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Alloy Castings | The Key Benefits of Aluminum Castings

Have you ever wondered why most manufacturers and end consumers use aluminum alloy castings? By using aluminum alloys for the process of die casting, they get to produce strong metal components with less time and less cost. If your next project requires the use of aluminum castings, you’ll need to get a clear snapshot of each of the key benefits that this type of metal offers.

Castings Are Great for Producing Intricately Designed Parts

One of the best reasons why a wide variety of industries and consumers choose aluminum castings is the fact that it allows the manufacturer to produce die-cast parts that have intricate designs. In other words, it’s possible for them to order customized castings that perfectly suit their production needs.

The Production of Castings is Faster than Other Alloy Materials

Did you know that with aluminum castings, you’ll be able to produce die-cast components faster than you would with other types of alloy materials? Since it allows you to create near-net shapes, you can easily eliminate the process of machining to get your desired results. This implies that with aluminum castings, you’ll be able to produce the finished parts much sooner than you initially expected.

Castings are Very Affordable

If you want to obtain top-quality metal products at a much cheaper price, choose aluminum castings. Since they require less machining, the unit cost is considerably lower compared to other alternatives.

Aluminum Alloy Castings are as Strong as Steel

Despite being weighing very little, this type of castings features the same strength as that of steel. Thanks to its superior metallurgical properties, aluminum castings exhibit a higher degree of pressure tightness. In fact, their strength advantage is evident over sand castings and other options.

who offers alloy castings?

Need Alloy Castings?

If you need more information about aluminum alloy castings, feel free to contact Ferralloy, Inc. today. We’re the experts in all casting processes.

Alloy Castings | Tips for Choosing the Right Alloy Castings

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.

Strength

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.

Weight

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.

Cost

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.

where are the best alloy castings?

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.

Inconel | Popular Uses for Inconel Alloys

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.

Marine 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.

Jet Engines

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.

who offers the best inconel?

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!

Castings | The Different Applications for Aluminum Castings

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.

Aerospace

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.

where are good castings?

Do You Need to Learn More About Castings?

Does your next project require the use of top-quality castings? Contact Ferralloy, Inc. today for more information or a quote.

Closed Die Forging | Facts About Closed Die Forging You Need to Know

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.

Where can I get closed die forging?

Looking for Closed Die Forging?

If you’re looking for a major supplier of closed die forgings, contact Ferralloy, Inc. today!

Rolled Rings Forgings | Design Factors to Consider When Purchasing Forgings

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.

Dimensional Tolerances

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.

Surface Finishing

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.

where are the best rolled rings forgings?

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!

Closed Die Forging | All About the Closed Die Forging Process

In case you’re not familiar, forging refers to the manufacturing process that involves the shaping of a piece of metal with the use of compressive forces. A power hammer or a die delivers the blows. Today, it has become a major worldwide industry and its traditional products include hardware, kitchenware, cymbals, edged weapons, hand tools, and jewelry.

What is Closed Die Forging?

Sometimes referred to as impression-die forging, this type of forging process uses dies that have the precut profile of the desired part. These dies move towards each other and partially or wholly covers the metal piece. The raw material that’s been heated is positioned in the bottom die. The shape of the forging as a negative image is incorporated in the top or bottom die. When the top die presses against the bottom die, the raw material forms into the desired shape. In case you’re wondering, this process can be used to produce parts from a few ounces to 60,000 lbs. You may also be surprised to find out that some of these smaller parts are forged cold.

 

What Are its Capabilities?

Closed Die Forging of steel, titanium, aluminum, and other alloys can create a virtually limitless variety of 3-dimensional shapes that weigh from a few ounces up to over 25 tons. While closed die forges that are routinely produced on hydraulic presses have capacities up to 50,000 tons, those that were produced on mechanical presses have capacities up to 20,000 tons. Lastly, those that were regularly produced via hammers have capacities up to 50,000 lbs.

 

Since this type of forging process restricts metal flow due to the presence of the die contours, you won’t be surprised to know that Closed Die Forging can yield more complex shapes as well as closer tolerances compared to the open-die forging process. However, it’s important to note that if additional flexibility is required in forming symmetrical and non-symmetrical shapes, pre-forming operations that involve bending will have to be implemented on the piece of metal before it is forged in finisher dies.

Where are the best forgings?

Closed Die Forging 

Since Ferralloy is a trusted supplier of engineered products and services to a wide range of industries across the globe, we can give you straight answers about Closed Die Forging or anything that’s related to metal production. Contact us today!

 

 

Open Die Forging | Closed Die Forging vs. Open Die Forging

The forging industry has come a long way from using inefficient processes and antiquated applications. Today, we see forging engineering in various industries including machinery, construction, automotive, agricultural, oilfield equipment, and so much more. Although there are numerous options for metal deformation using the forging concept, the most widely-applied processes are closed and Open Die Forging.

