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#1 Continuous Cast Iron Supplier

A superior alternative to steel and sand cast iron

The continuous cast process conducted in our cast iron foundry ensures iron solidifies more uniformly, so it's more durable and reliable than traditional sand cast iron. Versa-Bar is manufactured with less scrap material and reduced machining, so it is stronger and costs less because there are no tooling charges.


Gray cast iron suppliers

Versa-Bar gray iron is the most metallurgically superior steel alternative on the market. Fluid power and bearing manufacturing industries across the United States are switching to our continuous self-lubricating iron castings because they are more cost-effective than other steel alternatives. AIA's gray cast iron is built for strength, durability, and reliability, making AIA a superior cast iron foundry. 

Grades of Versa-Bar gray iron:

Ductile iron suppliers

Continuous cast Versa-Bar ductile iron turns the de facto iron for America's water system infrastructure into a more resilient and wear-resistant metal for applications needing high machinability and corrosion resistance. AIA cast iron foundry manufacturers ensures uniform solidification, resulting in a stronger and more durable material.

Grades of Versa-Bar ductile iron:

Versa-Bar continuous cast iron stock

American Iron has the most extensive inventory of Versa-Bar continuous cast iron in North America. Our custom cast iron foundry supplies various shapes and sizes to fit your custom metal processing needs. The standard length of continuous cast iron is 72 inches, but upon request can be up to 144 inches in length.

Continuous Cast Iron Bars, Rounds & Rods
Bars, Rounds, Rods
Cast Iron Bars, Rounds & Rods

We supply companies nationwide with custom continuous cast rods, rounds and bars. .625" - 23.6" Dia. (Ductile rounds start at 1.5" in diameter.)

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Continuous Cast Iron Tubes & Tubing
Cast Iron Tubes

Custom cast tubes are available as part of our huge supply of raw iron stock. Stock and custom I.D.s with O.D.s up to 22".

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Square & Rectangular Cast Iron Billet Supplier
Squares & Rectangles
Cast Iron Squares & Rectangles

Squares & rectangles may be machined into custom dimensions - for raw stock or custom processed components.

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Cast Iron Plate Supplier
Cast Iron Plates

We provide custom machined iron plates cast to your exact specifications.

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Continuous Cast Iron Specialty Shape Supplier
Special Shapes
Cast Iron Special Shapes

Upon request, we'll provide specialty shapes. Stock and custom cut available up to 18.5" x 22" x 72" and 10.5" x 24" x 82".

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Custom cut pieces of continuous cast Versa-Bar
Cut Pieces
Cast Iron Cut Pieces

American Iron & Alloys' capabilities include machining of custom cut pieces for your application.

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Why choose Versa-Bar continuous cast iron?

Lower cost. Better performance.

Versa-Bar's unique metallurgical properties make it a superior alternative to traditional sand castings. Versa-Bar is much more affordable than alternatives such as aluminum, brass, bronze, and many grades of alloy and carbon steel.

Our continuous cast iron features microscopic flakes or graphite spheres with tiny recesses that promote oil retention. Lubricated parts stay oily longer, and the highly dispersed graphite acts as a self-lubricant in the case of oil loss. Naturally non-abrasive qualities give Versa-bar tubes, rounds, bars, and rods superior wearability, making it the true hydraulic metal. Our cast iron foundry supplies raw stock and custom-fabricated components in our versatile cast iron supply program. 

Get more information on our standard rounds and bars and stock sizes.

Choose Versa-Bar for:

  • Decreased material cost
  • Improved machinability
  • Superior performance and durability

Field test comparison chart - continuous cast iron vs. aluminum, bronze, and steel

The chart below displays the speeds and feeds for aluminum, bronze, and steel and comparable rates for Versa-Bar. The field test operator used the rates for normal production requirements on a seven horsepower lathe machine. The machine produced hydraulic cylinder pistons. The cutting tool used for this analysis was a Valenite VC 67 Carbide Insert.

The operators were asked to reach the optimum SFM (surface feed per minute) on the Versa-Bar and still maintain a comparable depth of cut and surface roughness with the other three materials. Results show that all three grades of Versa-Bar far exceeded the conventional machinist handbooks for SFM on cast iron. If you were to run the same test on a CNC machine or use one of the new high-tech inserts, rates comparable to those shown on the NGK chart are possible.

Gray and ductile iron differences

Some metallurgists will say the difference between gray and ductile iron is that ductile iron is an "upgraded" version of gray iron. It's not that simple.

Continuous cast gray iron is recommended for straight-wear applications in the hydraulics industry due to its lower tensile strength, higher thermal conductivity, and higher damping capacity. it's an ideal metal for bearings and bushings, but ductile iron is much better for moving parts because it is more malleable and impact resistant. Our continuous cast ductile iron is commonly used for pistons and other machinery requiring high tensile strength.

The basics of hydraulic and pneumatic systems

Since Versa-Bar is one of the cast iron foundry industry’s finest metals for the fluid power industries, its role in hydraulic and pneumatic power systems is critical. Reaching peak efficiency in the creation of power minimizes costs and maximizes total output. Versa-Bar continuous cast iron’s natural lubrication and ability to dissipate heat make it ideal for these applications.

Sand casting vs. continuous casting

Sand casting has been one of the most popular and simplest types of casting for centuries because it's inexpensive and can be used for ferrous and non-ferrous metals. However, sand casting tends to yield a lower degree of accuracy and a rougher surface finish when compared to continuous casting.

Continuous casting is a refined process used in our cast iron foundry, specifically designed for large-volume production. It's also known as strand casting and produces high-quality products in various shapes and sizes, including square bars, tubes, hexagonal profiles, and slabs with varying thickness levels. Learn more about the advantages of continuous casting.

Continuous cast gray and ductile iron round Suppliers

A truly flexible continuous cast iron supply program

American Iron offers the most flexible and customizable purchasing program for cast iron. Most other cast iron foundry USA distributors and CNC machining firms restrict you to certain quantities or finish styles.

We pride ourselves on our customer service and unparalleled flexibility to tailor our products and services to your needs. Getting you exactly what you need means less waste and lower prices. YOU decide if you want your metal stock raw, processed, or machined. 

Industries that rely on AIA's Versa-Bar cast iron

Our advanced in-house custom cast iron foundry and precision CNC machine shop allow us to produce metal parts to your exact specifications - and do so with fast turn-around times. However complex the part is, we can produce it. We can create a prototype with a blueprint and start manufacturing your part at the required volume. Our Wisconsin cast iron foundry can produce the metal parts you need, and our supply chain can get your parts to you on time. We're here to help improve your bottom line. Some of the industries benefiting most from our products, services, and partnership include:

Regardless of your industry, if you need a metal supply partner, consider partnering with American Iron for high-quality metal, precision CNC machining, and a reliable supply chain. We supply metal components across the United States, including MilwaukeeNew YorkNorth CarolinaCaliforniaTexas, and Illinois

New! We now have a Versa-Bar distribution center at our sister company, QESC, in Houston, Texas!

Contact American Iron for continuous cast iron distribution and a free quote on our metal supply programs.
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