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Continuous Casting Standard Grades and Process

American Iron has a variety of continuous cast iron grades available. We offer years of knowledge in the industry to provide you with the exact grades for your specific application. Call us if you don’t see what you're looking for below. Our custom metal supply program options are endless.

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Gray iron

Gray iron is preferred for producers looking for a low-cost option to produce custom continuous cast iron components with high density and strength. It is best used in vibration-damping equipment such as blocks and frames for manufacturing equipment.

Gray iron is an excellent thermal conductor with good wear resistance but is not very flexible, containing no recognizable elongation. It can survive approximately two foot-pounds of impact, featuring lower impact resistance than ductile iron (ductile iron can withstand around seven foot-pounds of impact).

Ductile iron

Ductile iron is a more flexible alloy, featuring more fatigue resistance and higher impact resistance than its counterpart, gray iron. Instead of rod-like flakes, the ductile iron bar is composed of graphite nodules, making them flexible during solidification. In addition, ductile iron molecules are more malleable and feature greater ductility—the ability of a metal to be shaped into wires.

Ductile iron stock is available for sale as a raw material for you to process and finish on your own, or we can finish and machine it into custom continuous cast iron components based on your requirements at our state-of-the-art CNC facility in Waukesha. We provide you with high-quality ductile iron in whatever form you desire.

V-2 Gray Iron

V-2 Class 40 gray iron has a tensile strength of 40,000 psi with a compression strength of 150,000 psi. It's ideal for bearings, bushings & hydraulic components.

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V-3 Ductile Iron

V-3 ductile iron has a tensile strength of 65,000 psi with a yield strength of 45,000 psi. It's fine ferritic structure makes it a very easily machinable material.

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V-4 Ductile Iron

With a tensile strength of 80,000 psi and a yield strength of 55,000, V-4 ductile iron is a more efficient and affordable alternative to steel.

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V-5 (HT) Ductile Iron

Minimal tensile strength of 100 psi and a minimal yield strength of 70,000 psi. Ideal for pumps, compressors, and automotive parts.

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The difference between gray and ductile iron

Gray and ductile continuous cast iron are two of the most dominant metals produced in the industry today. Ductile is often considered an “upgraded” version of gray iron, but this outlook is sweeping and simplistic. Each has unique and distinguishable metallurgical characteristics to situate them strategically in the metal goods market. Therefore, when considering what's best for your application, you must know the differences between ductile and gray iron.

Frequently asked questions about gray and ductile continuous cast iron

Is gray/ductile iron magnetic?

Yes, under the right conditions. Iron ceases to be magnetic at 1043 K (about 770°C or 1418°F). This temperature is called the Curie point. Applying thermal energy to iron reduces its magnetism. 

Why is gray iron more brittle and weak in tension?

Gray iron's composition has a lower tensile strength under 60,000 psi. Gray iron contains graphite flakes, so it has a harder time withstanding compression. Its weakness becomes a strength because it's easier to machine. 

How is gray iron made?

Gray iron is an alloy comprised of carbon, silicon, and graphite. The metal is continuously cast by feeding molten iron horizontally through a water-cooled die. 

Can you weld ductile iron?

It is not recommended. Ductile iron is still more likely to crack under stress than other non-cast iron metals because of its changes in composition when heated. Gray iron is easier to weld. 

Is ductile iron conductive?

Yes, but it has a lower thermal conductivity than gray iron. 

Is ductile iron malleable?

Yes, ductile iron is malleable and uses less energy than malleable iron. 

Is ductile iron ferrous or nonferrous?

Ductile iron is ferrous. Ferrous materials are materials that contain iron. Some characteristics include magnetic properties, excellent tensile strength, and vulnerability to rust.

Is ductile iron stronger than steel?

Yes! Ductile iron is a stronger alternative to steel.


Continuous casting process for Versa-Bar iron

Versa-Bar is manufactured using a continuous casting process, making it metallurgically superior to sand-cast iron and other steel alternatives on the market. Continuous cast iron solidifies more uniformly than sand cast iron, making it more durable. Learn about the advantages of continuous casting and how your company saves money utilizing the remarkable process.

Contact American Iron for more information on Versa-Bar grades.
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