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Common Machined Casting Myth Debunked

Although the process of machined castings may originally come across as rather a straightforward method, there is a lot of misinformation surrounding this industry. At Ferralloy, we believe in using the most efficient, safest, and best methods in the machine shop to guarantee that our products are cast with exceptional accuracy. Machined castings are castings that went through the process of cutting, grinding or other nontraditional machining processes. Below are some of the myths debunked to give you clearer and more concise pieces of information.

Amount of Time to Run

Although the tools and machines used in machined castings can make production comparatively simple and stress-free as they automate the job, its presence still cannot guarantee that every job will have the exact run time. Thus, it is a common misconception that all jobs require the same amount of running time.

Extremely Easy

A lot of individuals assume to think that the computerized automation of the casting and machining procedure makes it simple and faster to complete. Conversely, without the right workers for the job, the procedures will be very impossible to complete. Thus, the thought that machining is extremely easy is a myth. Every company or industry that deals with machined castings must employ people with experience, training, and skills to guarantee the accuracy, efficiency, and safety of the procedures; absence of which would mean that delivering high-quality products is highly impossible. Additionally, machine experts are accountable for monitoring and activating the loading and unloading of workpieces, the cycle of the process, and making all the indispensable adjustments.Â

Machining is Automatic

The most common myth is that machining is automatic. Notwithstanding the huge consistency that this time’s modern machined castings offer, it is highly impossible to allow the machines to do the entire job. Although previous jobs may be copied for future plans, these will still require professional help of an experienced machinist who has the ability to easily and efficiently identify and eliminate anomalies, nuances, and variations.

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Are you Searching for Exceptional Machined Castings?

Machined castings present various misconceptions. At Ferralloy, we guarantee to provide you only the best and first-class machined castings. Contact us today!

Zirconium | Top Questions About Zirconium

As you navigate through your metalworking needs, you’ll need to decide on the type of material that your project requires. One of the best materials that’s widely used in multiple industries is the silver-grey transition metal called zirconium. If you’re clueless about it, check out these zirconium facts that may surprise you.

What Exactly is Zirconium?

Essentially, zirconium is a chemical element that presents itself as a strong solid when placed at room temperature. If your goal is to obtain a pure version of it, the material needs to go through a complicated physicochemical process.

Who Discovered it?

For a long time, it has been known to be one of the components that are found in gemstones. However, it wasn’t until 1789 when it officially became an element. It was then when Martin Heinrich Klaproth, a German chemist, discovered it as he was trying to analyze zircon. Thirty-five years later, a Swedish chemist named Jöns Berzelius was able to isolate the element, although not in its purer form. The successful isolation of pure zirconium took place in 1925 when Dutch chemists Jan Hendrik de Boer and Anton Eduard van Arkel were decomposing zirconium tetraiodide.

What Makes it Desirable and Useful for Metalworking Industries?

Aside from the fact that this element is known for its malleability and ductility, it’s also highly resistant to corrosion, steam, high temperature, and water. In fact, it’s very much similar to steel in terms of features and characteristics. For this reason, it is ideal for environments where the metal components are subjected to extreme environments.

What are its Common Uses?

These alloys can be used in heat exchangers, pipes, fittings, lamp filaments, lab crucibles, catalytic converters, surgical instruments, television glass, furnace bricks, and so much more.

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Looking for More Information About Zirconium?

If you’re looking to find more information about zirconium alloys, feel free to get in touch with the leading global supplier of engineered products and services – Ferralloy, Inc. We offer total supply chain management to a diverse metalworking customer base. Call us now.

Machined Castings | What You Need to Know About Machined Castings

Before you can truly appreciate the beauty of machined castings, you’ll need to understand the importance of the casting process as a part of metalworking. This process makes it possible to produce a wide variety of complex metal components in a vast array of metal selections for many industries. Although castings can be used in the form that they leave the mold, in most cases, castings still need to be machined to make each part even better.Â

How Does Casting Work?

During the casting process, the hot liquid metal is poured into a mold that has a cavity or a hollow cutout of the required finished shape. After the molten metal is left to cool down and solidify, it is then removed from its mold to reveal the casting form. To ensure a high-quality end product, these castings go through rigorous quality checks that usually involve a video borescope. This tool enables the manufacturer to check for residue, FOD, and other imperfections.

How Does Machining Work?

Machining refers to the process that’s utilized to cut away certain materials to alter the shape and appearance of a metal product or casting. Examples of machining processes include cutting with the use of single-point or multipoint cutting tools, grinding, and non-traditional machining processes that utilize chemical, electrical, and other sources of energy. Aside from the fact that machining can seal surfaces and threaded holes, it also allows you to produce fine and detailed components that are impossible to create through the use of casting techniques alone.

