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The Basics of the Machined Casting Process

Whatever business you may be in, efficiency is always a good thing. It doesn’t matter if your industry is service or manufacturing-oriented. Countless process efficiency always provides a wide array of benefits above “business as usual.” Hence, it is always imperative to determine the ways on how to efficiently better the ways of production. Check out the process of making machined castings:

what are alloy castings?

The Machined Casting Process

The Basics

To attain various specific metal components, there are certain developments that the metal undertakes. For products like a machined investment casting component, it is required to undergo a procedure after the part is cast known as machining. Aside from knowing what machining is, there are numerous diverse tools and processes within machining that are precise to the component and its purpose. Depending on what the machined investment casting components will ultimately be used for, the type of machining it undergoes could vary.

Pay Attention to Part Details

To cast better aluminum, use fillets in place of sharp corners. Disparity shrinkage at the sharp corners will lead to persistent shrinkage porosity, which may develop during the machining process. Gussets and ribs must be used in place of immense sections. A regular blending of light into substantial sections is suggested.

Understanding the Lifespan

If you think that aluminum die casting is the perfect option for your production requirements, you should know by now the maintenance and lifespan than aluminum die casting require. Since the life of the die is difficult to determine since it is heavily dependent on several factors, you’ll need to keep a selection of aspects in mind, which includes the desired part quality, aluminum alloy utilized, heat treatment, mold configuration, and tool steel used.

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Know More about Machined Castings

Ferralloy, Inc. is an international company serving the global marketplace, offering competitively priced, engineered products produced in North America and Asia. Schedule an appointment today!

What Materials are Used to Make Closed Die Forgings?

Although closed die forging is enforced for almost all the metal materials, especially in physical production, only a portion of the materials is used for several characteristics. The prevailing materials used are one of the main factors that affect the cost of the forgings. Check out the prevailing materials used in closed die forgings to determine which best suits your goal.

what are closed die forging?

Different Closed Die Forging Materials Used

Brass or Copper

Brass or copper is also popularly used in closed die forging, which is the most expensive of the common materials that will be discussed. Brass or copper forging is more often than not the most frequently used material for pump and valve fittings.

Aluminum

This type of material is commonly used by forgers because of its easy machining, high strength, and low density. It is extensively used in the closed die forging process, particularly for the aerospace and automotive industries. While it is commonly used in the automotive and aerospace industries, it is a daring process for domestic forging due to the fact that it is straightforwardly deformed after forging. However, the typical heat treatment can assist in the hardness improvement of other properties.

Steel

Among the prevailing materials used in closed die forging, steel is by far the frequently used material due to its quality and durability. Stainless steel, carbon steel, and alloy steel are all used subject to what the forging will be used for. Carbon steel and alloy steel are the most extensively used in forging because of its easy deformation capability and competitive price.

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Do you Need More Information About Closed Die Forging?

One of the best things about forging is its versatility and adaptability with its components because the manufacturer can use any form of raw metal or even alloys using this method. It doesn’t matter if the user needs small or medium-sized metal parts – closed die forging can easily produce them. If you need more information about open and closed die forgings, Ferralloy, Inc. is the leading global supplier of engineered products and services to a diverse metalworking customer base. Schedule an appointment with us now to know more!

Castings Investment | The Value of Castings Investment

Is your current metalworking process hampered by component variance and additional cost? Perhaps you should consider switching to castings investment so that you can add more value to your project. Its manufacturing process is nothing short of versatile because it allows you to create a wide range of metal parts with various applications in many industries.

What are the Disadvantages of Secondary Operations?

Technically functioning parts can be produced by casting pieces and machining from solid. However, such secondary operations can be very inefficient when they’re being compared to investment casting. Factors such as production timeline, cost, and the required performance of the specific component need to be considered. For this reason, most manufacturers choose to steer clear of secondary operations that can negatively affect the speed-to-market, as well as part performance.

What are the Advantages of Investment Casting?

On the other hand, the investment casting process can offer near-net-shape or net-shape components without taking a lot of time. With the help of the latest software technology, manufacturers can make sure that the intricately detailed parts will come out mechanically sound even before the molten metal is poured into the mold. Furthermore, this metalworking method gives engineers and designers free rein while eliminating material waste that usually results from secondary machining.

