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Try to imagine a metal that has the strength of steel bar stock but that can be machined into finished components twice as fast with less tool wear. It is 10 percent lighter, can be heat-treated without carburizing and will not distort. It has damping properties that make quieter gear sets, and the cost per pound is about the same as steel bar stock. What is it? If you haven’t already guessed, the high-tech metal described above is today’s cast iron.

Often dismissed as a cheap, dirty, brittle metal, cast iron is getting much more attention today because of its machinability, light weight, strength, wear resistance and damping properties. The engineered cast irons of today are much different than they were even 20 years ago because of better understanding of, and improvements in, the processes used to produce them. Continuously cast ductile iron bar stock produced in the United States competes very favorably with low-cost foreign steel bars because of its ability to be machined at speeds in excess of 1,200 surface feet per minute (sfm) with standard carbide inserts. Ductile iron’s mechanical properties are very similar to steel, making it an excellent material for the machinist and the design engineer.


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