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Do You Need Machined Castings?

If your next project requires you to look for machined castings, you’ll need to get these components from a company that’s an expert in both the casting and machining techniques. Ferralloy, Inc. is the leading global supplier of engineered products and services that offer total supply chain management to a diverse metalworking customer base. Contact us today!

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.

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Learn More About Machined Forgings

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

Seamless Rings | The Major Benefits of Seamless Rings

If you’re clueless about how seamless rings are made and the major benefits they offer, you’ve come to the right place. Seamless forged rings are produced through ring rolling, which is a process that requires the use of a rolling mill. This rolling mill has the capacity to generate seamless rings that come in various diameters and weights.

How a Seamless Ring is Formed

It starts with the creation of a donut-shaped component by piercing a circular piece of metal. Next, the component is heated to recrystallization temperature before it’s placed on an idler roll towards a drive roll. This causes the ring to rotate and increase its diameter and wall thickness. Furthermore, these seamless rings are created by using a range of configurations that include smaller parts resembling washers, tall cylinders, and more.

Uses for Seamless Rolled Rings

In case you’re wondering, seamless rings are used for couplings, clutches, bearings, flanges, drives, gears, machines, robotics, valves, and glass-lined reactors. They’re widely used by the military and in power generation, mining, aerospace, and oil industry. They help power jet engines, windmills, railways, and rock crushing equipment.

The Benefits of a Seamless Ring

Seamless rings are known for their strength because they’re able to maintain it through high-temperature fluctuations. They’re also popular because of their cost-effectiveness – they closely match the contour of the finished shape and therefore, require less machining. A seamless ring is more reliable compared to other components because the grain pattern that’s used in creating them gives the metal more resistance and strength. Aside from the fact that you won’t have to worry about rings melting or deforming under maximum heat, the flexibility that these rings offer allows the usage of forgeable materials such as alloy, stainless steel, aerospace materials, and carbon.

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Are You Interested in Learning More About Seamless Rings?

If you want to know more about seamless rings, Ferralloy, Inc. is here to give you the answers that you’re looking for. Contact us today!

Closed Die Forging | All About the Closed Die Forging Process

In case you’re not familiar, forging refers to the manufacturing process that involves the shaping of a piece of metal with the use of compressive forces. A power hammer or a die delivers the blows. Today, it has become a major worldwide industry and its traditional products include hardware, kitchenware, cymbals, edged weapons, hand tools, and jewelry.

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What is Closed Die Forging?

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Sometimes referred to as impression-die forging, this type of forging process uses dies that have the precut profile of the desired part. These dies move towards each other and partially or wholly covers the metal piece. The raw material that’s been heated is positioned in the bottom die. The shape of the forging as a negative image is incorporated in the top or bottom die. When the top die presses against the bottom die, the raw material forms into the desired shape. In case you’re wondering, this process can be used to produce parts from a few ounces to 60,000 lbs. You may also be surprised to find out that some of these smaller parts are forged cold.

 

What Are its Capabilities?

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Closed Die Forging of steel, titanium, aluminum, and other alloys can create a virtually limitless variety of 3-dimensional shapes that weigh from a few ounces up to over 25 tons. While closed die forges that are routinely produced on hydraulic presses have capacities up to 50,000 tons, those that were produced on mechanical presses have capacities up to 20,000 tons. Lastly, those that were regularly produced via hammers have capacities up to 50,000 lbs.

 

Since this type of forging process restricts metal flow due to the presence of the die contours, you won’t be surprised to know that Closed Die Forging can yield more complex shapes as well as closer tolerances compared to the open-die forging process. However, it’s important to note that if additional flexibility is required in forming symmetrical and non-symmetrical shapes, pre-forming operations that involve bending will have to be implemented on the piece of metal before it is forged in finisher dies.

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Closed Die Forging Â

Since Ferralloy is a trusted supplier of engineered products and services to a wide range of industries across the globe, we can give you straight answers about Closed Die Forging or anything that’s related to metal production. Contact us today!

 

 

Open Die Forging | What You Need to Know About Open Die Forging

When it comes to the forging process, there are many different types. One of the more popular types used to create parts that are used in your everyday life is through open die forging.

The Process

The open die forging process is a popular and effective way to produce the parts that you need and use on a daily basis. The process itself consists of deforming metal parts by heating them between a top die attached to a ram and bottom die. Depending on what type of metal is used, it will be exposed to temperatures that range between 500 °F to 2400 °F while slowly shaping the metal into the desired shape. This is done through pressing and/or hammering the metal into place. The process usually requires a secondary machine or refining in order to reach the desired specifications.

