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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.

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!

 

 

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.

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.

Alloy Castings | Fabricated Annealing Fixtures

The ‘Heat Resistant Alloy Division’ of Ferralloy, Inc. recently shipped the first four (4) ROD COIL ANNEALING FIXTURES to a customer in the steel processing industry.

The fixtures were engineered and produced for the customer and were constructed from Cast HT alloy base grids along with a centrifugally cast center post also made in HT material. The gussets and stiffeners were laser cut from 330-grade alloy sheet. All components were assembled utilizing a double pass welding process.

The fixtures for this customer are used to anneal alloy rod on coil in furnaces operating at 1,600 degrees F.

 

alloy castings

Heat Treating Baskets | Benefits of Steel Fabrications

Heat treating baskets can be an efficient way to handle the parts finishing process. A well-designed basket is effective at keeping parts safe from damage and is often useful for a variety of processes. While the baskets can be made out of a variety of materials, steel fabrications are the best for a number of reasons. Let’s take a look at the benefits of using steel fabrications with your heat treating basket.

Heat Resistance

Obviously, when it comes to a heat treating basket, the biggest need is heat resistance. With steel, the heat resistance far exceeds that of plastic or other materials. The melting point of a basic stainless steel alloy is about 2,550 degrees Fahrenheit while even the strongest of plastics has a melting point of 750 degrees Fahrenheit.

High Load Capacity

On average, steel has a much higher tensile strength than plastic. The higher tensile strength of steel allows baskets made from this material to handle loads that would crush a frame made of plastic.

Lasts Longer

While there are many factors that can cause a plastic basket to fall apart, steel baskets, are able to resist those factors. They include being impervious to:

  • High temperatures damaging the polymer’s bonds
  • Chemicals soaking into the basket and contaminating it
  • Oxygenation of the basket decaying its molecular structure

Are You Looking for Heat Treating Baskets?

At Ferralloy we offer high-quality heat treating baskets in steel and other materials. Contact us to learn more about how we can get you the heat treating basket you need today.

 

What are heat treating baskets?

Furnace Rolls | Gas Furnace Types

Furnace rolls work in some of the harshest environments. They will typically see temperatures in excess of 500 degrees Fahrenheit for years at a time. Materials used are made to withstand this criteria, so they are also difficult to machine. Let’s take a look at some of the different types of gas furnaces that furnace rolls are found in.

Modulating (or Variable Speed) Furnace

This furnace adjusts its flame incrementally so that the true temperature never varies more than 1 or 2 degrees from the thermostat’s target temperature. In terms of comfort, it is the most comfortable gas furnace you can buy. Modulating gas furnaces are among the most energy-efficient furnaces and are rated at 98% efficiency.

Two-Stage or Dual-Stage Furnace

The two-stage furnace is not as complex than the modulating furnace but better than the single stage furnace. Rather than a simple on/off operation, its flame can be on/high, on/low, or off. Adding this second flame setting makes a dramatic difference in energy costs.

Single Stage Furnace

With a single stage furnace, the gas flame is either on or off. Because of that, the furnace waits for the temperature in the house to get cold before firing on. Then, the furnace rams the house full of heat until the thermostat shuts the system down.

Are You Looking for Furnace Rolls?

No matter what the use, Ferralloy offers high-quality furnace rolls at competitive prices for your next project. If you are looking for furnace rolls, contact us today to learn more.

 

What can furnace rolls do?

Heat Treating Baskets | What is Heat Treating?

Heat treatment is the process of heating and cooling metals to change their microstructure and to bring out the physical and mechanical characteristics that make metals more desirable. Let’s take a look at the heat treating process as well as some examples of heat treating, such as heat treating baskets.

What is Heat Treatment?

Heat treatment occurs when a metal is heated and then cooled in order to change its shape and structure. The temperature metals are heated to and the rate of cooling after heat treatment can significantly change metal’s properties. The most common reasons metals undergo heat treatment are to improve their strength, hardness, toughness, ductility and corrosion resistance.

