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Casting Investment | Casting Investment vs Die Casting

Did you know that manufacturers have been using the casting technique since 1838? Although the basic aspects of the casting process haven’t changed much since then, modern-day machines and technological advancements make it possible to produce end products or parts in different ways – two of which are die casting and casting investment. If you’re curious to know the difference between both, take a look at this:

Die Casting Process

This metal casting process involves the injection of molten metal under high pressure into a mold cavity that’s made up of two steel dies. These steel dies have been hardened after being machined into shape. In most cases, non-ferrous metals such as aluminum, zinc, copper, magnesium, pewter, lead, and tin-based alloys are used in producing die castings. The manufacturer can use a hot-chamber or cold-chamber machine, depending on the type of metal or material that’s being cast. Furthermore, the die casting process is known to produce end products with an excellent surface finish as well as dimensional consistency. This method works best for manufacturing large quantities of small-sized to medium-size castings. For this reason, die casting creates more castings compared to any other casting method.

Casting Investment Process

Castings are based on lost wax casting. It’s one of the oldest metal-forming techniques that has been used for over 5,000 years. People in the olden days used beeswax to form the patterns they use in the casting process. Currently, manufacturers make patterns using advanced waxes, specialist alloys, and refractory materials. Casting involves coating a wax pattern with a refractory ceramic material before heat is applied to drain out the wax. Casting investment is known to produce metal and alloy parts with repeatability, accuracy, integrity, and versatility.

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If you need more information about the die casting and casting investment process, contact Ferralloy, Inc. today. We’re your comprehensive engineered product resource.

Castings | The Production of Metal Castings Explained

Are you wondering about how the process of producing metal castings work? Perhaps you already know that casting is a method that involves the dissolution of solid metal through the application of heat. Once liquefied, it is then poured into a mold or a shaped cavity where it is cooled during its solidification. Its end product can have almost any designer needs and setting.

The Earliest Industrial Process

The oldest known form is that of a copper frog. Historical data confirms that it was produced in 3200 BCD in Mesopotamia before iron was discovered around 2000 BCE. Years later in 700 BCE, China developed the first production of the cast iron and invented the sand molding process of casting metals in 645 BCE. Since the early 1st millennium CE, the crucible process which was a technique that was used to produce tool steel appeared and disappeared in different locations across the globe. It didn’t resurface until 1750 when it was reinvented in England by Benjamin Huntsman.

The Process of Producing Metal Casting

Although the process of producing metal castings into objects that are usable has evolved to become more accurate and automated, the method is essentially the same at its core. Its two main divisions are classified according to the nature of the mold being used. First is the expendable mold which can only make one casting. It’s made of sand or other materials that are similar to it and uses binders to support the material as it holds its shape.

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To wipe out castings, the molds should be damaged. Second is the long-lasting mold which is capable of creating multiple metal castings. It’s made of metals or refractory ceramic and has parts that can be closed or opened which allow the eradication of the castings. If you’re interested to know more about metal castings, contact Ferralloy, Inc. today. We’re the leading supplier of quality castings all over the world.

Heat Treating Baskets | The Benefits of Using the Right Heat-Treating Basket

The heat-treating process is one of the most important steps in preparing components to be used on job sites. One crucial piece of the process is the heat treating baskets. These baskets are often overlooked but play arguably the most important part of the process.

What is a Heat-Treating Basket?

A heat-treating basket is used in the heat-treating process. It is what the components that are about to be heat treated get put onto before being exposed to the extreme heat. Depending on what kind of treatment they are getting, it will vary for how long these baskets need to be exposed to the heat. Normally, these baskets break down quickly and can only be used a couple of times before they are completely broken down.

Benefits of a Better Basket

Typically, the average treating basket is designed to break down. Due to the extreme environments that they are constantly exposed to in the heat-treating process, manufacturers usually do not try to create something that lasts. But by doing that, you are already tacking a lot onto the final cost of the project because of all the baskets you will have to buy. Our heat-treating baskets are designed to last longer so you can get the most out of them without re-buying them constantly or having them break down mid-project.