The Benefits and Applications

Even though parts created through open die forging usually require secondary machining, it is still a popular process that sees results. Parts created by open die forging are:

  • Discs
  • Rings
  • Sleeves
  • Shafts
  • Cylinders
  • And more

The biggest benefit of this type of forging is that the repeated working of the metal increases its strength and grain structure of the finished product. Parts made by this type of forging are tough and last long. They are resistant to fatigue and typically have a lower number of voids compared to other processes.

Where can I find the best open die forgings?

Looking for More Information About Open Die Forging?

Have you been looking for more information about open die forging, the process, or it’s practical applications? If so, contact us today. Ferralloy is here to help you find what you need for your next project.

Castings | What You Need to Know About Gravity Fed Castings

Have you wondered about how castings are made, specifically gravity fed casting? Fear not, it isn’t as complicated as you might think.

How Are They Made?

Making castings is one of the oldest manufacturing processes known to man. While it is an old method, it is one that is constantly evolving and improving. They are created by a unique mold that workers apply coatings in order to create and recreate intricate parts and more. This not only allows workers to produce high-quality castings but produce them quickly. They can be made with a wide variety of materials, especially alloys and other heat-resistant metals.

What Goes into The Gravity Process?

When it comes to gravity process, it isn’t as difficult to understand as you might think. Basically, gravity is used to fill the mold instead of gas pressure or a vacuum process. The process starts with a preheated mold that helps the materials flow where they need to go. After that, workers or machines coat the mold to prevent it from sticking. Lastly, the material is then poured, hardened, and removed. This is repeated until the order is fulfilled.

Why You Should Use Gravity Fed

They are mostly used for completing a large production order. It is really easy to repeat the molding process for several different castings. Another benefit is there is less gas trapped within the mold, which makes it stronger and less likely to be compromised.

Who sells castings?

Looking for Different Types of Castings?

If you have additional questions about castings, contact us today. For 40 years, Ferralloy has been providing engineered products and services to a diverse metalworking customer base.

Investment Casting | What are the Different Methods of Machining?

Investment casting, forging, rolling, and more. There are so many ways that you can get the best out of your metal materials. Machining can do just that. Machining is a manufacturing process that cuts a component to specific dimensions that allows them to be even more precise. But, how do metalworkers machine materials?

Milling

A milling machine rotates at a very high speed. So, a metalworker will feed the workpiece into the machine and material will be cut away in small shapes. This is ideal for components that have features like holes, slots, and pockets.

Drilling

Metalworkers will use a drill bit to create a circular hole. So, drilling involves a rotary cutting tool and can perform anywhere from hundreds to thousands of rotations per minute. And, the machining will cut off little chips during this process.

Boring

Boring mills can come horizontally or vertically. Then, a metalworker can place a spindle in either orientation. Workers use this method to create clean and smooth finishes.

Facing

Facing cuts the face, or surface, of a component. This requires a planar, or flat, surface. So, the piece of metal rotates around one point. This allows for a nice and smooth face surface by removing material from the end of the piece.

Does Your Next Project Require Durable Investment Casting?

The integrity of your next industrial project relies on the durability of your metal components. At Ferralloy, we dedicate our time and expertise to creating the highest-quality metalwork. So, if you are interested in our investment casting capabilities or other services, contact us today to learn more!

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Machined Castings | What Is Machining?

The casting process is an essential part of metalworking. This process holds the ability to create a variety of complex parts in a wide selection of metals for countless industries. Sometimes, castings can be utilized in the exact form that they leave the mold. They often, however, need to be machined in order for the part to be further perfected. Keep reading to learn more about machining and to find out if you should use machined castings for your next project!

What is Machining?

Machining is a broad term used to describe the processes used to cut away materials in order to alter the appearance and shape of a casting or another metal product. Some specific machining processes include:

  • Cutting, generally using single-point or multipoint cutting tools with a clearly defined geometry
  • Abrasive processes, including grinding
  • Nontraditional machining processes that use electrical, chemical, and other sources of energy

No matter the specific process used, machining generally consists of the work piece, the tool, and the machine.

Why is Machining Used?

 Machining is used because it helps create very fine and detailed objects that would have been impossible to manufacture through casting techniques alone. Furthermore, machining has the ability to seal surfaces and threaded holes.

How Do I Get Machined Castings?

Machined castings can present some challenges. As a result, it’s important to get your parts from a company that understands both the casting and machining process. If you need machined castings for your next project, we are here to help! Established in 1978, Ferralloy Inc. can provide you with quality as-cast or fully machined parts at a competitive price and delivered on time. We are a driven organization that is committed to process improvement and customer satisfaction. Contact our metalworking experts for more information or a quote for your machined castings today!