 

The Difference Between Closed and Open Die Forging

  • Closed die forging is also called impression die forging. It’s a process that involves the compression of a piece of metal under high pressure in order to fill an enclosed die impression for the required shapes. Sometimes, a second forging operation is needed to achieve the shapes’ proper dimensions. Among the factors that determine the cost of a closed die forged part are the type of material, the need for heat treatment, and the tightness of tolerances.

In terms of application, closed die forging is commonly used for small critical parts such as forged fittings, forged automotive parts, forged lifting and rigging hardware, etc. because of its high precision. Its benefits include better surface finish, it requires little or no machining, no material limitation, cost-effective for large production runs, and the dimensions of net shapes and tighter tolerances are highly achievable.

  • Open die forging is also known as free forging or smith forging. It refers to the process of deforming a workpiece by placing it in between dies that are usually flat and don’t completely enclose the material. Through a series of continuous movements, the dies hammer the metal until the required shape is formed. This process is used for simple products in small quantities such as cylinders, rings, discs, and shafts.

This forging technique is found to be more appropriate for large parts in a number of tons. Examples of these parts include forged rollers, forged long shafts, and forged cylinders. The benefits of Open Die Forging include cost savings, minimal material waste, reduced chances of voids, reduced lead time, little or no tooling cost, finer grain size, continuous grain flow, longer part life, increased part strength, improved microstructure, and better fatigue resistance.

Open Die Forging

Ferroalloy is a reliable comprehensive engineering resource that offers total supply chain management to a diverse customer base on a global scale. If you want to gain a deeper insight between closed and Open Die Forging, contact us today.

Heat Treating Baskets | The 3 Different Heat Treatment Processes

For hundreds of years, people have been heat-treating metals for the purpose of improving their physical and chemical properties to fit a given application. However, we’ve come a long way since the blacksmiths of the middle ages forged and tempered metals to produce tools for everyday life. Today, material engineers and metallurgists use more specialized techniques and tools such as Heat-Treating Baskets to customize materials for definite applications.

 

The 3 Major Heat Treatment Processes

  1. Hardening

This process involves the heating of steel at a specific temperature until its pearlite is transformed into austenite before it is rapidly quenched in water or oil. The appropriate temperature at which the transformation quickly takes place is highly dependent upon the steel’s carbon content. For the core to be fully transformed into austenite, the heating time must be increased. In case you’re wondering, the hardened steel part’s microstructure us martensite, ferrite, or cementite.

 

  1. Tempering

When steel that has both been quenched and hardened for a period of time prior to being heated, the process involved would be tempering. The temperature at which this process is carried out is a critical factor that dictates the hardness and strength that is obtained. For example, high temperatures will produce high ductility, but low in hardness and strength. Conversely, low temperatures will result in low ductility, but high in hardness and strength. It’s extremely important to select the appropriate tempering temperature to achieve the desired level of hardness and strength. Tempering is performed on carbon steels that have been hardened to reduce their brittleness.

  1. Annealing

When steel is treated up to high temperature then cooled very slowly to room temperature to produce its high ductility and strength, but low in hardness, the process of annealing is being applied. In other words, annealing is performed by heating a component to the appropriate temperature before it soaks it at room temperature. The furnace is then shut off while the piece of steel is inside it.

What are forgings

Are You Looking to Find Heat-Treating Baskets?

Heat-Treating Baskets are crucial pieces of any kind of heat-treating process. Only Ferralloy offers high-quality baskets that are second to none. Contact us today!

 

 

Alloy Castings | What You Need to Know About Alloys

When it comes to the modern industrial site, you need materials that can stand up to a lot of different environments. Alloy castings are going to be something you use often on projects. What are alloys? They are a highly-useful material that can change the way you do business.

Properties

Some metals have better electrical conductivity than others, some metals are more heat resistant than others, and some are resistant to corrosion. But what happens when you need something that has all of these properties? This is where alloy comes into play. Steel is a great example because it requires the right combination of carbon and iron. Alloys are not just a combination of materials but finding out what works on a chemical and elemental level.

Production

When it comes to alloys, some are naturally occurring while others require some processing to be used in an industrial setting. Ferro-alloys like Ferro-chromium or Ferro-silicon are produced by smelting mixed ores and are used in steel production. Producing alloys is not an easy process, it requires the right environment and temperature or else you could end up with two metals separating into layers like oil and water.

Composition of Metals

Some popular alloys that you probably interact with on a daily basis are:

  • Brass
  • Bronze
  • Pewter
  • Cast and wrought iron
  • Coin metals
  • Solder
  • And more

Not only are existing alloys produced every day, but thousands of new alloys are being developed as well. Meeting certain standard and purity is the most important part of creating a new alloy that can be used in the real world.

What are alloy castings?

Looking for Alloy Castings?

Have you been looking for more information about alloy castings? If so, contact us today! Ferralloy is your destination for everything to do with alloys.