Did you know that aluminum and steel are two of the most powerful contenders in the current metal casting scenario? Countless manufacturers around the world depend on these alloy castings in their pursuit of producing corrosion-resistant parts and products that are light yet strong. Have a look at a comparison between both of these metals.
In terms of strength, steel is generally much stronger than aluminum. However, you can find certain aluminum alloys that are stronger that other kinds of steel alloys. Furthermore, since enough strength for operation is required for structural units and applications that are weight-bearing, manufacturers prefer steel alloy castings than aluminum ones for such purposes. While aluminum alloy castings can provide you with weight benefits, it needs to be diligently engineered to meet specific strength requirements.
When it comes to density, aluminum is nearly three times less dense than steel. For this reason, aluminum has more weight advantages compared to steel. Due to its low density, it can keep its overall weight low without compromising its stiffness and strength. This leaves us no reason to wonder why more manufacturers prefer aluminum alloy castings much more than steel alloys.
There’s a huge difference between steel and aluminum alloy castings in terms of cost. In case you’re not aware, their prices always fluctuate in both domestic and international markets. While aluminum is solely based on bauxite ore, steel is produced from iron ore. Although both of these sources are quite common and readily available in most areas, iron is less expensive to its source. It’s also important to note that it’s possible to recycle both aluminum and steel and that the recycling process isn’t as costly as the production process of their raw material.
Do You Need to Know More About Alloy Castings?
If you need more information about alloy castings, don’t hesitate to contact the leading comprehensive engineered product resource – Ferralloy, Inc. We offer total supply chain management to a diverse metalworking customer base across the globe.
Have you ever considered choosing Inconel for any of your upcoming projects? In case you’re not really familiar about it, Inconel happens to be a trading name designating a series of nickel-chromium-based superalloys. Aside from the fact that it is able to maintain the integrity of its structure in high-temperature atmospheres, it’s also known for its high levels of oxidation resistance and corrosion resistance. Various Inconel alloys differ in properties such as elasticity and resistance to corrosion, malleability, temperature, and more. Since Inconel is a relatively expensive material compared to most formulations of stainless steel and other materials, it is best reserved for some of the toughest use conditions where other options won’t work as well. Here are some of its popular uses:
Rapid Temperature Changes
Since most Inconel alloys have the ability to retain outstanding oxidation resistance at both high and low temperatures, you can use a single basket made from Inconel in various processes where temperatures can differ between heat treatment highs and near-cryogenic lows in rapid succession.
Rigorous Heat Treat Applications
It won’t lose shape as it continues to hold moderate loads even at high temperatures which makes it the most ideal basket material for rigorous heat treat applications.
Due to its incredible resistance to salt at various temperatures, it is often used in marine applications for locations near the ocean or processes that use salt. Needless to say, it’s the best material for a parts washing basket.
Since jet engines need to withstand extreme temperatures during use, it is the ideal material for jet engine and turbine construction. At 3,600 ft. which is a passenger jet’s standard cruising altitude, the average air temperature is -69.3˚F or -56.3˚C. However, the combustion process may exceed temperatures of 2120˚F or 1,150˚C.
Need More Information about Inconel Alloys?
If you’re looking to find more information about Inconel alloys or to get a quote, contact Ferralloy, Inc. today. Providing the metalworking industry with their raw material requirements is what we do!
You probably know that aluminum is known to be one of the most well-rounded metals that cater to a vast and diverse market. This material that comes with a luminous finish is used in producing different commercial and household goods. To give you an idea about the various applications for aluminum castings, take a look at this:
Construction and Architecture
Since aluminum is known for its outstanding conductivity and its light weight that works well for extended lengths of cable runs, copper has now been replaced by aluminum as the base for electrical transmission lines and power grids. Furthermore, architects use aluminum castings for renovations that include ornamental door framings, rooftop corner pieces, and reinforcement pieces.