Annealing

Annealing is a form of heat treatment that brings a metal closer to its equilibrium state. It softens metal, making it more workable and providing for greater ductility. With annealing, the metal is heated to a higher temperature than normal before being slow-cooled.

Quench Hardening

Quenching is a heat treatment method that quickly returns metal to room temperature after it is heated above its upper critical temperature. This method is less expensive than annealing and stops the cooling process from altering the metal’s microstructure.

Precipitation Hardening

Precipitation hardening is also known as age hardening. It is a heat treatment process that creates uniformity in a metal’s grain structure.

Are You Looking for Heat Treating Baskets?

At Ferralloy, we offer heat treating baskets for any project you might need. Contact us today to learn how we can help you with your next project.

 

Where can I find heat treating baskets?

Furnace Rolls | Where Can I Find the Best Furnace Rolls?

Furnace rolls are just what they sound like. They are specialty rolls that are found in furnaces and used to allow furnaces to operate efficiently. A popular use for these rolls is found in a method called carburizing. Let’s take a look at carburizing and where you can find furnace rolls?

What are furnace rolls?

Carburizing

Carburizing is a common heat treating process that hardens a surface to make it resistant to wear while maintaining the strength of the core. Carbon steel parts, high alloy steel bearings, gears and other components that require higher than usual resistance and strength all go through the carburizing process. During carburizing, temperatures can reach 1560°F to 1740°F. Because of the high temps, all the components within the furnace need to be extremely heat resistant.

Furnace Rolls

One of those components that is extremely heat resistant that is found in a furnace is furnace rolls. They will typically see temperatures in excess of 500 degrees Fahrenheit for years at a time. These rolls are made of stainless steel that can withstand extreme temperatures for an extended period of time.

Where Can I Find the Best Furnace Rolls?

When you are in need of metal components, like furnace rolls, Ferralloy takes the time to learn and understand what your needs are in order to provide you with the highest quality product that you need. Only the highest quality metal components leave our factories, and to your specifications. Contact us today to learn more about how we can help with all your metal needs.

 

Where can I find the best furnace rolls?

Heat Resistant Castings | Everything You Need To Know

When it comes to different types of projects involving metal parts, it’s important to consider the sensitivity of the metals you’re using. Depending on the project, you must make sure that the parts can withstand the processes you intend to use. One example of a process to be wary of is extreme heating. In the case of extreme heating, heat resistant castings would be best. Many industries benefit from this type of casting. These include air craft and aerospace, oil and gas, road construction, coal mining, steel production and processing, off road equipment, food equipment, railroad, biowaste and more.

What Are Heat Resistant Castings?

heat resistant castings

Heat resistant castings are castings that don’t melt or corrode during high-end industrial operations involving high temperatures. In fact, they have the capability of performing in conditions above 1200°F. Heat resistant castings are usually higher in alloy content than other types of castings. They mainly consist of nickel and chromium. Nickel is usually present in amounts of up to 70 percent. Chromium is usually present in amounts of 10 percent to 30 percent. Other elements, however, are used as well. These include iron, carbon, silicon, manganese and molybdenum.

If you have a project coming up that requires parts to perform at temperatures above 1200°F, Ferralloy Inc. assist you. Here at Ferralloy Inc., we can supply you with all of the parts you need for your heat resistant castings. Our products include trays, baskets, fans, furnace rolls, retorts, skid riders, muffles, roller rails, piers, grids, pickling hooks, walking beams, radiant tubes, fixturing, corrugated boxes, generator tubes, chain guides, pusher heads, heating elements, burner nozzles, hanger bars, tube support and enameling hangers. And if you need us to, we can make recommendations about which products are best for your specific wants and needs. So don’t hesitate any longer to start your project! Contact us today!

heat resistant castings help