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Process Capability of Closed Die Forging

Closed die forging usually is precision-machined to achieve net shape or near-net shape finished products. When you use forging, less post-forging operations are needed because near-net shape products are formed and created. Otherwise said, you’ll save a substantial amount of time and effort when you use this type of process.

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Closed Die Forging Process

Basics of Closed Die Forging

Also known as the impression-die forging of titanium, aluminum, steel, or other types of alloys, closed die forging can practically produce a wide array of 3D shapes that differ in weight from ounces to tons. This type of forging is primarily created on hammers, mechanical press, and hydraulic presses with powerful capacity that can reach up to 50,000 pounds.

What it Contains and Yields

As the name suggests, two or more closed dies comprising impressions of the shape are merged together as forging stock that endures plastic deformation. Since the die contours control the metal flow, closed die forging can produce closer tolerances and more difficult shapes as compared to open die forging processes.

Best Thing About Closed Die Forgings

One of the best things about forging is its adaptability and versatility 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 quickly produce them.

Forging Process

Closed die forging involves the most complex components with long and thin portions that integrate small webs and relatively high vertical projections like bosses and ribs. Likewise, it also includes simple elements to forge secure disc-like configurations, block-like shape solids, and spherical shape configurations. While most of these parts are commonly symmetrical, others integrate all kinds of design components such as pockets, cavities, holes, protrusion, flanges, and a whole lot more. These are used to produce a very non-symmetrical forging. Additionally, portions of the materials used can be easily curved and bent in one or more planes.

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Know More About Closed Die Forging

Ferralloy, Inc. is your comprehensive engineered product resource, contact us today for more inquiries!

Benefits of Utilizing Global Sourcing in the Production Process

As product demand increases making whatever product be more competitive in the trade and retail market, it is essential that you hire a company with global sourcing goals and capabilities. Since extensive global sourcing awareness and expertise can be the solution to marketing and manufacturing needs, every company must know how to speak the global sourcing language.

Generates Substantial Cost Savings

Studies show that appropriate sourcing can dramatically produce substantial cost savings. For instance, the purchasing cost of a company that source globally method can lead up to 10%- 15%. Industries that have used this sourcing methods have enjoyed tons of advantages that boost their earnings.

Additionally, manufacturing costs are mostly lower and industries can often purchase goods at a lower unit price. For industries with not much to spend, this can be an ideal solution to exploit their bottom line. Nevertheless, it is important to remember that there are still other factors, aside from global sourcing, that may affect a probable cost-savings increase.

Contiguity to Raw Materials

Another notable advantage of sourcing is that you have the chance to get more proximity when it comes to raw materials. You no longer have to reach out and avail the services of remote companies and industries just to get the raw materials. Moreso, global sourcing also offers state-of-the-art manufacturing technology and substantial knowledge of local languages and cultures, making it even easier on your part.  With the availability of advanced technology, you are guaranteed that the manufactured products are in perfect built, design, and condition.

The most common benefits of globally sourcing are knowing how to do business efficiently in the new market, evolving and searching for alternative supplier sources that may encourage competition, and decrease costs. It possesses an essential role every time you need to search for scarce resources and skills that are hard to find in your area. Hence, your manufacturing volume and other technical services will radically increase once sourcing is used properly.

Searching for a Global Sourcing Partner

At Ferralloy, our global sourcing permits us to deliver quality materials that result in strong and durable products. For more inquiries, contact us now!

Benefits of Using Forged Rolled Rings

The forged rolled rings process begins with a heated circular mass of metal that is ready to be molded after being formed and pierced to form a hollow “doughnut”. This is then heated to a high temperature and placed over the mandrel roll.

The roller then moves under extreme pressure towards the constantly rotating drive roll that reduces the thickness, increasing the diameter of the final product. It can produce everything from flat washers to tall cylindrical parts.

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Process and Benefits of Forged Rolled Rings

What is the Process?

When it comes to the rolled rings process, it can be broken down into six steps. In the first step, the billet is cut to the proper size and is then upset to achieve the right properties. After that, the center is punched to create the ring that is rolled.

After the donut is ready for ring rolling, the ring is placed on an idler roll and is manipulated by axial rolls and the drive roll. The ring diameter slowly increases as more pressure is applied and once the desired size is reached, the process is done.

Benefits of Forged Rolled Rings

When it comes to this kind of forging, there are a lot of benefits. Given the rolled rings process, one of the biggest benefits is how strong the final product is. Any material that is forgeable can be used to make rolled rings.

That includes alloy, stainless steel, carbon, and aerospace metals. The ability to use several different materials makes them not only more cost-effective, but also allows them to be used in many different industries including power generation, chemical, and refinery industries.

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Where to Get Forged Rolled Rings?

Are you looking for state-of-the-art rolled rings that are processed with utmost precision and accuracy? Schedule an appointment today!

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:

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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!

Why Should I Start Using Steel Forgings?

Steel forgings started in the olden times when there is a need for producing different kinds of end materials with unique properties. Today, hydraulic hammers and machines enable the forging systems to forge steel and other metals easier than ever.

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Everything You Need to Know About Steel Forgings

Properties of Forged Steels

Forge casting is another treatment that can be compared with steel forgings. The latter has various properties of forged steels that seem to be distinctive when compared to the former. The properties you need to take note are range, uniformity, persona, and solidity. When you talk of range, there is a limit on the thickness and size of the steel. Because of these factors, the metal can be forged easily since shaping steel is rather a tiresome job. As for uniformity, the forger must be reasonably meticulous and has the ability to get a precise measure in order to maintain the same steel consistency. When it comes to persona, it is essential to note that the strength of your material is never consistent during the entire process. The last but not the least among the properties you need to consider is solidity. Steel forgings constitute to top-notch durability, greater toughness, and amazing strength, making it less likely to break or shatter.

