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What is Shock Resistance?

In product condition processes, shock resistance testing is used to assess the impact of sudden acceleration due to the collision, drop, and explosion. Companies focused on castings investment and forging perform this test to develop products that can withstand harsh military, transportation, and industrial environments.

Castings Investment

What You Need to Know About Shock Resistance Testing

Simulate Real-World Use

Although shock resistance testing is sometimes compared to vibration testing, the former involves a more complicated and extreme process. The procedures are designed to use a specific type of force to recreate real-world use. Producers and manufacturers use an accelerometer to gauge the force and speed. Through this, the materials will be exposed to loads of pressure and impact.

After which, they assess and classify the material for stress and damage. Because of these rigid procedures, manufacturers and producers are able to guarantee that the product can meet the demands of its work setting.

Accurate Results

A team of experts conducts shock resistance testing that complies with several military and industrial standards such as EN 60068, DEF STAN 00-35, MIL-STD-810, and RTCA DO-160. These engineer experts aim to support custom and complicated projects through the assistance of specification selection and protocol development processes. Since manufacturers and producers possess a global platform of experts and laboratories, getting accurate results on time is never an issue.

Other Tests

Aside from the shock resistance test, there are also other tests that manufacturers routinely perform to guarantee quality results. Some of the tests employed are impact testing, drop testing, shock and impulse testing, bump/shock testing, decaying sine wave testing, shock pulse testing, and operational crash safety.

Castings Investment

Tests Employed in Castings Investment

Are you interested in learning about the other tests used in castings investment and how they can benefit the material cast? Contact Ferralloy Inc., today so our experts can address your questions!

Why Go for Aluminum Castings Investment?

Aluminum is considered to be one of the best materials used in castings processes. It is often used in permanent mold casting, sand casting, die casting, and castings investment. This material is widely known for its excellent strength-to-weight ratio, making it an ideal metal component for numerous casting applications.

aluminum castings investment

Perks of Using Aluminum Castings Investment

Heat Treatment

When employing castings processes for this type of material, it’s best to use the extensive de-gassing procedure and resistance melting process. This guarantees that tight tolerances are maintained and excellent repeatability from the first material to the last. Likewise, the casting process allows for heat-treating that can be utilized to provide the product greater machinability, corrosion resistance, ductility, and strength.

Wide Applications

When it comes to casting aluminum, there are a lot of companies that benefit from this process. The numerous industries that utilize aluminum castings are those engaged in electronics, military, aerospace, food and dairy, and dental or medical equipment. Examples of aluminum-casted products are pistol frames, levers, medical devices, valves, and heat sinks.

Near-Net Shape

Another advantage of using aluminum is that the material provides better surface finishes, tight dimensional tolerances, and greater alloy flexibility. With this, the result can achieve the near-net shape that needs less machining and other processes that may increase the cost.

aluminum castings investment

Inquire About Aluminum Castings Investment

Ferralloy Inc. offers high-quality aluminum-casted products. We are a leading supplier of quality castings to major companies throughout the world. Our staff is equipped with extensive domestic and international expertise to cater to your needs.

If you’re planning to use aluminum castings in your company, request a quote today by contacting us through this link so we can provide you with as-cast or fully machined parts in many different ferrous and non-ferrous alloys!

Seamless Rolled Rings Process for Bearings

The seamless rolled rings process is normally used to create a shape for metals. In this process, the metal is formed into a hollow doughnut, providing the shape of the ring after the process as per the requirement and design of the product owner. Although the process may seem easy, in reality, it involves a difficult and intricate process. Below are the reasons why the process is used for manufacturing bearings.

bearings seamless rolled rings

Why Use Seamless Rolled Rings Process?

Strong and Versatile

Seamless rolled rings can be designed and created using any forgeable material. This includes alloys, stainless steel, carbon, aerospace metals, and more. Its strength and versatility make any metal component an approachable and flexible solution for parts used in chemical, refinery, and power generation industries. Likewise, they are stronger compared to other metal components. Seamless rolled rings are also able to maintain their strength during high-temperature fluctuations. 

