Contact Us: 1-440-250-1900

Rolled Ring Forgings | What Is the Process?

Rolled ring forgings are used in a wide range of industries. Rolled ring forgings are an appealing metalworking option thanks to their strength, versatility, and cost effectiveness. But how do they get that way? Rolled rings are able to hold so many advantages thanks to their forging process. Keep reading to find out everything you need to know about this metalworking method!

3 Steps of the Rolled Ring Forgings Process

The forging process performed to create rolled rings is extremely difficult and complicated. To help make it easier to understand, we broke it down into 3 simple steps.

Step 1: A thick and circular piece of metal is heated. It is then pierced to form a hollow ring. This ring should somewhat resemble a donut.

Step 2: The ring is heated to recrystallization temperatures. It is then placed onto an idler roll. Squeezing, stretching, and in some cases, pounding, then occurs until it forms into a thin ring.

Step 3: The shaping on the idler roll continues until the forgings possess the desired diameter and wall thickness.

This is the process that creates rolled ring forgings. The final ring products can range from tall cylindrical shapes to small washer-like parts. They can be created using basically any type of metal or alloy. The diameters can range from 1 to 300 inches. Weights can range from 1 to 3000 pounds. No matter how complex or customized the shape is, the rolled ring forging process creates extremely dependable and sought after parts. Some specific components include valves, bearings, flanges, gears, clutches, drives, and so on.

If you need rolled ring forgings for your next project, we can help. Ferralloy, Inc. is the best in the metalworking industry. We provide high quality, competitively priced metal components to a variety of industries throughout the global marketplace. Visit our foundry online today to learn more!

Closed Die Forging | What is Closed Die Forging?

Forging is a favorable and effective manufacturing process. It is able to form high quality metal components for countless industries. Forging is able to do this because it can be subdivided into specific forging processes. The forging process used depends on the specific needs of the project. Closed die forging is one of the many types of forging. Keep reading to find out the process, advantages, and applications of closed die forging!

What Is Closed Die Forging?

Closed die forging is a forging process. It is sometimes referred to as impression die forging. This process involves two or more dies that contain a precut profile of the desired component. The heated raw material is placed at the bottom of the die. The dies then move towards each other until the raw material is formed into its required shape and size.

Why Is It Used?

Most metals and alloys can be forged through the closed die process. Closed die forgings of steel, stainless steel, titanium, aluminum, and other alloys can produce an unlimited variety of 3-D shapes in a wide range of weights and sizes. As a result, this is one of the best processes for complex shapes that require elaborate designs.

What Are Its Applications?

Closed die forging is used for applications that require high quality components. People turn to closed die forgings when their project requires strength, reliability, and resistance to fatigue. Because of this, closed die forging is an appealing manufacturing process for numerous industries. Some specific parts that are formed by this type of forging can be found throughout the automotive, aerospace, and defense industries.

Ferralloy Inc. can meet any and all of your forging needs! We’re a leading global provider of forgings to major companies in numerous industries. We produce rolled ring, cold headed, open die, and closed die forgings in a variety of alloy steel grades. Connect with our metal manufacturing company online today!

What Is the Difference Between Castings and Forgings?

There are several different methods and techniques that can be used in manufacturing a variety of different metal components. Based on the purpose and ultimate use of the metal part, different procedures are used to create the highest quality piece possible. While determining the best process, some arrive at the question of whether they need castings or forgings. Which would be more effective for their metal component and most cost effective? Keep reading to find out the differences and find out which process would be more beneficial to your business!

What Are Castings?

Valve Sand Castings

The casting process is where the metal is heated until molten and then poured into a die to form a specific shape. This process is beneficial when the shape of the component is intricate or when the component needs to be a very large size. Another advantage of castings is that machining costs can sometimes be cut down because the component can be made to certain specifications.

What Are Forgings?

Forging is a technique where metal is heated up and then hammered and manipulated into the final desired shape. Forgings are generally stronger than castings, but there are some limitations to manufacturing capabilities of forging. Components can not be very intricate or complex when forging. Usually if a component needs to be forged and also needs to meet certain size requirements, the component needs to be machined after it has been produced.

Are Castings or Forgings Better?

Which metal component production method is better? This will completely depend on what the component will ultimately be used for. Both castings and forgings have their advantages, so depending on what the component will be used in will determine which production method will serve you better. If you have questions about what type of metal component you should be purchasing for your company give Ferralloy, Inc. a call today! We are metalworking industry leaders and have the technical authority to deliver the highest quality castings and forgings! Whatever your metal need is, we can meet it and exceed your expectations!

Dryer Drum Tires

Ferralloy, Inc. is shipping 2 sets of rolled ring forgings to a customer in the cement industry.  The seamless rolled rings sets are 80 x 70 x 7” and 78.5 x 72.5 x 6.5”, rough machined to a surface finish of 125 RMS from 4140 material.

Rolled ring forging process is a specialty of Ferralloy Inc!

These forged rings are components of a dryer drum used in the cement industry to process cement powder.

For more information about the processes behind cement manufacturing see this link!

