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Alloy Castings | What are Super Alloys and Why Would I Use Them?

The integrity of any project requiring metal work lies on the integrity of the material used. There is a reason super alloys are named “super.” Their strength and stability make them ideal for particular products and alloy castings. If you are looking to create strong and high performing castings for your next industrial project, super alloys may be an option. Read why they are continuously growing in popularity:

What are Super Alloys?

Super alloys – also known as high-performance alloys – are alloys that offer paramount strength. They do not only have great mechanical strength. But, they are able to withstand high temperatures without deforming. And, super alloys are made even stronger every year. New chemical processes raise the temperature limit for different super alloys.

When Would I Use Super Alloys?

Super alloys have become more available in recent years. So, this has made them more popular. And, new super alloys are always under development to create stronger alloy castings. When a piece of metalwork needs to maintain strength while reaching high temperatures, a developer may want to use super alloys.

The aerospace and marine industries use super alloys for turbine engines. And, over the years, the heat resistance of super alloys has been growing. However, super alloys can be susceptible to environmental factors. Thermal fatigue, hot corrosion, and oxidation – all of which can weaken chemical bonds – may affect surfaces of certain super alloys. But, protective materials cam coat super alloys to prevent such issues from occurring.

Want More Information on Our Alloy Castings?

Ferralloy goes above and beyond the industry standard for our customers. And, we can help you find the best materials for your next project. Whether you’re looking for super alloys or an alternative, we want to provide you the best information on alloy castings, so please contact us today!

does ferralloy offer super alloy castings

What are the Benefits of Titanium Tubing?

In the metalworking world, every metal part possesses its own unique set of benefits. No matter what industry you’re in, it’s important to know the benefits of different metal components so that you can choose the part that will be the most valuable for your specific project. One metal part that is used in various industries for it’s advantages is titanium tubing! What are the benefits of titanium tubing? Keep reading to find out!

4 Benefits of Titanium Tubing

1. Lower Density

The density of titanium tubes is significantly lower than steel, copper, or nickel products. Despite their low density, they are very strong and rigid when compared to other alloy components.

2. Resistant to Corrosion

Another benefit of utilizing titanium tubing is that titanium alloys are resistant to corrosion. This makes these tubes an appealing option if you need a part to work efficiently in a highly corrosive environment.

 3. Resistant to Chemicals

 Corrosion is not the only thing that titanium tubes are resistant to. They are also resistant to chemicals. These titanium parts can withstand different chemical compounds while still preforming effectively.

 4. Great Heat Transfer Properties

Titanium tubes have great heat transfer properties thanks to its thermal conductivity and resistance. The same can’t be said for copper and carbon steel tubes. Their resistance to heat also allows them to work successfully at temperatures up to 600 degrees or higher.

These are just a few of the many benefits that come from utilizing titanium tubes. Because of these benefits, you can find titanium tubing in countless important industries such as power generation, sporting goods, marine, nuclear, and paper industries.

If you’re interested in using titanium tubes for your next project, Ferralloy, Inc. can help! We also have the infrastructure and facilities to supply raw materials in numerous grades and forms! Visit our metalworking foundry online today!

Forged Furnace Roll Trunnions

Ferralloy, Inc. began shipping an order for 120  furnace roll trunnions, or bell ends as they are sometimes referred to, for a new heat treating furnace ordered by a large international steel producer.

The requirement for forgings in this application is somewhat unusual as this component is typically supplied as a sand cast component. For reasons related to the inherent mechanical properties of a forging, we were asked if we could source the billet material in the desired chemistry, forge the trunnions, and rough  machine them to the drawing dimensions. We produced the open die forgings, which were then normalized and machined.  The forgings will be welded to centrifugally cast tubes and then the entire assembly will be finish machined before field installation in the new furnace.

The forgings weigh 70 pounds in the rough machined condition and were produced from a grade of heat resistant alloy steel.

forget furnace roll trunnions

What Are Radiant Tubes?

If you have a project that requires parts to function in extreme heat above 1,200 °F (670 °C), you need a heat resistant casting. It’s important to know, however, that all heat resistant products are not the same. There are countless factors that go into deciding which component is best for your specific industry and need. Radiant tubes are one of the many types of heat resistant products. Keep reading to find out if it can benefit your project!

What are Radiant Tubes?

The performance of a heating system depends not only on the furnace burner, but also on the radiant tubes. The aim of the radiant tubes is to transfer heat to the load through irradiation. Heat exchange occurs when the combustion fumes are generated by the burner and then are conveyed through the tube. Various sizes and shapes of different heat resistant materials are used for these tubes depending on the specific need, service temperature, and furnace atmosphere. 

Why are They Used?

Regardless of their shape or size, they are used to ensure no contact between the flames from the burner and the material in the furnace occurs. Radiant tubes are also used because they are able to reach process temperatures up to 2000 °F (1200 °C) and maintain temperature uniformity.

What are their Applications?