Cost-Effective

Gears, slewing bearings, and large-diameter bearings are commonly used in enormous industrial equipment such as those used in nuclear power, hydropower, barge cranes, and harbor machinery. In contrast with casting, seamless rolled rings can efficiently eliminate slag inclusions, shrinkage cavities, pores, and other defects.

Aside from better mechanical and quality performance, one of the biggest advantages of utilizing seamless rolled rings is that it costs less than similar components to manufacture them. This is possible because the rings closely match the contour of the finished shape. As a result, the product requires fewer machining operations, reduced weight, and lower costs for raw materials.

forging seamless rolled rings

Get Quality Seamless Rolled Rings at Ferralloy Inc.

Being one of the prominent forging companies, you can have exceptional products at the best affordable price. Furthermore, we also aim to provide you customized options to cater to your needs and requirements. For more information related to seamless rolled rings, contact us through this link!

Alloy Casting for Pressure Valves

Aside from the fact that alloy castings are more cost-effective than other methods, casting also allows you to create certain parts that are designed according to your requirements. To give you a better idea about how beneficial it is for your business to choose alloy castings for pressure valves, read on.

alloy castings

Advantages of Using Alloy Castings

Flexibility

Alloy castings are shaped as liquid and possess features like low melting point, high fluidity, and good as-solidified strength. They are widely used in the form of die castings and general-purpose sand castings. Additionally, this type of castings is used where fluidity, good corrosion resistance, and rigidity are of greater importance than strength.

Unquestionably, the most widely used alloys are those containing between 9.0% to 13.0% silicon, which occasionally have small amounts of copper. Silicon increases fluidity and decreases shrinkage of molten aluminum alloy so that castability is high and intricate shapes and complex geometry can be cast. Hence, it becomes easier for alloy castings to be used in creating pressure valves.

Lightweight Yet Powerful

Although alloy steel castings are extremely lightweight, their sturdiness allows them to be effectively applied for companies that are involved in the manufacturing of vehicles. Furthermore, when it comes to the production of high-performance wheels, this type of casting can be your best option.

Durable

The calcium, zirconium, nickel, and cerium components in alloy castings make them highly durable compared to other options. You can expect your alloy castings to exhibit better resistance to wear and tear, as well as high heat.

alloy castings

 

Applications of Alloy Castings

Most alloy castings are applied in components that require intricate castings. This type of casting is widely used in water jackets, valve bodies, pressure-tight components, heavy-duty pistons for diesel engines, cylinder-heads for liquid and air-cooled engines, and automobile pistons.

If you want to know more about the applications of alloy castings, contact Ferralloy Inc. through this link!

How Are Steel Forgings Made?

Steel forging involves the heating, deforming, and polishing of steel to create a durable and precise material. These materials are created by forcing materials into customized shapes, either by the die press surrounding a piece of metal or forcing such metal into custom-built patterns. Steel forgings have a broad range of properties and can use different types of materials.

steel forgings made

Properties of Steel Forgings

Limit on Size

Throughout the forging process, shaping a certain type of metal can be very difficult. The reason for this is that forging transpires while the metal is still solid. Because the metallurgists engaged in this project will have a bit of a challenge in altering the shape of the metal, there is a limit on the thickness and size. Hence, the larger the steel section being worked on, the more difficult it is to forge.

Consistency

The great thing about steel forgings is that there is consistency. Because the procedures are deliberate and controlled, each forging goes through the same processes. With steel forgings, it is ordinarily possible to guarantee a consistent material.

Anisotropic

As for the strength of steel forgings, it is not consistent throughout the process; instead, it is anisotropic. In physics, anisotropic is defined as a difference in a material’s physical or mechanical properties. This means that when the steel is worked on, deformation typically occurs.

Durable and Strong

This type of forging produces results that have exceptional strength and are generally tougher than steel produced through other means. Since steel is less likely to break and get altered in contact with other materials, it is often used by industries that require tools and components with increased durability and strength.

steel forgings made

Where Can You Get Steel Forgings?

Steel forgings are widely used by many companies, such as those in the mining, electronics, and aerospace industry. If you’re looking for quality steel forgings, you can give Ferralloy Inc. a call!

