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Materials and Processes in Seamless Rolled Ring Forging

Several industries have used carbon steel forgings, whether you are aware of it or not. Such material has a variety of uses and comes in 4 different grades with different purposes to achieve the desired product. Numerous industries use the method called seamless rolled ring forging to produce a material of high quality and durability.

who offers the best seamless rolled rings forging?

Material and Process of Seamless Rolled Ring Forging

The Process

To start the forging process, a circular metal component will be pierced to create a hollow ring that somewhat looks like a doughnut. Upon the creation of an empty piece, the ring is then handled and processed to recrystallization temperatures. After the recrystallization process, it is then placed onto the idler roll. Once it is under pressure, it will be positioned towards the drive roll.

Additionally, a seamless rolled ring forging may be manufactured using numerous variants of configurations. Whether it is a small washer-like part or tall cylindrical shape part, the rings are regularly in a rectangular cross-section shape. What’s more is that whether you want a customized or convoluted shape, these types of rings may be produced through the use of shaping tools.

The Material

The notable aspect of a seamless rolled ring forging is that it is dependent on the material used. In every tool or metal component manufacturing industry, hardness, strength, and the ability to resist wear and tear are the most vital factors that need focus.

Among the three elements, the most important is the ability to withstand wear and tear since several of these products are used in engines and machines. These tools and components must be able to sustain heat as these are exposed to high temperatures.

As for the two factors, both hardness and strength are critical in the material. Most of these products are used by industries engaged in heavy-duty methods and processes. Thus, the tools and components must be strong enough to withstand collision and impact.

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At Ferralloy Inc., we offer competitively priced and engineered metal products to companies throughout the world. Contact us now for more inquiries!

Understanding Forged Carbon Steel and Why You Need to Use It

Carbon steel forgings are designed and shaped by means of a steel forging process. This type of steel forging comprises an unspecified amount of alloy, without the need of employing any minimum required percentage. Various kinds of alloys found within this steel forging are zirconium, cobalt, chromium, tungsten, titanium, nickel, and a lot more. However, it is important that there should be a sufficient amount of steel alloy as it can lower the melting point to create better steel forging.

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Advantages and Options of Carbon Steel

Advantages of Choosing Carbon Steel Forgings

Every knowledgeable forging manufacture understands the essence and importance of producing cutting-edge and durable forgings for every project need. Some of the many benefits of opting for carbon steel forging are tight grain structure, economical, product efficiency, and impact strength.

Carbon steel forgings often have a tight grain structure, making it mechanically strong to withstand friction and other effects. Hence, this type of steel forging does not require a number of expensive alloys just to achieve high strength components. With this, you may infer that this forging is definitely economical as compared to others. Additionally, it uses an open-die process to produce final products with extremely cost-effective resources.

As for product efficiency, forgings can be designed in various sizes, which make the product more efficient and flexible. Likewise, it has exceptional strength quality that allows the end product to withstand heavy load, impact, and stress.

Options of Carbon Steel Forgings

Subject to the type of project your needs, there are several available options when it involves carbon steel forgings grades. All of these grades can be treated to enhance its ductility, strength, and machinability. The most common option is medium carbon steel wherein it is composed of about 1.65% manganese and 0.54% carbon content. This grade stabilizes the good wear resistance, strength, and ductility. Additionally, the end product is often used for cars, forging, and large mechanical parts.

what is steel forgings?

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Why Should I Start Using Steel Forgings?

Steel forgings started in the olden times when there is a need for producing different kinds of end materials with unique properties. Today, hydraulic hammers and machines enable the forging systems to forge steel and other metals easier than ever. 