What are heat treating baskets?

Looking for the Best Heat Treating Baskets on the Market?

If you’ve been looking for the best heat treating baskets that are second to none, then you need to contact us today. Ferralloy only carries the highest-quality baskets that are made to last longer than the average piece of equipment. Save yourself from constantly re-buying heat treating baskets by picking up the phone and getting in contact with one of our sales representatives today.

Castings | What is Gravity Fed Casting and are the Benefits?

When it comes to casting, there are primarily two popular methods. Pressure casting, which uses gas or air pressure to help facilitate the flow of material into the casting and gravity fed casting uses the natural force of gravity to help the material flow where it needs to. Castings are all around you and are not as hard to make as you would think.

The Process

The gravity fed casting method can be broken down into primarily three steps. First, the heated mold is coated with a releasing agent that will help the final product come out of the mold at the end. It also helps cool the mold after the previous part was added. After that, the molten metal is poured into the mold and nature takes its course. Once the molten metal has spread to where it needs to in the mold and the part has sufficiently cooled, it is removed from the mold and the process is repeated until the order is filled.

Benefits of Gravity Fed Casting

Gravity fed casting has a lot of benefits. For starters, this method has a much smoother cast surface finish compared to sand casting. Because of that, it requires less machining and thus should lower the cost of your project. Gravity fed casting also allows you to create thinner walls and has a much faster production time compared to other casting methods. The process is very repeatable and offers good dimensional accuracy too.

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Have you been looking for more information about castings? If so, contact us today. Ferralloy Inc. is here to help you find the parts and components you need for your next job at the right price.

Heat Treating Baskets | What Stackable Cast Baskets Can Do for You

When it comes to heat treating your parts, a crucial part of the process is using a heat treating basket to expose the parts to extreme conditions. When it comes to heat treating baskets, there are a wide variety of types. Typically, even the strongest baskets that have previously been on the market do not last very long but thankfully that isn’t the case anymore.

What Is a Heat Treating Basket?

One of the many steps in the process of finishing parts is heat-treating them. You do that by exposing them to high heats in a controlled environment. This gives them the proper treatment to withstand high heats when they are put to use in machines. Heat-treating baskets are how this result is achieved. These items are put inside the baskets and then exposed to extreme conditions to temper the parts.

Benefits of Stackable Cast Baskets

The biggest benefit of using heat treating baskets is how durable they are. Traditional baskets used for heat treating break down due to the extreme temperatures and conditions. A lot of the baskets normally used do not last very long and usually end up being warped beyond repair in little to no time. Heat treating baskets last much longer than these baskets because of their high nickel content and superior design in comparison.

What are heat treating baskets?

Looking for Heat Treating Baskets?

When it comes to selecting the proper heat treating baskets for your next project, make it the Ferralloy Stackable Cast Basket. They are built tougher to last longer and can save you money in the long run due to their durability. Contact us today for more information about our baskets or a wide variety of other products.

Inconel | What is Inconel and How Can It Be Used?

There are many different types of materials that are used in the industrial world. One of the best is Inconel. Given all of its applications and uses, you can find the material anywhere that you might need a material that is resistant to heat and corrosion. Check out this blog to learn more about Inconel and why you need to be using it for your next project.

What is Inconel?

It is an alloy of nickel that also contains chromium and iron. It is resistant to both corrosion and high temperatures, making it a valuable material. One downside to it is that it is very expensive to produce. While it is extremely strong and durable, it is one of the more expensive materials you can use. It is worth the cost because the material is extremely tough and does not break down or falter often.

How is it Used?

Given the properties of the material, it has a ton of practical applications. It is famous for the extreme temperatures that it can withstand. It can retain enough tensile strength to hold sizable loads while being exposed to temperatures over 2,000 degrees Fahrenheit. In addition to that, Inconel is great when it comes to dealing with rapid temperature changes too. It can withstand the cold just as well as it withstands the heat. Given that the material does not corrode, it is very popular to use for various marine applications too.