Categories of Forged Steel

Steel forgings are composed of two categories – closed die and open die. In the closed die process, the steel is pressed between 2 dies that consist of the precut profile of the preferred shape. On the other hand, open die forging undergoes a deformation between several dies that do not entirely surround the material.

Steel Forgings Materials

Among the common materials used in steel forgings, the following are the most common: carbon, stainless steel, alloy steels, Haynes, Incoloy, Inconel, Rene, stainless steel, cobalt alloys, superalloys, tantalum, carbon steels, titanium, carpenter 20, molybdenum, tool steel, Monel, tungsten, nickel, Hastelloy, zirconium, cobalt, NX-188, and nickel aluminide.

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Looking for More Information About Forgings?

If you’re looking for a reliable steel forging company, Ferralloy, Inc. is a major supplier of the open die and closed die forgings to a global customer base. We have the ability to provide custom components as forged, rough machined, or finish machined to meet your exact specifications. Contact us today!

Forged Rolled Rings | How are Forged Rolled Rings Produced?

Did you know that manufacturers implement certain rolling procedures during the production of seamless forged rolled rings? Although the features of each rolling mill vary, they can shape rings that come in a wide range of weights – from a pound to over 300,000 lbs.

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Facts About the Production or Forged Rolled Rings

A Preform is Pierced in the Middle

In case you’re wondering, the entire process begins by piercing or upsetting a preformed metal in order to create a hollow shape that looks like a doughnut. Next, high heat is applied to the piece of metal before it is positioned about a mandrel roll. Continuous pressure is then applied to the part is it travels to the drive roll. During the process, the metal component is frequently rotated in order to decrease its wall’s overall thickness.

Variety of Configurations are Used

Although a wide variety of configurations are utilized in the process of producing seamless rolled rings, washer shapes and cylindrical shapes are the ones that manufacturers commonly produce. Furthermore, they also produce forged rolled rings that can be more than nine feet tall. This versatility in terms of thickness to height ratio provides various industries with plenty of options to choose from. A piece of specialized processing equipment can make it possible for manufacturers to produce rings that have greater proportions.

Custom or Complex Shapes Can Be Produced

If there’s one thing you need to know about rolled rings, it’s the fact that special tooling equipment can be used to produce rings in different shapes. In fact, you might be surprised to know that the most popular ones are those that are shaped like rectangles.

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Where You Can Find High-Quality Forged Rolled Rings

Looking to find high-quality forged rolled rings for your next project? Get in touch with Ferralloy, Inc. today. We’re the leading global supplier of engineered products and services.

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.

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!

Closed Die Forging | Why Closed Die Forging is the Best Manufacturing Technique

Most manufacturers use the closed die forging technique when they need to forge metallic parts that are small or medium-sized. The fact that multiple elements and factors are being merged during the process of forging leaves us no reason to wonder why this technique is able to generate results that are geometrically accurate. Here are some of the reasons why forging is one of the most popular options in the metalworking industry:

Strength and Durability

In terms of strength and durability, the finished products of closed die forging come first. Thanks to the internal structure, the continuity of the grain is maintained. If you’re interested in producing high-performance products that are both strong and durable, use the close die forging manufacturing technique.

Production of Net Shapes or Near Net Shapes

Forging dies are typically precision-machined that’s why their finished products are the net shape or near-net shape. When you use forging, less post-forging operations are required because near-net shape products are produced. In other words, you’ll save a significant amount of time and effort.

Cost-Effectiveness

Since forging creates products that feature close tolerance with optimum surface finish, the need for post-machining operations and finishing is greatly reduced. This implies that you’ll get to spend less money for mass volume production.

Versatility with Components

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.

what is closed die forging?

Do You Need More to Know More About Closed Die Forging?

When your requirement dictates closed die forgings, contact Ferralloy, Inc. today. We can help you determine your best, low-cost solutions.

Seamless Rolled Ring Forging | How to Produce a Seamless Rolled Ring

Did you know that a seamless rolled ring forging is a process that involves ring rolling on rolling mills? In case you’re wondering, these rolling mills come in different sizes in order to create rings with outside diameters that range from a few inches to over 300” and weights that range from 1lb. to about 300,000 lbs.

How Does the Process Work?

The process of producing seamless rolled ring forging begins with a circular preform of metal that was previously upset and pierced through the open die forging process to create a hollow donut-shaped component. The heat that is above the recrystallization temperature is applied to the donut before it is placed on the mandrel or idler roll. The donut is continuously rotated as the idler roll is moving under pressure toward a drive roll. As the donut is being rotated, its wall thickness is being reduced and its diameters are being increased.

Continuing the Process

Furthermore, different configurations can be used to produce various rings that are flat, washer-like parts or tall cylindrical shapes. In most cases, the ring ratios between wall thickness to height can range from 1:16 up to about 16:1. However, it’s important to note that it’s also possible to achieve greater proportions (thanks to special processing.)

Shaping and More

The most commonly used shape that’s known for its simplicity is a rectangular cross-section ring. But you can also use shaped tooling to create complex seamless rolled rings and custom shapes that have contours inside and/or outside of its diameters.

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Do you Need More Information About Seamless Rolled Ring Forging?

If you’re curious to know more about seamless rolled ring forging, it’s best to ask our team of experts at Ferralloy, Inc. We’re the leading global supplier of engineered products and services. What’s more, we offer total supply chain management to a diverse metalworking customer base. Ring us up now to learn more about our products and services.