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A Closer Look at the Value of Castings Investment

The process involved in creating castings investment allows manufacturers to achieve repeatability and reduction or elimination of various downstream operations. Furthermore, this will further reduce loops for reworking the parts and streamlines the process of delivery from the manufacturers to the various industries they serve. While you satisfy your customers’ requirements, you’ll also get to experience the benefits of one of the most optimized and repeatable precision metal processes in all of history. If you want to know more about castings investment, call Ferralloy, Inc. today. We’re the leading global supplier of engineered products and services and we offer total supply chain management to a diverse metalworking customer base.

Seamless Rolled Ring Forging | Different Types of Forging Processes

Manufacturers use different types of forging processes in order to create the metal products their clients require. The forging process has four main types including impression die forging, cold forging, open die forging, and seamless rolled ring forging. Take a closer look at each one of them here:

What is seamless rolled ring forging?

The Main Types of Forging Processes

Impression Die Forging

This method involves placing a precut profile of the required component between two dies called tooling. The dies press the metal parts that can range from a few ounces to about 60,000 pounds. Furthermore, the process can work well with various kinds of materials such as titanium, aluminum, steel, and other alloys. It’s able to create 3D shapes that are as heavy as 25 tons or even more.

Cold Forging

Although most forging methods are performed with the application of heat that reaches temperatures of up to 2300˚F, this variation of forging uses temperatures that can reach several hundred degrees. Furthermore, cold forging covers a variety of processes such as cold drawing, bending, cold heading, extrusions, and coining in order to produce a diverse array of metal shapes.

Open Die Forging

The key to this method is not to confine the metal preform between flat dies during the forging process. The desired shape is achieved by progressively working the starting stock. In terms of size limitations, the produced parts are only limited to the starting stock’s size. Any forgeable ferrous, as well as a non-ferrous alloy, can be forged through this process. Lastly, the process can produce round, rectangular, square, hexagonal bars, hollow cylinders, ring-shaped parts, and more.

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Seamless Rolled Ring Forging

This process is performed by piercing a hole at the center of a round pre-form metal to create a donut shape before it is rolled, squeezed or pounded into a ring. It’s possible to produce rings with diameters that can range from a few inches up to about 30 feet. If you want to know more about seamless rolled rolling and the other types of forging processes, contact Ferralloy, Inc. today.

Investment Casting | Common Casting Surface Treatment Methods

Investment casting refers to the metalworking manufacturing process that’s widely used in various types of industries. Sometimes called lost-wax casting or precision casting, it involves the use of a wax pattern in shaping a ceramic mold before molten metal gets poured into the ceramic shell to create the desired part. To improve the appearance and quality of an investment casting, manufacturers apply surface treatment methods.

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What are the Common Types of Surface Treatment Methods for Investment Castings?

Hot Dip Galvanizing

The application of this method requires the immersion of the carbon steel part in a plating bath of liquefied zinc at 510˚C in order to turn the iron-zinc alloy on the steel component’s surface into passivated zinc. This process is a lot similar to the hot-dip aluminizing method.

Auto-catalytic Plating

Commonly known as chemical plating, this popular surface treatment method is primarily known for being eco-friendly and easy to operate. Its end product is a workpiece that exhibits high resistance to corrosion, as well as good wear.

Vacuum Plating

This encompasses different types of vacuum evaporation, ion plating, and sputtering plating. These are all utilized to facilitate the deposition of various metal as well as non-metal films on the surface of the parts until it reaches the point where a thin coating is obtained. Compared to other surface treatment methods, vacuum plating offers extremely fast adhesion. For this reason, this method is typically used as an internal shield or a functional coating that’s ideal for products of higher-grade.

Paint Finishing

Did you know that various types of coating can be used to complete this surface treatment method? These types include electrophoretic coating, hand coating, and electrostatic coating. Primarily operated according to the manufacturer’s sample or even their color number, the paint finishing surface treatment method is commonly used for both iron and steel castings.

what is investment casting?

Where to Find Top-Quality Investment Casting

If you’re looking to find top-quality investment casting, get in touch with the leading comprehensive engineered product resource – Ferralloy, Inc.