Radiant tubes are normally used in applications that require the furnace atmosphere to remain stable and without any chemical changes. Specific industries that often require radiant tubes include the steel industry, chemical industry, and ceramic industry.

Whenever you need to count on radiant tubes to provide consistent heat transfer, you can count on Ferralloy Inc. No matter your industry or application, we can provide you with high-quality parts that are competitively priced and delivered on time. Give us a call at 440-250-1900 or visit our foundry online to learn more about how Ferralloy Inc. can help with any of your metalworking needs!

What are radiant tubes?

From Sand Casting to Investment Casting

A large manufacturer of industrial motors requested Ferralloy, Inc. to redesign an internal motor component, so as to eliminate a large portion of the machining required to finish it.

By utilizing the investment casting process, the company was able to reduce the weight of the casting and actually ‘cast in’ a few features that were machined into the former design.

The reduction of weight, the near net shape of the redesigned casting and the reduced machining time, all contributed to a significant cost reduction for the customer.

Investment castings with Ferralloy can help reduce costs for your company

Investment Cast Boats

Ferralloy, Inc. is producing a family of investment castings for a international producer of refractory metal powders.

Investment castings from Ferralloy can help your business!

The castings are used in applications which require a reduction of the powder at temperatures in excess of 2,000 degrees Fahrenheit.  The investment casting process allows the boats to be cast to a near net shape while holding very close tolerances. These boats are produced in high nickel chrome materials which resist high temperature thermal cycling and oxidation.

Fabrication to Casting Conversion

Ferralloy, Inc. was recently contacted by a large automotive parts manufacturer to design a cast heat treating basket that would replace their current fabricated design.

Metal fabrications from Ferralloy Inc.

The customer provided Ferralloy, Inc. with their specific requirements such as operating temperature, the need to build in outside pockets for lifting and also to consider their need to stack the baskets on top of each other.

Steel castings can be ordered from Ferralloy Inc.

The resulting design gives them more strength, better heat resistance values and an estimated life expectancy increase of more than 100%.

Heat Resistant Castings | Steel Mill Application

There are a variety of applications where heat resistant castings are needed. Especially when temperatures reach extremely high levels, making sure that components in the equipment being used will withstand the circumstances is important in order to ensure the manufacturing process is successfully accomplished. What kind of applications benefit from heat resistant castings? The focus of this article will be on steel mills and how they accomplish what they aim to produce with heat resistant castings.

High quality heat resistant castings are available from Ferralloy Inc.

What are Steel Mills?

Simply put, a steel mill is an industrial plant used to manufacture steel. There are several processes that can take place in a steel mill; sometimes the iron ore is being processed in to steel and sometimes there are casting parts that are being manufactured from pig iron or scraps. In an integrated mill, the primary functions include iron making, steel making, casting, roughing rolling and product rolling.

For all of these processes to take place, different types of furnaces are employed, including a blast furnace where raw materials are integrated and liquefied. Heat resistant castings in this case are needed within the furnaces that can reach 2000oC. Furnace rolls and heat resistant castings are employed within the furnace being used to liquefy the raw ores into molten iron.

Heat Resistant Castings

For all different types of applications, it is important to have high quality metal parts that will withstand the strains of whatever processes you intend to do with them. High quality heat resistant castings can be produced and delivered for your project from Ferralloy, Inc. We have the technical authority to produce high temperature alloy components for your manufacturing needs. Our goal is to provide you with high quality parts are the most competitive cost. The range of products that we have the capability of producing is wide, so contact Ferralloy, Inc about your heat resistant casting needs today!

Furnace Rolls | What is Carburizing Furnace?

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 produce the highest quality and most effective product. Some clients are in the business of carburizing metals and for this industry we produce the highest quality heat resistant fabrications and castings available, including high quality furnace rolls.

Specialized furnace rolls are important for carburizing furnaces.

What is Carburizing?

For many, this action is unfamiliar, they just reap the benefits of “case hardened” metals. But what is it? Carburizing is a common heat treating process that hardens a surface to make it resistant to wear while maintaining strength of the core. This process is usually performed on carbon steel parts, high alloy steel bearings, gears and other components that require higher than usual resistance and strength.

Most times the process entails heating components in a pit furnace or sealed atmosphere furnace and then carburizing gases are then added at temperature. This is a very heated process, with temperatures usually hitting 1560°F to 1740°F. With these high temperatures, the components within the furnace operation need to be heat resistant and able to withstand the intense pressure of the process.

Specialized Furnace Rolls

A heat treating furnace requires heat resistant castings and specialized furnace rolls in order to operate efficiently. All of these parts make up a carburizing furnace and without the heat resistant characteristics, the process would not be able to take place.

Think of aerospace components, that need to definitely be resistant to wear and maintain a strong structural integrity. This process needs to occur in order to add a case hardness to many metal structures we use everyday. And in order for carburizing to occur the proper components need to be manufactured and produced at the highest quality. That’s why Ferralloy is your foundry of choice! Only the highest quality metal components leave our factories, and to your specifications. Give us a call for your heat resistant metal component needs!