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Standard Products
Special Application Manifolds

Ductile Iron Manifolds

Hyteco offers hydraulic manifolds manufactured in Ductile Iron (SG Iron) as well as 250 and 350 Grade Mild Steel, Aluminium, Stainless Steel and Brass.

Overview:

GRADE : ASTM A536 Class 65-45-12 - Ferritic/Pearlitic Ductile Iron

This Ductile Iron grade of Continuous Casting Ductile Irons (CCDI) are recommended for applications that require high mechanical properties, high toughness and excellent leakage resistance.

The grade presents an ultimate tensile strength and yield strength similar to SAE 1020/1030 steel grades. 

Ultimate Tensile Strength (min.): 450 MPa ( 65,000 psi)
Yield Strength (min.):  310 MPa ( 45,000 psi)
Elongation (min.):  12 %
Hardness: 25-50 mm: 143-27 BHN
50-533mm: 143-207 BHN
Fatigue Strength (without notch): 202.5 MPa
Impact Strength (with notch):  10-5 J
Modulus of Elasticity:  169 GPa
Thermal Conductivity  36-36 W/m.K

This grade is suitable for applications such as machine components that suffer impact and are crack-resistance. 

 It is an excellent choice for hydraulic components which operate in high pressures such as hydraulic manifolds.

Continuous Casting Ductile Irons (CCDI) are alloys of iron-carbon-silicon. Carbon is added to the melt in amounts that exceed the solubility limits of the iron and precipitates as graphite particles.  The graphite shape can be lamellar (gray iron) or nodular/spherical (ductile iron). 

The shape and distribution of the graphite, as well as the structure of the matrix, influences directly the properties of the CCDI. 

This is the reason why the selection of the proper grade of CCDI  or any other cast iron is the first and most crucial step in a new application. 

The continuous casting process makes it possible for the production of bars with fine-grained as-cast structure. 

 This gives the structure the following benefits; 
  • Excellent free machining 
  • Excellent wear resistance 
  • Good mechanical properties
These characteristics, combined with a near net shapes in rounds, squares, rectangles, and special shapes, makes CCDI an economical and a high performing material, which can be used in many metal component part applications.

Hyteco has chosen this type of CCDI for its notable advantages due to the unique nature and manufacturing process, such as:

1.  Minimal gas holes: Casting defects that occur internally in a casting and generally appear round in shape with smooth internal surfaces. They also may appear elongated and occur in different sizes.
In the production of CCDI, the graphite die, unlike the cores and other tradition molding materials, does not release gases when submitted to the high temperatures of the molten iron.

2. Centerline shrinkage: Voids caused by the lack of molten iron in the cross section during the solidification. The continuous flow of homogeneous material through the Versa-Bar casting machine makes this defect almost nonexistent.

3. Minimal slag inclusion: This nonmetallic residue has always plagued closed mold casting foundries. Those impurities are routinely poured into as material is poured from the ladle into the mold.
The CCDI process first pours the molten iron into the feeding furnace. This allows the impurities, such as slag, to remain on the surface, where it is easily removed and remain far from the exit of the die on the base of the furnace.

4. Minimal leakage problems: In sand casting it is not unusual to find sections of open grain structure, which in a pressure application where fluid is applied, can create a leaking through the micro passages in this open structure.
With CCDI, the water-cooled graphite die allows for a faster and uniform cooling rate of the molten iron; (cooling modulus). This cooling modulus is responsible for an important characteristic of CCDI. That is grain density which yields good strength, and protection from leakage, a fundamental concern in the production of hydraulic manifolds.

5. Weight Advantage Over Steel
Compared to Steel. (Weight and Dampening) 
Density of CCDI  =  7.20 gms/cc (0.260 lbs / in3)
Density of Steel =   7.86 gms/cc (0.284 lbs / in3)

The density difference of approximately 10% lower in CCDI compared to steel is due to the content of carbon (density = 0,0794 lbs / in3) in form of graphite in the structure of the cast iron.
This translates into lower weight consideration and dampening characteristics. 
As a result CCDI performs better with reduced noise and vibration: normally a large concern for gears and other machine components.

6. Less stock removal: The continuous casting process of CCDI allows for the production of bars in different shapes and dimensions. Those can be produced very close to the desired dimensions of the finished part. As cast it is free from surface sand inclusion, parting lines, gating, and other feeding or venting inconsistencies found in other castings. This means smoother uninterrupted tool cut and less time to machine finish.

7. Superior machinability: Besides the benefit from less material removal, there are more machining enhancing characteristics present in
CCDI. The high percentage of graphite structure works as a natural chip breaker and machining lubricant. It produces superior cutting speed and lower tool wear. 

8. High strength grades: The shape and size of the graphite flake influence enormously the strength of the bar. The bigger the graphite flake size is, the lowest the strength will be. In CCDI the solidification process results in very fine graphite particles with excellent mechanical properties.
Hyteco Standard Products
Special App. Manifolds
Benefits of Manifolds
Manifold Design Criteria

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