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Everything You Need to Know About Steel Forgings

Properties of Forged Steels

Forge casting is another treatment that can be compared with steel forgings. The latter has various properties of forged steels that seem to be distinctive when compared to the former. The properties you need to take note are range, uniformity, persona, and solidity. When you talk of range, there is a limit on the thickness and size of the steel. Because of these factors, the metal can be forged easily since shaping steel is rather a tiresome job. As for uniformity, the forger must be reasonably meticulous and has the ability to get a precise measure in order to maintain the same steel consistency. When it comes to persona, it is essential to note that the strength of your material is never consistent during the entire process. The last but not the least among the properties you need to consider is solidity. Steel forgings constitute to top-notch durability, greater toughness, and amazing strength, making it less likely to break or shatter.

Categories of Forged Steel

Steel forgings are composed of two categories – closed die and open die. In the closed die process, the steel is pressed between 2 dies that consist of the precut profile of the preferred shape. On the other hand, open die forging undergoes a deformation between several dies that do not entirely surround the material.

Steel Forgings Materials

Among the common materials used in steel forgings, the following are the most common: carbon, stainless steel, alloy steels, Haynes, Incoloy, Inconel, Rene, stainless steel, cobalt alloys, superalloys, tantalum, carbon steels, titanium, carpenter 20, molybdenum, tool steel, Monel, tungsten, nickel, Hastelloy, zirconium, cobalt, NX-188, and nickel aluminide.

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Looking for More Information About Forgings?

If you’re looking for a reliable steel forging company, Ferralloy, Inc. is a major supplier of the open die and closed die forgings to a global customer base. We have the ability to provide custom components as forged, rough machined, or finish machined to meet your exact specifications. Contact us today!

Steel Castings | The Benefits of Manufacturing Valve Bonnets by Stainless Steel Casting

One of the most important components of a pressure valve is called the valve bonnet that comes in various shapes and sizes. The valve bonnet covers the valve body and is usually connected to it by a welded, bolted, or threaded joint. Although they’re necessary for most valves, they can potentially complicate the valve’s manufacturing process, can become a source for leakage, increase the valve size, and represent a huge chunk of the valve cost. However, when stainless steel castings are used for valve bonnets, you can expect to enjoy the following benefits:

Flexibility of Design

Due to the wide array of stainless-steel grades to choose from, you’ll enjoy the flexibility to configure the cast according to your need. Stainless steel castings for valve bonnets can even take on complex shapes or contain hollow section parts. Since stainless steel castings are made through a repetitive process, multiple valve bonnets can be produced efficiently.

Not Prone to Rust or Corrosion

If you use stainless steel castings for valve bonnets, you won’t have to worry about rust or corrosion. For this reason, these become the top choice for most industrial applications that subject these parts in conditions where metal has the tendency to corrode. Other manufacturers also choose cast iron to produce valve bonnets that stay free from corrosion. However, these don’t exhibit the same degree of strength, resistance to high pressure or durability as stainless-steel castings.

Strength and Durability

Most manufacturers choose to use stainless steel castings for valve bonnets because of their incredible durability and strength. You can expect these types of valve bonnets to function well and remain in excellent condition for a long period of time even when you use them in extreme temperatures.

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You don’t have to look far if you need to find top-quality steel castings. Ferralloy, Inc., the leading comprehensive engineered product resource is here to help you. Contact us now!

Seamless Rolled Ring Forging | Solution to Achieving Structural Integrity

A seamless rolled ring forging is created through the process of ring rolling with the use of rolling mills. A circular preform of metal is pierced using the open die forging process to form a hollow shape that looks like a donut. Before placing the donut over the mandrel roll or the idler roll, the donut is heated above the recrystallization temperature. Once it is placed over the idler roll, the idler roll moves toward a continuously rotating drive roll to reduce the thickness of the ring’s walls while increasing its diameter. With the use of rolling mills that come in various sizes, seamless forged rings that have outside diameters that range from a few inches to more than 300 inches can be produced. It’s also possible to create forged rings that could weigh from a pound up to over 300,000 pounds.

Why Use Seamless Rolled Rings?