The History of Forging

Ever wondered how open die and closed die forging began? The art of forging emerged around 4,000 B.C. – some even say that it began way before this time. Metals like iron and bronze were forged to produce hand tools and other weapons for defense. However, the earliest recorded metal forged by early generations was made out of gold. If you want to know more about the history of forging, please read on.

closed die forging

Centuries of Forging Developments

Before the 19th Century

Limited amounts of natural gold were found in Spanish caves and were said to be used as tools and weapons in the late Paleolithic period. The forging of steel and iron continued in the 19th century and its improvements became the pillars of what has become of today’s forging processes.

19th Century

Forgers and other experts on the forging process were specifically skilled at hand, especially when it comes to open die and closed die forgings. Since bent and twisted iron can only be produced in high heat, the forgers became dexterous in hammer welding and several large shaft forgings.

In 1856, the emergence of the Bessemer steel-making process became a breakthrough in the history of the forging process. People now have an abundant supply of low-cost steel for creating and designing large quantities of forgings.

Historians say that the first cavity steel forging began with the help of the closed die process. It commenced in the United Stated in 1862.

20th Century

The Industrial Revolution and World War II both lead to the development of better forging equipment and processes. Eventually, electrical motors and induction heaters enabled forged rolled rings to be produced quicker, easier, and more effectively than ever before.

closed die forging

Know More About Closed Die Forging

Clearly, forgings have come a long way since 4,000 B.C. Start using the modern power of forged rolled rings for your next project by contacting our accommodating staff at Ferralloy Inc.

Get Raw Materials with Ease

Engineering production units use numerous types of raw materials in their operations for giving an exceptional shape to a new product. Occasionally, it becomes a big challenge to get the essential goods in local markets due to high demands, costs, and other factors. This concern normally affects the entire manufacturing process which results in different problems. Nowadays, global sourcing allows manufacturing companies to attract various organizations which mainly depend on engineering products.

global sourcing

Why is Global Sourcing Essential?

Purchasing Raw Materials is Made Easier

Global sourcing allows manufacturing companies to purchase various types of materials from other countries to enhance their production levels. There are numerous suppliers who provide supply chain management services for a lot of industries to gain major benefits. With this method, engineering firms can focus more on reducing costs on their labor and raw materials for achieving the best results.

Nonetheless, it is important to research the suppliers from the internet before choosing services.

Materials Often Subjected to Global Sourcing

It is essential to know how to purchase the materials needed from other countries that will ultimately help you overcome complex issues. Below are the materials often purchased through global sourcing.

Zirconium

It is a silver-gray metal used in ceramic industries, food packaging, furnace linings, and other applications. Zirconium is a highly resistant product that gives ways for meeting exact needs in the manufacturing process.

Inconel Alloys

These are often purchased by chemical manufacturing companies to improve the structure of a product at maximum temperature.

metal global sourcing

Global Sourcing Keeps the Process Going

Most of the time, companies engaged in casting and forging processes are the ones who greatly benefit from global sourcing. Since these procedures use different kinds of materials, easy access can keep things going. If you want to know more about the benefits of global sourcing, contact Ferralloy Inc. today!

Steel Castings vs. Cast Irons: Which is Better?

Among the most ideal ways to make lasting and quality components are through castings. It allows for a high level of detail, which results in not needing additional fabrication or assembly. When it comes to rolled ring forgings, steel and iron are the two most popular due to their exceptional mechanical properties for a vast range of applications.

Keep reading to find out which is best suited for your specific application!

rolled ring forgings

How Do Steel Castings and Cast Irons Differ?

Steel Castings

Steel castings are components that are formed by pouring molten steel into a mold cavity. The liquefied steels then cool and solidify within the mold. You can create the shape and the casting to perfectly fit your specifications. Although the casting process of steel can be difficult, the results are well worth it.

Moreso, steel castings are mainly used when other types of cast irons do not have enough strength or shock resistance. Its physical properties allow the castings to be both strong and ductile, making it extremely tough. Also, it limits the chances of fracturing under pressure.