Zirconium Components | Metalworking | Ferralloy

For the wide variety of uses available for metal across the multitude of industries, it may be difficult to decide on the specific material, process or shape needed. Ferralloy is available to help you navigate through you metalworking needs. From choosing which material is best suited for your project to determining which processes would benefit your company the most. In some cases, the material Zirconium is required for zirconium components, but there are some unfamiliar with the reasons and features that make this metal desirable and useful. To find out more about how Zirconium could benefit your project as a metal component, keep reading!

Zirconium components can be used in a variety of applications.

What is Zirconium?

 A chemical element, Zirconium is a solid at room temperature; and it’s a strong solid at that. In nature Zirconium does not exist in a pure state. It must undergo complex physico-chemical processes in order to obtain pure zirconium. The metal itself resembles steel in many of its features and characteristics. Zirconium is resistant to corrosion and high temperature steam and water. The different alloys that can be created from Zirconium are design to also withstand highly corrosive environments, like organic and mineral acids and strong alkalis. Because of these features, this metal is highly useful in scenarios where components and parts will be exposed to extreme environments.

What Are Zirconium Components Applications?

The metal has a wide variety of products it is used in. Zirconium ingots, forgings, plants, sheets, rods, tubing and other zirconium components are just a few of the variety of products that can be made from this metal. As far as applications go, it is a key component in many military tools. Heat exchanges, condensers, piping systems, reactor vessels and valves are just some of the applications where zirconium could play a part.

For all of your zirconium component needs, Ferralloy can provide a rapid response, competitive pricing and just-in-time delivery. The wide variety of metals we offer includes metals of all grades and temper, as well as exotic and heat resistant alloys. We have the ability to supply the raw material or offer your company the finished and machined component. Call us at 440-250-1900 today or connect with our metal manufacturing company online. We can help your company get the metal components it needs today!

Machined Forgings | What is Machining?

When working with foundries to order the manufactured metal components you need, there may be several options offered to you for your specific piece. To deliver a completely finished and high quality product, Ferralloy offers machined forgings to the customers who require this value added service. Our efficient and established processes can produce premium machined forgings. Find out more about machining below!

What is Machining?  

Machining is a manufacturing process in which a metal component is cleaned up to the specific measurements that companies require them to be. After the forging process the product that is produced is a rough shaped component. For some applications it is important for the forging to be exact measurements and exact shapes and this is where the machining process comes into play. With several different tools and techniques, the component is perfected through the machining process. There are several different tools available to use during this process, including boring, cutting, drilling, grinding milling and turning tools. There are also different types of cutting techniques like laser, plasma and oxy-fuel cutting.

What are Machined Forgings Applications?

There are several industries where machined forgings are required, including, in particular the aerospace industry. In order to manufacture vehicles in which will be utilizing the laws of physics to fly in the air, there is a specific science behind it. The pieces used in such aircrafts need to be manufactured to precise measurements in order for the product to function correctly. Machined forgings are just one of the components used in the aerospace industry.

Closed Die Formed Machined Forgings

At Ferralloy we supply high quality products and services to a large range and varied metalworking customer base. We are experts in the foundry industry and can manufacture machined forgings to your exact specifications. Contact our metalworking supply company today for more information about our product selection and manufacturing capabilities! We can help supply your company with the metal components you need!

Rolled Ring Forging Vs. Plate Burnout

Metal Rings are needed for several different types of applications. One of the most widely used metal components, metal rings can vary in size, thickness and in diameter. In order to achieve a strong, durable and cost effective metal ring for your project, there is one process that stands above the rest, but which is it? Keep reading to learn the differences between the rolled ring forging and plate burnout processes in order to manufacture a metal ring.

Rolled ring forging is the best process for rolled ring components

Plate Burnout

In the Plate Burnout process, which is just one of the many processes in which a metal ring can be achieved, the metalworker begins with a plate of metal. Once the component specifications are known, the plate is punctured in the shape and size of the metal ring that is needed. Essentially, the ring is just punched out of the metal to form in the metal ring. This type of method make the metal ring more susceptible to fatigue.

Rolled Ring Forging

In the manufacturing method of seamless rolled ring forging, the waste of the metal that is punched out is avoided and the piece and stronger and more durable. A donut shape is formed from metal and then is forged into the metal ring that is needed. The size and diameter is shaped from this donut shaped metal, as the metal is at extremely high temperatures and is malleable. This process saves wasting the metal from a plate when the ring is punched out, which makes it a more cost effective method. This process also results in stronger components.

For all of your metal manufacturing needs, Ferralloy Inc has the authority and experience to help you. They are industry leaders in metal working and can suggest the best methods for manufacturing your metal component and at competitive rates. They are dedicated to producing and delivering the highest quality products, to fulfill your project in the best manner. Contact Ferralloy Inc today to inquire about your metal working needs!

What is the Seamless Rolled Ring Forging Process?

