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The advantages
of Ductile Iron which have led to its success are numerous, but
they can be summarized easily - versatility, and higher performance
at lower cost. As illustrated, other members of the ferrous casting
family may have individual properties which might make them the
material of choice in some applications, but none have the versatility
of Ductile Iron, which often provides the designer with the best
combination of overall properties. This versatility is especially
evident in the area of mechanical properties where Ductile Iron
offers the designer the option of choosing high ductility, with
grades guaranteeing more than 18% elongation, or high strength,
with tensile strengths exceeding 120 ksi (825 MPa). Austempered
Ductile Iron (ADI), offers even greater mechanical properties and
wear resistance, providing tensile strengths exceeding 230 ksi (1600
MPa).
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In addition to
the cost advantages offered by all castings, Ductile Iron, when
compared to steel and Malleable Iron castings, also offers further
cost savings. Like most commercial cast metals, steel and Malleable
Iron decrease in volume during solidification, and as a result,
require attached reservoirs (feeders or risers) of liquid metal
to offset the shrinkage and prevent the formation of internal or
external shrinkage defects. The formation of graphite during solidification
causes an internal expansion of Ductile Iron as it solidifies and
as a result, it may be cast free of significant shrinkage defects
either with feeders that are much smaller than those used for Malleable
Iron and steel or, in the case of large castings produced in rigid
molds, without the use of feeders. The reduction or elimination
of feeders can only be obtained in correctly designed castings.
This reduced requirement for feed metal increases the productivity
of Ductile Iron and reduces its material and energy requirements,
resulting in substantial cost savings. The use of the most common
grades of Ductile Iron "as-cast" eliminates heat treatment costs,
offering a further advantage.
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