular graphite will have the highest endurance ratio.

Heat Treat Response：

Cast iron bars have excellent response to heat treating. An achievable matrix hardness of HRC60 and an average hardness of HRC50 are possible.

Machinability：

Cast iron bars continuous casting process and the product's graphite properties result in faster machining (as much as 30%) and less scrap over carbon and alloy steels. The superior machinability is possible due to the graphite in cast iron bars giving it natural chip breaking abilities and resulting in precision machining at optimal speeds. The material being removed will either come off in long stringers or small chips, commonly known as free machining.

Manufacturing Process：

Continuous iron casting was originally developed in Europe after World War II as an alternate method of producing cast iron bar stock without patterns and conventional molding methods. Hua-an cast iron bar works is the largest manufacturer of continuous cast iron bar stock in Asia.

The only part of the bar that is solidified when it exits the die is an outer skin; the core is molten iron. The entire bar cools in air until it is notched and broken off in standard lengths. The rim has a finer graphite structure in a matrix that is more ferritic than that in the center.

The most notable characteristic of continuous cast iron is its fine-grained, dense, as-cast microstructure. Since the bar is pulled from the bottom of the holding crucible, dross, slag and other impurities float to the top, away from the opening of the die

Reduced Scrap：

The metallurgical properties of cast iron bars means better machinability resulting in little or no scrap. The Hua-an bars continuous casting process and rigorous on-line and laboratory testing procedures detect any imperfections before shipment to the customer. In contrast to normal scrap rates of 10 to 40% with iron castings, users of continuous cast bars can virtually eliminate scrap.

Surface Finish：

Cast iron bar's fine grained microstructure allows excellent surface finishes after machining. Optimal surface finishes are achieved with fine flake size. Coarse graphite flakes can lead to tearing of the material during machining resulting in a rougher finish. Slight modifications in tooling and machining conditions will correct this condition. Surface finishes to 10 RMS can be achieved without secondary operations such as grinding and honing. Machined finishes of 32 RMS are typical, however single-digit values are readily obtainable.

The need for deburring is virtually eliminated. Parts are free from dross slag and other tool wearing inclusions. The superior finish, free from sand inclusions, results in longer tool life.

Thermal Conductivity ：

Cast iron bars irons have excellent thermal conductivity due to the presence of graphite. This is an advantage in applications such as permanent molds and glass molds. Coarse flake graphite in a ferritic matrix has a thermal conductivity value of approximately 2 times that of low carbon steel.

Vibration Damping ：

The graphite composition in Cast iron bars gives it a much higher damping capacity than low carbon steel, cushioning vibrations as they are transmitted through a part. This ability to dampen vibrations results in a quieter product than is possible with a steel product manufactured to the same dimensional tolerances and with similar surface finishes. Gray cast iron bar has at least ten times the damping capacity of low carbon steel and ductile cast iron bar has three times the capacity.

When three "chimes", same size pieces, of gray iron, ductile iron and steel are each struck, the vibration and ringing sound resonate for different lengths of time. Gray iron, which may even be difficult to hear, stops immediately, ductile iron is short while steel resonates for an extended period of time.

Wear Resistance ：

The graphite particles in cast iron bars prevent friction welding which causes galling. cast iron bars resist galling and scuffing and will outperform heat treated steel in a standard pin abrasion test when in the quench and tempered or austempered condition. Additionally, localized thermal stresses are reduced because of cast iron bar's high thermal conductivity. Alloy additions, such as chrome, will stabilize carbides and improve wear properties if necessary.

Weight Reduction ：

Cast iron bars weigh 10% less than steel resulting in substantial savings in transportation and delivery costs to the manufacturer. This can also be especially important when meeting requirements in applications where weight is a consideration.