Casting and rolled and welded plates are both metalworking processes that allow you to produce rolled rings. Cast rings are prone to inclusion defects that need extra machining as well as weld repair. After the fabricated ring goes through extensive welding, the integrity of its part is reduced, its corrosion resistance is jeopardized, and its shape becomes distorted. On the other hand, with the forging process, the directional grain flow causes the forging’s overall strength to be increased. Plus, the maintenance of the part’s corrosion resistance and shape is ensured because of the absence of welding.

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Do You Want to Know More About Seamless Rolled Ring Forging?

The utilization of the rolled ring forging process will definitely reduce the cost that’s typically seen with plate burnouts and other process options. If you need more information about seamless rolled ring forging, get in touch with Ferralloy, Inc. today.

Steel Castings | The Key Benefits of Steel Castings

Wondering about the many benefits that steel castings can offer? Why is this process widely used in industries as diverse as oil and gas to food equipment and automotive? To give you a clear snapshot of how your project may benefit from using castings, check this out:

Design Flexibility

With these castings, you can choose from a wide range of alloys that can give your designers the flexibility to configure your cast according to your needs. Aside from the fact that maximum design freedom to produce complex shapes and hollow section parts is made possible, these can also be configured in a sturdy and repeatable manner. Since this flexibility allows you to make quick changes as needed, your delivery time is shortened significantly.

Economic Benefits and Greater Reliability

You can count on cast steel parts for day-to-day use because they’re made of an isotropic material that increases engineering reliability. When you factor in its design flexibility and shorter delivery time, steel castings can give you the economic efficiency that you’re looking for.

Metallurgical Versatility

Steel castings make it possible for you to choose among various chemical compositions and organizational control that fit your project’s requirements. In other words, steel castings offer strong metallurgical variability and adaptability. Furthermore, compared to any other cast metal, you can obtain a wide array of physical and mechanical properties by simply making variations in its carbon and alloy content and/or heat treatment.

It Allows a More Streamlined Approach

With steel castings, it won’t be difficult for you to create streamlined and repeatable shapes. Once you create the mold, you’ll be able to create multiple casts.

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Do You Need More Information About Steel Castings?

If you want to know more about steel castings, get in touch with Ferralloy, Inc. today. We are the leading supplier of quality castings to major companies throughout the world.

Open Die Forging | Facts About Open Die Forging

You’re probably aware that open die forging is a type of hot forging that’s commonly used to create bigger and simpler components in weights that range from a few pounds to over thousands of pounds. However, did you know that open die forgings are known to exhibit soundness, durability, high strength, homogeneity, and flow line characteristics?

The Nature of Open Die Forging

In case you’re wondering about how the open die forging process works, it’s performed between two flat dies that don’t have any impression made in them. Furthermore, forging the metal into the desired shape is heavily reliant on the movement of the workpiece. Depending on the forging shop’s capabilities, the size of the original stock limits the size of the open die forgings.

Materials that are Commonly Used for Open Die Forging

Although the open die process is capable of forging various types of metals, among the most common materials used are alloy steel, carbon steel, stainless steel, Inconel, copper alloy, and high-temperature alloy.

The Benefits of Using the Open Die Forging Process

If you want to create products that are characterized by superior strength and durability compared to products that are either machined or welded, you’ll be better off with open die forging. It has this ability to change and form the metal into your desired shape while breaking up the cast structure and producing finer grains. Aside from this, it improves mechanical properties because it consolidates low-density areas, gas porosity, and micro-shrinkage while enhancing the density and aligning the grain flow. If you work with advanced forging shops, you can produce custom metal parts with unique shapes.

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Seamless Rolled Ring Forging | What are the Industries that Use Seamless Rolled Ring Forging?

Seamless rolled rings are popular among a number of sectors because of the advantages that they offer – cost-effectiveness, strength, reliability, its ability to withstand the maximum heat, and the fact that they can be made from practically any forgeable metal. Furthermore, these rings come in different sizes ranging anywhere from 2” to 300” inched in diameter that weigh as little as a pound or even as much as 300,000 pounds! If you’re curious to find out which industries use seamless rolled ring forging, read up.