Investment Castings | What You May Not Know About Gravity Fed Castings

If you need unique parts for your next project, you may want to consider choosing investment castings. Due to the fact that it offers flexibility in terms of design, these components are widely used in various industries. Primarily created by utilizing a specific mold for the series of coating and hardening processes, investment castings feature remarkably unique surfaces that can be easily recreated. One of the methods used to create investment castings is through the gravity-fed process.

what are investment castings?

A Closer Look at Gravity Fed Castings

What Exactly Are Gravity Fed Castings?

Gravity is a force that we’re familiar with. However, when it comes to metalworking, this natural force can be used to produce durable industrial parts. Also referred to as permanent mold castings, gravity-fed castings are created after the liquid metal is poured from a vertical position into a specific metallic tool. Aside from the fact that no additional force is applied during the entire process, gravity fed castings can also be produced using semi-permanent mold casting cores that are made of metal and sand.

How are Gravity Fed Castings Made?

It all starts with a mold that has already been preheated. Preheated molds make it a lot easier for the material to flow. It also protects the casting from being damaged before the mold is coated by metal workers or machines. The coating process keeps the material from sticking. Next, the material is poured or invested and hardened before it is removed. This entire process is done repeatedly until the target is fulfilled. As mentioned earlier, no extra force is applied except for gravity.

What are the Advantages of Using Gravity Fed Castings?

Gravity-fed castings are great for large production orders because it’s easy for manufacturers to redo the molding process for more castings. Furthermore, these castings offer more structural integrity than other alternatives because less gas gets trapped within the molds.

Learn More About Investment Castings!

If you’re curious to know more about investment castings, call Ferralloy, Inc. today. We’re the leading comprehensive engineered product resource.

Seamless Rolled Rings | Materials Used for Rolled Ring Forging

If you want to know more about how seamless rolled rings are produced and the common materials that are used to make them, you’ve come to the right place. The entire process begins with the creation of a preform workpiece via the open die forging method. Through the use of this method, a piece of stock is processed to align the metal’s grain flow before a hole is punched in its central part. Creating the hole enables the manufacturer to place the component in the ring mill. Once placed in the ring mill, the workpiece is rotated by an idler roll while it applies pressure to the ring’s inside part. At the same time, the driver roll is used to apply pressure to the outside part of the ring. During the process, the ring’s diameter increases while the material flattens and two axial rolls control the ring’s height. This continues until the desired diameter is attained.

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What are the Top Materials Used for Seamless Rolled Rings?

Alloy Steel

Many manufacturers across the globe turn to alloy steel for projects that require strong, hard, and tough rolled ring forgings. In most cases, the most popular alloy steel options include 4130, 4140, and 4340. It’s important to note that you may need to use additional heat treatments for specific types of alloys in order to achieve your desired ring quality.

Stainless Steel

Stainless steel is widely used for seamless rolled rings because of its physical and chemical properties which include strength, stability, durability, and resistance to heat as well as corrosion.

Carbon

Carbon is another material that’s widely used for rolled ring forgings. However, when more of this material is added, cracks may occur and the material may become more challenging to deform and weld.

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Do You Need Top Quality Seamless Rolled Rings for Your Project?

It doesn’t matter what your desired material is, you can count on Ferralloy, Inc. to deliver top quality seamless rolled rings. Contact us today!

Alloy Castings | Steel vs Aluminum Alloy Castings

When it comes to producing light alloy castings that feature strength and resistance to corrosion, manufacturers across the globe rely on two types of metals – steel and aluminum. A wide range of grades and alloys are available for these top materials of choice. If you want to take a closer look at these two contenders, check out the advantages and disadvantages of each metal.

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Differences Between Aluminum and Steel Alloys

Steel is Stronger than Aluminum

Although steel is the stronger metal, other aluminum alloys feature more strength than some varieties of steel. When engineered carefully, aluminum can be used for specific applications that need strength for operation. However, steel would still be your best bet if your project requires weight-bearing structural elements.

Aluminum Offers the Weight Advantage

Most aluminum alloys are about 2.5 – 3 times less dense than steel. This implies that in terms of weight advantage, aluminum wins. When aluminum is increased in a product’s vital areas, the material can offer enhanced stiffness and strength without compromising its lighter weight.