Industries that use steel castings range from food processing and electronics to oil and gas. Some specific industries that use this type of casting include the railroad, construction, drilling, transportation, and mining industries

Cast Irons

When it comes to corrosion, iron has better corrosion resistance than steel. It is also often cheaper because of the lower material costs, energy, and labor required to produce a final product. Additionally, cast iron is relatively easy to cast–it pours easily and doesn’t shrink as much as steel.

rolled ring forgings

Other Substances Used in Rolled Ring Forgings

If you don’t know what to use for your next project, allow our team at Ferralloy Inc. to help you decide. Schedule an appointment today for more information about cast irons, steel castings, and other metals used in rolled ring forgings.

Properties and Categories of Steel Forgings

There are various materials that can be used to create forged parts and components. Inconel, cobalt alloys, titanium, nickel, and steel are just a few of the innumerable forging materials. Which one you choose all depends on the specific application of your desired part. Below are the properties and categories of steel forgings you may want to consider for your next project.

steel forgings

What Are Its Properties?

Discussing the properties of steel forgings will give you an idea as to why it’s so commonly used. Because of the properties forged steel possesses, everything is made easier and more precise. Its properties are a bit unique when compared to steel casting.

Range and Uniformity

Although there are some limitations as to the thickness and size of the forgeable steel, it can still precisely follow the design’s consistency. Every forged steel that is manufactured undergoes an accurate and meticulous process that guarantees optimal results.

Persona and Solidity

Most experts say that when a metal is anisotropic, its strength tends to be unpredictable throughout the forging process. Such a persona of steel makes it easier to produce a good resulting grain flow during the fabrication method.

As for its solidity feature, steel forgings are known for their first-rate durability, greater toughness, and superb strength. When it comes in contact with other metals or substances, it is very unlikely to shatter.

What Are Its Categories?

Steel forging can be categorized into two main types:

Open die forging is a type of drop forging technique of deforming a metal according to the desired shape. Without any limitation, it can utilize the inflicted pressure and power.

In contrast, closed die forging relates to a process in which a metal is placed between shapes customized to fit the metal. Such metal is then pressed and hammered, causing it to fill and flow in the cavities of the custom-shaped dies.

steel forgings

Learn More About Steel Forgings

At Ferralloy Inc., our commitment to high-quality engineered products and services is evident from our diverse metalworking customer base. For more inquiries, contact our experts through this link!

Advantages of Investment Castings

Investment castings provide limitless advantages. It is often used as a metal component for energy, gas and oil, food service, commercial, military, automotive, firearm, power generation, and aerospace industries. For instance, the firearms industry turns to cast parts for firearm receivers, triggers, hammers, and other precision parts. Castings investment is even used by beverage equipment manufacturers and industries, as well as, international pressure relief valve manufacturers in the oil and gas industry.

castings investment

Advantages and Uses of Investment Castings

What Are the Advantages?

Investment casting is perfect for crafting complex and small geometric shapes that have delicate features with only a single mold. Since it is highly flexible, you can combine it with various wax patterns to make a single unique mold. It allows you to rearrange parts you could not make with a tool or machine. Hence, the results become a worthwhile substitute to wielding.

Smooth finishes and dimensional precision are some of the advantages of this casting process. The manufacturer forms a ceramic shell surrounding even patterns, eliminating any presence of a parting line. The reason for this is there’s only a single mold created. Therefore, this process can lead to a smooth finish and the post-process smoothing can produce better results.

Castings investment also provides excellent design capabilities, tight tolerances, and makes use of reusable materials. In this way, the project can achieve accurate results without having to spend more money. Thankfully, the process takes advantage of reusable materials.

How Are Investment Castings Used?

Investment casting is great for creating prototypes and small products. It has boundless applications across numerous industries, specifically in the industrial and automotive industries. How industries use this process today varies on the metals they need. Nonetheless, refractory metals that can withstand high temperatures work best. The most common metals used are titanium alloy, steel, and aluminum alloy.

castings investment

Get the Finest Investment Casting Product Today!

At Ferralloy Inc., we supply investment castings to quality-controlled companies and industries. If you’re interested in purchasing these castings, you can contact us through this link. Don’t hesitate to get in touch with us. Your business interest is what we prioritize!