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Machined Forgings | The Biggest Benefits of Machined Forgings

Are you aware of the increasing global demand for machined forgings? The fact that the global forging market is expected to grow by leaps and bounds between 2017 to 2025 makes us wonder why machined forgings are preferred in high-precision industries that include automotive, automation, aerospace, fire systems, water circulation, and more. Check out the biggest benefits of machined forgings:

Strength and Reliability

If you want to make sure that your metal parts will exhibit superior strength and reliability, go for machined forgings. Compared to products that were produced via casting, fabrication, and welding, machined forgings are able to maintain their performance on a wider temperature range because of their tight grain structure.

Versatility

You’ll be amazed at the wide array of metals that can be forged into your desired shape. Although each of these options comes with a unique set of characteristics, the forging process can be applied in the production of specific parts that your project requires. Commonly used metals that are used to produce machined forgings include titanium, copper, carbon, brass, aluminum, stainless steel, and more. As a result, industries are able to spend less money to create strong components.

Enhanced Metallurgical Properties

In most cases, a process that involves selective heating and non-uniform cooling leads to failure of a particular component. With machined forgings, you can be sure that your finished shape will exhibit superior grain flow without internal voids. You’re probably aware that shrinkage and porosity are often seen in casted products. However, with machined forgings, the occurrence of unexpected failure under high-temperature differences or stress is greatly reduced.

Cost-Effectiveness

When it comes to precision metal manufacturing in high production runs, machined forgings offer a significant cost advantage because of the fact that the materials that can be used in the process are cheaper compared with the materials that are required in other metalworking processes.

what are machined forgings?

Learn More About Machined Forgings

Are you searching for technical consultation about machined forgings? Contact Ferralloy, Inc. today!

Investment Casting | The Advantages of Investment Casting Over Other Processes

Anyone who’s in the field of metalwork is aware of the fact that various casting methods can be used to turn molten metals into specific shapes and designs for commercial and industrial purposes. However, if you’re interested to determine which of these casting methods would best affect your bottom-line profits, you may want to take a closer look at the advantages that investment casting has over other options.

Investment Casting vs. Die Casting

Since the process involved in die casting involves forcing molten metal into a mold cavity, it would require the use of hardened tool steel for tooling. This implies that start-up costs to new programs can become extremely expensive. Moreover, the fact that a tool wears quickly means that you’ll need to spend on refurbishments and replacements throughout its life. The usefulness of the die casting method is also limited because it won’t work well for ferrous metals such as stainless steel and carbon steel. On the other hand, the process of investment casting involves injecting wax into a less expensive aluminum cavity that’s also easier to cut and cheaper to maintain. Aside from the fact that wax is easier on tooling, investment casting can also be used for both ferrous and non-ferrous metals.

Investment Casting vs. Sand Casting

Since cavities for sand castings are created by making a negative in a bed of sand, each sand shell produces a rough exterior to castings. Therefore, extensive work to create a surface finish is necessary. Compared to investment castings, sand castings couldn’t hold as tight of tolerances and will need more machining. A much smoother finish is made possible by using investment casting because the process uses a ceramic mold. This implies that the amount of machining needed after casting is significantly reduced. Plus, for most of its applications, it holds a .0005”/inch tolerance.

where are good investment casting?

Looking for Information About Investment Casting?

If you want to know more about investment casting, reach out to one of Ferralloy’s sales professionals today.

Forged Rings | Where Can I Find High-Quality Forged Rings?

Forged rings are produced by a process called ring rolling on rolling mills. That’s the basic part, but there are several different types of forgings depending on what you are looking for. Here are some of the different types of forging processes.

Impression Die Forging

Impression die forging pounds or presses metal between two dies that contain a precut profile of the desired part. Parts from just a few ounces to 60,000 lbs. can be made via impression die forging. It is also referred to as closed-die forging and forges steel, aluminum, titanium and other alloys. Impression die forging can produce a variety of 3-D shapes that range in weight from mere ounces up to more than 25 tons. The process is used to produce hydraulic presses and mechanical presses and hammers.

Cold Forging

While the majority of forging is done at extreme heat, there is one that is done cold. Cold forging can make a wide variety of part shapes such as shaft-like components, cup-shaped geometry’s, hollow parts with stems and shafts, and all kinds of upset and bent configurations. The process uses many steps such as bending, cold drawing, cold heading, coining, extrusion, punching, and thread rolling.

Open Die Forging

Open die forging is done between flat dies with no precut profiles is the dies. Larger parts over 200,000 lbs. and 80 feet in length can be hammered or pressed into shape this way.

Where Can I Find High-Quality Forged Rings?

Ferralloy is a leading global provider of forgings to major companies across all industry verticals. Contact us today to learn more about how we can help you with your forging ring needs.

 

What is forged rings?

Machined Stainless Steel Forgings

Ferralloy, Inc. is supplying a manufacturer of valves to the oil and gas industry with machined stainless steel valve bodies produced  from forgings in 304 grade material.  The company can supply open and closed die forgings in carbon, alloy, and stainless steel materials in the ‘as forged’ or fully machined condition.  Ferralloy, Inc. also produces Seamless Rolled Rings from the same materials as well as exotic alloys and aluminum.

machined stainless steel forgings

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!

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!

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.

Ferralloy ships forged and completely machined Dummy Bar Chain Assembly

Ferralloy, Inc. shipped a forged and completely machined Dummy Bar Chain assembly to a leading steel mill supplier who supplies MRO products to the steel industry. This project required forging the components, welding and then completely machining each of the components. The forged 4140 links, bushings, washers and pins totaled more than 18,000 #. The tolerances of each component were very critical as they were interdependent on each other as the assembly came together. This product moves raw material that is required in the production of steel bar and plate in the steel industry.

Ferralloy is providing closed die forgings to the metalworking industry in weights from 2 pounds to more than 150 pounds each. Most of the products supplied have been machined. Alloy steels currently supplied are 4140, 8620, 8637H as well as 316 SS.