A process used widely and performed to the highest level by Ferralloy, the seamless rolled ring forging process plays an important role in the manufacturing of certain components. Forging is a method of manufacturing inherently stronger components for machinery. When apparatuses are needed for the development of wind turbines or when high quality gears are needed for mechanical parts, the seamless rolled ring forging process is used to manufacture superior pieces. What is this process? Keep reading to learn more about the role that the seamless rolled ring forging process plays in the metal working industry!

Rolled Ring Forging Process can be accomplished at Ferralloy Inc!

What is the Process?

 To begin the seamless rolled ring forging process, an ingot or billet is cut to size and then upset to achieve mechanical properties. What this means is that the starting stock pushed between flat dies at its plastic deformation temperature in order to achieve the proper shape. Then the center of the ingot’s center is punched to create a ring rolling “donut”. The stock would be hot at this point and the middle would be pierced to displace the metal radially.

Once the punch out has been done and a complete hold through the stock is created, the ring is now ready for the ring rolling operation. It begins with ID and OD pressure being applied to the ring, and as the pressure increases, so does the ring diameter. When the desired ring diameter is achieved, the seamless rolled ring forging process is complete.

Rolled ring applications range from ring gears that can be used in industrial and farm equipment to bearings and flanges. Rolled ring components can be seen in power plants, chemical plants, freighters, cargo ships and wind mills. For the best quality metal components, trust none other than Ferralloy, Inc for any metal manufacturing needs. Connect with our metal manufacturing company today and find out how we can help you meet your metal working needs!

Rolled Ring Forging Process in an illustration

Steel Forgings | What Is Forging?

When there is a need in the metal working industry for steel forgings or a product that will need to withstand a large amount of pressure and wear, or if a company is in need of a mechanical piece, the process of forging may be required. Most of the parts in a car and aerospace components are made with this process, and these industries require steel forgings often because the strength and durability requirement. Forging is a specialty of Ferralloy and we will discuss in detail the process, to help you better understand why our products are of the highest quality.

Steel forgings of the highest quality can be ordered from Ferralloy Inc.

What is the Forging Process?

The forging process is a manufacturing process that involves applying force to metal in order to deform and change the shape of the metal and form a specific piece. Usually the metal is deformed using a negative cavity, or a die, and then is hammered, pressed, rolled or squeezed to modify the metal into the desired geometric shape. Metal forging is used to create some of the strongest manufactured parts, like steel forgings, as mentioned previously, that are commonly used in cars and aerospace components.

The forging process can be done either with cold or hot forging, depending on the ultimate shape and purpose of the part being created. If the component required a lot of detail and sophistication in the design, hot forging will most likely be used. However, if the steel forgings are less sophisticated and need to be manufactured in large quantities, cold forging will be the best option.

No matter what your steel forgings specifications are, our professional metal working company can manufacture whatever component you need. We offer many value added services, like machining, for industries like the automotive, aerospace, off-road equipment, mining, food service and more across the board! If you find your business in need of steel forgings, know that Ferralloy will deliver a high quality metal component at a competitive price! Call or visit us online today!

Forgings | Difference Between Hot and Cold Processes

 As a company focused on providing only the highest quality metalwork products to the companies and industries in need of castings, forgings and machining goods, we understand the importance of all the different types of processes involved in developing these products. We stay at the forefront of advanced techniques in the production of fabrications relating to the metalworking industry. One of these processes is forging and in this following post we will examine the differences between the different types of metal forgings available for producing high quality metal workings.

What is Forging?

High quality forgings can be found at Ferralloy Inc

It is a good idea to begin with what “forging” is in respects to our metalworking industry. Forging is the process in metal works manufacturing where the metal is pressed, pounded or squeezed under great pressure into different unique parts, known as “forgings”. The metal used in this process is never melted, as it is in other processes relevant in this industry, and the process can be done using different techniques and temperatures; hot and cold.

What is the Difference Between the Different Types of Forging?

The difference between the different types of processes is the temperatures and the effects that the temperatures have on the process and forgings. First, cold forging involves impression die forging or true closed die forging with lubricant or circular dies at room temperature. In cold forging it is easier to impart directional properties, there is increased dimensional control and it handles high stress and high die loads. In this process, little to no finishing work is required and so it helps saves on the costs side of the product manufacturing. But on the flip side, this process is generally restricted to simple shapes being produced in high volumes.

For more complex shapes and configurations, hot forging is required. The metal is deformed at a high enough temperature so that the recrystallization occurs simultaneously with the deformation in order to avoid strain hardening. In order to avoid oxidation of certain metals, a process refereed to as isothermal forging is used, and it simply refers to the deformation taking place in a vacuum. This forging technique allows for a more customized component production, however with this method there is a loss in precision for dimensional tolerance in the process.

Essentially, when manufacturing a metal fabrication is important to consider the desired component and required functionality of the component when determining which forging method to utilize. At Ferralloy we supply high quality products and services to a wide range and diverse metalworking customer base. We are experts in the metalworking industry and can manufacture forgings to your exact specifications. Contact our metalworking supply company today if you have any additional questions on the types of manufacturing processes or products necessary for your metalworking business.