Since the combination of aluminum castings’ properties including its light weight and strength make them ideal for the development of vehicles that are both strong and light enough to go beyond the earth’s atmosphere, the aerospace industry has been greatly dependent on them. In fact, commercial transport planes are comprised of 80% aluminum castings. Plus, aluminum is extensively used in the space industry for shuttles as well as for various structures at the international space station.
Appliance and Technology
Aluminum castings are also used for refrigeration applications primarily because of its thermal properties and its light weight that allow easy transport.
Renovation and Restoration
In most cases, restoration projects can present unique challenges because they can be quite difficult to source designs that match the metal elements that need to be replaced. It doesn’t matter if the existing casting needs to be directly copied or a new master pattern needs to be carved – aluminum castings will be perfect for duplicating hard-to-find castings that can help you finish the historical restoration with the components that you need.
Did you know that a number of factors have to be considered when purchasers select a specific metal forming process that’s perfect for their products or precision design? These considerations include economy, quality, and more. Thanks to the advancements of modern industry, they can choose from various metalworking processes such as casting, powder metallurgy, stamping, machining, and forging. However, if you’re your project requires safety and strength factors, your best option would have to be closed die forging.
What is Closed Die Forging?
When you’re looking for part quality as well as cost-efficiency that work best for applications that necessitate special sizes, critical performance, and maximum strength for small or medium metal components, closed die forging or impression die forging is the ideal choice.
How Does the Process Work?
The process involves forcing the molten metal to flow in a die or a closed shape that resembles a mold attached to an anvil. For the material to flow and fill the die cavities, the hammer is repeatedly dropped on the workpiece within milliseconds. The ‘flash’ or the excess metal that’s squeezed out of the die cavities cools faster than the rest of the metal – which means that the flash forces the metal to fill the die completely as it prevents more flash from forming. Once the forging is completed, the flash is removed.
What About Commercial Closed Die Forging?
When produced commercially, each workpiece is moved through various cavities in a die from the part’s ingot form to its final form. An ‘edging’ or a ‘bending position’ is used to distribute the metal into the rough shape in accordance to what’s needed later in the blocking cavities where the piece is working into a shape that closely resembles the final product. Generous bends and large fillets will be given to the workpiece during these different stages until the final shape is forged in a finisher.
Have you made the decision to purchase a forging? Whether you’re thinking about buying seamless rolled rings forgings, impression die forgings, cold forgings or open die forgings, aside from having basic knowledge about the forging process, you’ll need to consider your ideal design so that you’ll get the best bang for your buck. Otherwise, you’ll cost your business a lot of money and a grueling buying experience is bound to happen. Check out these important design factors.
Selection of Material
In order to select the best material that can achieve the desired performance, heat treatability, forgeability, machinability, and cost, service requirements of the part being forged must first be established. Using these requirements as the realistic basis for mechanical properties such as hardness, impact, etc. will lead you to the best price.
Configuration of Parts
A forger may need to make small changes in a component’s shape. To do so, its tooling and processing requirements need to be checked so that these alterations will be made possible without affecting the part’s function.
In holding tight as-forged tolerances, a considerable cost is involved. Make sure that the forger can help you in the evaluation of trade-offs between reduced machining and increasing die and processing costs.
Almost all forging companies possess machining capabilities and some of them even offer finishing services. You can save on material and machining time if the forger can design the desired forging around the finished part.
Are You Looking to Purchase Rolled Rings Forgings?
Knowing the mentioned design points will help you make wise buying decisions. If you need more information about rolled rings forgings, get in touch with a global supplier of engineered products – Ferralloy, Inc.! We offer total supply chain management to a diverse metalworking customer base. Contact us today to know more about our products and services!
More often than not, high-performance alloys may require the use of a vacuum during castings investment. This method is specifically used when control of exposure to oxygen as well as component detail is highly critical. For example, structural automotive parts that have thin to medium wall sections need to meet stringent requirements that include high mechanical strength, low production scatter, and excellent welding characteristics. The only way to satisfy the structural quality they require is through vacuum casting.
What is Vacuum Casting?