What is inconel?

Where Can I Find Inconel?

If you are looking to use Inconel at your next project, contact us today. Ferralloy has been your destination for all industrial materials for going on 40 years.

Investment Castings | What is an Investment Casting?

Investment castings, otherwise known as lost-wax casting, makes parts from molten metals. Typically, it is used to make stainless-steel alloys, brass, aluminum, and carbon steel. It is also used to mass produce parts and make small, detail-oriented parts that require a lot of precision.

How is an Investment Casting Made?

There are three ways to make an investment casting:

  • Form a gelatin mold around a 3D model of the final product
  • Create a metal mold of the final product and fill it with hot wax
  • Carve a replica of the product out of wax

To cast several parts at once, you can put many wax patterns into a tree. The tree is dipped over and over again in a ceramic slurry. After getting multiple layers, the ceramic hardens and is then heated to remove the wax. Once the wax is cleared away, molten metal is poured into the empty mold. After the metal cools, the ceramic mold is destroyed and the part is removed.

Benefits of Investment Casting

Investment casting is more expensive than sand casting, but it allows for so much more. You can cast more items with investment casting and you can create more detailed parts too. Engineers have tons of freedom to create complex shapes and small parts with investment castings. Investment castings are also smoother and do not show a seam as sand casting does.

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Investment castings are a great way to create the pieces you need. If you would like some more information about investment castings, contact us today. Ferralloy has been the best option for all metalworking needs and more for 40 years.

Radiant Tubes | What Are Radiant Tubes and Their Application?

When it comes to needing parts to work in high temperature, it is important to remember to work with a heat resistant casting. However, not all heat castings are created equal. There are numerous different factors that go into selecting the proper component. Radiant Tubes are one of the many types of heat resistant products that might be perfect for your next project!

What is a Radiant Tube?

A radiant tube is a very important part of furnaces that are used for the heat treatment of other metals. The tube is used to help heat the components that need heating but prevents the metals from coming into contact with things that might combust. They are classified by their contraction. The simplest tubes are just vertical or horizontal but they have been known to be very complex.

Why Are They Used?

Radiant tubes are important because of what they do. No matter what the size or shape of the radiant tube, they ensure that there is no contact between the heat from the burner and the material in the furnace occur. These tubes are used because they can withstand extremely high heats, upwards of 2000 degrees Fahrenheit.

What are radiant tubes?

Where Can I Find Radiant Tubes?

Have you been looking for radiant tubes for your business? Contact us today! Ferralloy is here to help you with all of your welding needs and more

Alloy Castings | Industrial Applications of Alloys

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.

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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.

Titanium Fasteners | Benefits of Titanium vs Other Materials

There are many different metals that can be used in an industrial setting, but the best is titanium. Titanium fasteners, tubing, and bolts are just a few things the material can be made in to. It can be used to make many different types of parts and has tons of benefits. As a result, there are many different parts that titanium can be used for.

Usually Maintenance Free

Given that titanium’s oxide layer protects the fasteners from corrosion, it makes it much more durable than the average material. Given that it doesn’t corrode, that means there is little to no maintenance needed on the piece. You will want something that is strong, durable, and sturdy like titanium for your next project.

Cost-Efficient

Because titanium parts are typically maintenance free and do not corrode in the first place, it is a very cost-efficient component. You will not need to keep replacing it or worry about it falling apart on you. Once you make the investment in titanium, you won’t need to worry about sinking more money into it.

Can Combine with Other Metals

One of the biggest advantages of titanium is that you can combine it with other metals to create an alloy. You can combine it with:

  • Steel
  • Aluminum
  • Manganese
  • And more

Having such a versatile material like titanium is not only very helpful but smart too. Using the best materials will lead to the best results.

Are you looking for Titanium Fasteners?

Looking for Titanium Fasteners?

If you are looking for the best titanium fasteners, contact us today. Ferralloy has been providing titanium parts to countless industries and companies throughout the world for almost four decades. We are here to help you and your business in any way possible.