Manufacturing Benefits of Ductile Iron

Components in High Pressure Systems

Molly Stieber
Undergraduate Research Assistant, Milwaukee School of
Engineering (MSOE), Fluid Power Institute

John Schultz
National Account Manager, Dura-Bar
1
Continuous Cast Iron Bar Stock

A high-quality alternative
for low-medium carbon
steel and castings

Grades:
Ductile, Gray, Ni-Resist

Shapes:
Rectangles/Squares, Rounds, Custom

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The Continuous Casting Process

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The Continuous Casting Process

4
Advantages of Continuous Casting

Impurities that cause gas and slag defects float to

Eliminates Gas & Slag Defects
the top of the molten iron and cannot enter the die
Water Flow

Molten Iron

Eliminates
The Shrink
head pressure and
in the Provides
bottom of the barExcellent
machine
Surface
constantly feeds Finishes
iron into the solidifying bar
Water Flow

Molten Iron

Eliminates Hard Spots and Provides Very

The bar exits the
Refractory Lining Graphite Die dieRefractory
extremely Cast Bar hot and cools to room
Consistent
temperature Machinability
Lining Graphite Die
in still Water
air Cooler
Cast Bar

Water Cooler

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 Benefits of Ductile Iron Chips over Steel

Simpler Chip
Management
– More easily
removed from
crevices
(deburring)
– More compact
– Can handle
without gloves if
need be
– Ductile iron chips
are cleaner
– Lead free

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 Advantages of Ductile Iron vs. Steel
Ductile Iron Steel
ASTM A536 65-45-12 AISI 1045/ JIS S45C
Surface Finish ---

Pressure

Quality

Noise/Vibration Damping ---

Machinability/Tool Life ---

Deburring ---

Availability ---

Size Ranges ---

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Typical Applications in Fluid Power

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Ductile Iron Pressure Ratings

Problem:
There is no industry
standard for ductile iron
pressure ratings.

Solution:
Daman, Dura-Bar and
MSOE team up to
determine ductile iron
pressure ratings.

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 MSOE Research
The Steel Alternative

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 Ductile Iron Pressure Ratings
Barlow Formula:
Pressure (psi) = 2 * (Wall Thickness (in.)) * (Material Strength (psi))
(Inner Diameter of Cylinder (in.))

Variables:
Fatigue Strength (psi): 40000 (true for all ductile iron grades)

Safety Factor: 4 10000 psi

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 How Stress is Calculated

2
. .

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What is the maximum hydraulic pressure?

1/8” Depends: Assume 45,000psi

maximum stress and a 3”
diameter cylinder with 1/8” wall.

3”
4,090

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If we increase wall thickness to 1”…

1”
Depends: Assume
45,000psi maximum
stress and a 3” diameter
cylinder with 1” wall.

3”
180,000

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 Minimum Allowable Wall Thickness (inches)
Bore Size Maximum Operating System Pressure (bar)
(inches) 4000 5000 5500 6000
0.250 0.05 0.06 0.07 0.08
0.500 0.10 0.13 0.14 0.15
0.750 0.15 0.19 0.21 0.23
1.000 0.20 0.25 0.28 0.30
1.250 0.25 0.31 0.34 0.38
1.500 0.30 0.38 0.41 0.45
1.750 0.35 0.44 0.48 0.53
2.000 0.40 0.50 0.55 0.60
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 Maximum System Pressure (psi)

Bore Size Burst Area Wall Thickness (inches)

(inches) 0.125 0.250 0.375 0.500 0.625
0.250 10000 20000 30000 40000 50000
0.500 5000 10000 15000 20000 25000
0.750 3333 6667 10000 13333 16667
1.000 2500 5000 7500 10000 12500
1.250 2000 4000 6000 8000 10000
1.500 1667 3333 5000 6667 8333
1.750 1429 2857 4286 5714 7143
2.000 1250 2500 3750 5000 6250
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 Statement of Challenge

Prove and expand table

Data to be used to optimize

manifold design

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 Pressure Rating Testing by MSOE

Test
pressure
= 6,000
psi

Rated
pressure
= 5,172
psi

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 Explanation of NFPA Standard T2.6.1 R2-2001

Cyclic Test Pressure = Rated Fatigue Pressure x Kv

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Component Test Results

No manifold failures

Only o-ring extrusions

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 Mechanical Property Comparison
Ductile Iron Steel
ASTM A536 65-45-12 AISI 1045

Tensile Strength 65,000 psi/ 448 MPa 81,900 psi

Yield Strength 45,000 psi/ 310 MPa 45,000 psi

Elongation 12% 16%

Hardness- Average 180 BHN 163 BHN

Machinability Rating (1212=100%) 170% 56%

Pieces/ Insert Edge* 340 112

*Relative tool life comparison done at 450 sfm, .010” feed and .125” doc
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Ductile Iron vs. Steel Testing, program overview

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Design Comparison
Varying bore sizes and wall
thicknesses

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 Ductile Iron vs. Steel Testing Results
Rated System Pressure*: 6,500 psi
No failures of either Bore Size (in)
Minimum Allowable Wall
Thickness (in)
material 0.5 0.16
1 0.33
2 0.65

Allowed minimum wall

thicknesses in this
configuration to be rated
for 6,500 psi

*Method of verifying the rated fatigue pressure (or establishing the rated burst pressure; or both) of the pressure containing envelope
conforms to NFPA/T2.6.1 R2-2000, Fluid power components - Method for verifying the fatigue and establishing the burst pressure ratings of
the pressure containing envelope of a metal fluid power component, for the values, categories and special conditions (if any) as specified.
The configuration shown above has an RFP = 44.82 MPa (6,500 psi), category C/90/ where k0 for ductile iron = 0.14
Testing, verification, and rating performed by the Fluid Power Institute at the Milwaukee School of Engineering.

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 Industry Benefits

Allows ductile iron to be designed into high

pressure systems

Increases the maximum pressure at which systems

can be run

Decreases manufacturing costs for manifolds

More intelligently, compactly designed manifolds

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Future Plans

Burst testing

Run test with smaller wall thicknesses to

achieve failures

Develop design tool for manifold design

Validate stress equations through testing

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Questions?

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