The company is supplying a 48″ diameter ‘Helper Roll’ to a large integrated US steel maker. This roll will be used in a galvanizing furnace and is cast from HK-40 material. The roll body is centrifugally cast, the bell ends are static cast and the shafts are machined from 309 bar stock. After assembly the roll was dynamically balanced. This assembly is 6,100 pounds.
Ferralloy is supplying an investment casting to a manufacturer of computer hardware components. This CF16FA material investment casting will be finish machined after assembly into a leading computer manufacturer’s subassembly. Annual volume of this component will be > 20,000 units.
Ferralloy is producing machined investment castings to the Rc 52 hardness grade of this cobalt based alloy. These bushings are used as orifices by a large international company in the oil drilling equipment industry. This type of material is also being used to produce sleeves for another customer in the valve industry. The sleeves are pressed into their safety relief valves to dramatically reduce wear which occurs when abrasive fluids are pumped through the valves.
Ferralloy, Inc. has begun supplying a major OEM of mining and construction equipment with machined forgings. The materials the customer is purchasing are 4140, 8637H and 8740H. The company has 12 tools in production now and are in the sampling stage with nine (9) additional forgings. The company ships the machined forgings against blanket orders from inventory based upon their customer’s requirements.
Ferralloy, Inc. is supplying machined investment castings to a customer in the water treatment industry. The three (3) investment castings are components in an assembly that are produced in Type 316-L stainless steel. Ferralloy, Inc. is stocking the products in its warehouse and releasing them according to their customer’s requirements.
Ferralloy, Inc. is currently shipping machined Type 316 stainless steel investment castings to a major US food equipment manufacturer. Ferralloy, Inc. is providing six (6) machined investment castings to this customer from an inventory stocking program. The investment castings in this program weigh between 10 ounces and 3.26 pounds each.
The photographs show the intricacies of a few of the investment castings both from a casting and machining standpoint.
Ferralloy, Inc. is currently evaluating additional opportunities for stainless steel investment castings for this customer after supplying the current requirements for more than two years.
Ferralloy, Inc. shipped a forged and completely machined Dummy Bar Chain assembly to a leading steel mill supplier who supplies MRO products to the steel industry. This project required forging the components, welding and then completely machining each of the components. The forged 4140 links, bushings, washers and pins totaled more than 18,000 #. The tolerances of each component were very critical as they were interdependent on each other as the assembly came together. This product moves raw material that is required in the production of steel bar and plate in the steel industry.
Ferralloy is providing closed die forgings to the metalworking industry in weights from 2 pounds to more than 150 pounds each. Most of the products supplied have been machined. Alloy steels currently supplied are 4140, 8620, 8637H as well as 316 SS.
Ferralloy Inc. performed investment casting services for a subcontractor to the United States Department of Homeland Security. The project required placement of perimeter bollard pipes that provide security around the main terminal of the Reagan National Airport in Washington DC. One of the biggest challenges the architect had was figuring out how to ensure the performance, durability and structural integrity of the bollards, while at the same time, incorporating a design that would be aesthetically pleasing to the public. The bollards, caps and collars were constructed from machined and polished 304 stainless steel. This project was successfully completed in 2003.
Ferralloy Inc. delivered the first shipment of investment castings made from a galvanized steel to a contractor performing work on the Triborough Bridge rebuild project in New York City. 54,000 investment cast washers will be used to replace the existing parts which are critical components to its design and construction.
The Triborough Bridge opened on July 11, 1936 and currently carries approximately 200,000 vehicles per day between Queens, Manhattan and the Bronx. In 1997 a long-term $550,000,000 program to rehabilitate the bridge began and is scheduled for completion in 2009.
This order consists of 100 cast “W” tube assemblies from a major United States steel mill. Order will be completed in April 2003.