In case you’re not familiar, castings investment with the use of vacuum has the ability to create the required conditions for decisively reducing the porosity of gas. Vacuum casting makes this happen by evacuating air from the die cavity. However, the required values to be achieved without additional heat treatment are dependent on the type of alloy that’s being used. However, if this treatment is necessary, surface flaws will be produced in the presence of even minor gas porosity. This is totally unacceptable on the end product.
What are Its Requirements?
For optimal vacuum castings investment process, high performance must be offered by the vacuum equipment and each individual step must also be optimized to reduce the gas porosity. First, you’ll need the die and shot assembly that’s tightly sealed to ensure process reliability. What’s more, velocity and pressure profiles must be controlled in real time with high reproducibility and high precision. Lastly, factors that include die temperate control, die spraying, molten metal feed, and plunger lubrication must be optimized as well.
Know More About Castings Investment’s Vacuum Casting Method!
If you need more information, contact Ferralloy, Inc. – the premier provider of quality castings investment that utilizes both gravities fed and vacuum casting methods in order to produce parts that range in weight from a few ounces up to about 75 lbs. Our years of experience means that we’re able to supply you with a superior net shape or near net shape components that need little or no finish work. Contact us today!
When it comes to industrial materials, alloys are used often and for a wide range of things. An alloy is any metal by combining two or more metallic elements. Doing this creates something much stronger or with a special feature to it, such as being resistant to corrosion. An alloy is used in things like alloy castings and more.
Why Use Alloys Instead of Pure Metals?
Alloys are usually more popular and useful in industrial settings than untreated metals because of all the benefits of using them. Some combinations yield stronger materials where others are useful because of abilities they gain like becoming resistant to corrosion. These alloys are used because they cut down on cost. While they may be more expensive to work with, they do not require a lot of upkeep and end up saving you money in the long run.
Common Types of Alloys and Their Application
One of the most common alloys is stainless steel. It is primarily used in wires and ribbon forms. Alloys like nickel-chromium, nickel-chromium-iron, and iron-chromium-aluminum are extremely popular given how they can be used for high-temperature heating elements. A majority of alloys are used for their anti-corroding effects. There are also alloys that are used for their magnetic properties in things like magnetic cores and switches.
Looking for Alloy Castings?
If you are looking for alloy castings, contact us today. Ferralloy has been providing industrial hardware on a global-level for over 40 years. We are here to assist with anything you might need for your next job.
To get the metal components you use in every day life, there are several processes that have to take place in order to achieve the end product. Even the most commonly used metal items that people use in their daily lives would be unrecognizable in its raw form. One of the many processes that metals undergo is alonizing. Even though not many consumers are aware of this process, it plays an important role in some of the most popular metal components. Keep reading to find out more about just one of the many products and processes Ferralloy specializes in!
What is Alonizing?
Alonizing is a type of process referred to as a diffusion metallizing process. Simply put it is a thermochemical treatment where the surface layer of a metal is enriched with some metallic element. A common type of alonizing is the diffusion of aluminum through high temperature vapors on the surface of another metal. After the process is complete, the results are a base metal that retains all of its inherent characteristics, whilst having the surface properties of aluminum. A common alloy used as the base metal is steel. The purpose of steel would then be to have a steel that retains its strength and rigidity, and is also resistant to corrosion. Aluminum is a highly corrosion-resistant metal in itself, so adding that to the surface of a metal would produce a strong and resistant alloy.
What are Alonizing Applications?
This process is commonly used in extreme environments where metal components need to be strong and also resist corrosion. An example would be tubing and piping in highly corrosive environments. Furnace tubes, reformer tubes, heat exchanger tubes, waste gas heater tubes and downhole tubes for wells and production vessels are all examples of scenarios that would require metals that have undergone alonizing. Also piping used in oil and chemical production as well as power generation circumstances would also be common uses for metals that have been alonized.
No matter what the purpose is, Ferralloy can deliver the high quality metal component that you require. We have the capacity and authority to produce and manufacture the widest variety of metal products. Simply call us or visit our metalworking company online today to find out how we can benefit your business by meeting all of your metal needs!