Steel is More Resistant to Heat Than Aluminum

Compared to steel, aluminum products are less resistant to heat because their melting temperature is much lower. In fact, as soon as aluminum is subjected to 900 degrees F, it starts to soften. On the other hand, steel stays intact unless subjected to a temperature above 2500 degrees F. For high-heat applications, steel is the better choice.

Aluminum Offers Advantage for Machining

Steel’s innate strength and durability is often a drawback for machining. This means that compared to aluminum, more time is needed, and more expensive tools are required to obtain the product’s required shape.

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Do You Have Questions About Alloy Castings?

A wide array of factors needs to be considered before you can decide on the material that best suits your needs. If you need more information about alloy castings, it’s best to consult the experts at Ferralloy, Inc. We are the leading global supplier of quality castings. Call us now!

Forging Rings | Top Questions Asked About Forged Rings

The process of producing forging rings involves a base plate that is ready-made and acquired from the steel manufacturer. In order to meet the exact dimensional requirements for the base plate, the material is hot-rolled and formed into the shape of a ring. If you don’t know much about forged rings, read on to find the best answers to the most commonly asked questions about them.

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FAQs About Forged Rings

How are Forged Rings Produced?

Did you know that the term “forged” is a classic misnomer? You might be surprised to know that a huge part of the process involved in forging steel rings is actually completed by the hot-rolling method. This method starts with the application of heat on a billet of steel before it is pressed or forged. Next, the ring shape is formed by hot rolling the material in two directions.

What’s the Difference Between a Forged Ring and a Hot Rolled Plate?

In case you’re wondering, it takes continuous rolling and casting to produce plates. It’s also possible to forge steel into a billet before it is hot rolled until it attains the desired thickness of its final plate. Forged rings are a lot similar to steel plates because the rings go through a forging process from a billet of steel before these are rolled into their required shape. The key difference between both is that forged rings need to be rolled in two directions while rolling the plates only requires a single direction.

What are the Major Benefits of Using a Forged Ring?

Compared to the hot-rolled plate, the lead time for obtaining forged rings of the same thickness is much shorter. In fact, depending on the thickness of the target component, the process of forging rings could be completed several months before the desired ring thickness can be achieved through hot plate rolling.

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Do You Need More Information About Forging Rings?

Ferralloy, Inc. is the leading global supplier of engineered products and services. If you need additional information about forging rings, contact us today.

Seamless Rings | Why Choose Seamless Rolled Ring Forging Over Other Options?

The process that’s involved in forging seamless rings produces components that feature toughness, strength, as well as fatigue resistance through its contoured grain flow. If you’re not familiar with this process, it starts with the starting stock of the desired material that’s being cut to size before they’re being rounded on open die presses. Once the rounded piece is produced, it’s upset and pierced in order to create a doughnut-shaped preform that’s ready to be placed on the rolling mill where the ring’s diameter is increased, and its height and thickness are decreased until the desired output is achieved.

who offers seamless ring forging?

Reasons for Choosing Seamless Rolled Ring Forging Over Other Options

Seamless Rolled Ring Forging vs Castings

Cast rings are vulnerable to cracks and fractures because of their lack of grain structure which significantly affects the rings’ ductility, toughness, and fatigue strength. On the other hand, the forging process features controlled directional grain flow – the result of which are seamless rings that’s superior in terms of structural integrity and highly resistant to inclusions and porosity.

Seamless Rolled Ring Forging vs Welded Rings

The chances of producing a distorted ring shape that has a jeopardized corrosion resistance and reduced part integrity are extremely high with extensive welding. Forged seamless rolled rings will not have these issues because of the absence of welding. You can expect to produce stronger rings with fewer chances of exhibiting part fatigue and breakage.

Seamless Rolled Ring Forging vs Hot Rolled Burnout Plates

A ring that’s produced through hot rolled plates has exposed grain ends when the ring shape is cut. This is due to the grain flow that’s inherently unidirectional in a hot rolled plate. This results in a ring that’s more vulnerable to fatigue and stress corrosion cracking. With the forging process, the target ring size is achieved because of controlled directional flow while minimizing waste.

what are the best seamless rings?

Do You Need Seamless Rings for Your Next Project?

If your next project requires the use of seamless rings, get in touch with Ferralloy, Inc. We supply rolled ring forgings in diameters up to 110” from carbon, alloy, and stainless steel. Call us today.