Production of Oil and Gas

It would be impossible to produce oil and gas without using seamless rolled ring forgings in forge flanges and pressure vessel connections for the pipelines. Aside from this, hydraulic fracturing or fracking, surface gas, and oil exploration, as well as subsea connections, all require the use of the seamless rolled ring forging.

Automotive and Aviation

Thanks to seamless rolled ring forging, our cars are performing as they should. These parts are used for almost everything in the automotive industry – clutches, gears, bearings, couplings, and so much more. In the aviation industry, the seamless rolled ring forging happens to be a key component in the production of critical parts such as jet turbines and jet engines.

Heavy-Duty Manufacturing

Seamless rolled rings are present in every manufacturing industry because they are viewed as standard components in chemical processing, gear and bearing applications, and more. Since seamless rolled ring forging works well in extreme environments and temperatures as well as harsh weather conditions, they’re used in the production of reactors, wind turbines, paper mills, heating and cooling systems, rock crushing equipment, mining, robotics, and shipbuilding.

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Where to Get Top Quality Seamless Rolled Ring Forging

Ferralloy, Inc. has a team of forging experts who are able to provide you with the strongest and most reliable seamless rolled ring forging. Give us a call today.

Investment Castings | The Primary Causes of Shrinkage Defect in Stainless Steel Castings

Perhaps the biggest problem that you’ve encountered in your attempt of producing stainless steel investment castings is shrinkage. Although these defects are invisible to the naked eye, these shrinking defects can be detected after post machining. The poor shrinkage of molten skill can be attributed to several factors, namely:

The Sprue Gate’s Effect

If a thin plane between two thick ones is present and the three surfaces aren’t in the same plane, you can place two sprue gates on the two thick planes in order to increase the molten steel. The shrinkage effect will occur at the intersection of the thin and thick planes if only one gate is placed.  However, if your customer agrees to thicken the thin plane, only one gate can be placed.

The Gating System’s Effect

You can use the gating system with a large cross-sectional area when no huge difference between the sprue gate’s thickness and the thickness of the stainless-steel investment castings. Unlike the small gating system. The larger gating system can facilitate feeding through its slow cooling feature.

The Stainless-Steel Casting Structure’s Effect

There are times when the shrinkage defects are found away from the gate. This usually occurs when the structure of the stainless-steel investment castings are more complex due to the molten steel’s insufficient packing between the gate and the shrinkage area.

The Pouring Temperature’s Effect

The appropriate increase of the pouring temperature can significantly reduce the shrinkage effect when only a slight shrinkage is detected on stainless steel investment castings. The slower the pouring speed, the more the shrinkage is reduced under the premise of ensuring that the casting isn’t deficient in terms of content.

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Ferralloy, Inc. is a premier provider of quality investment castings. If you need more information about our services, contact us today.

Steel Castings | The Different Properties of Cast Steel

Did you know that steel castings are made of a ferrous alloy that comes with a maximum carbon content of about 0.75%? In case you’re wondering, steel castings are formed when liquid steel fills the void within a mold. Moreover, you can find these in many of the same carbon as well as alloy steels that can be created as wrought metals.

What are the Different Properties of Cast Steel?

Cast steels can be produced with a wide array of properties.  Cast steels are carefully selected to be on par with the performance requirements of their intended application. Keep in mind that cast steel’s physical properties rely heavily on its chemical composition as well as its heat treatment.

The higher its carbon content, the higher its strength – which is why in terms of hardness and strength, cast steel is able to withstand abrasion because its maximum hardness or hardenability is determined by the amount of carbon it contains. Furthermore, its ability to deform under tensile stress depends on its carbon content as well. The lower the amount of carbon in it, the higher its ductility. Increase ductility would mean better toughness. Steel casting’s resistance to friction and use is similar to that of wrought steels that have the same composition. The weldability of steel castings is primarily dependent on its chemical composition as well as its heat treatment.

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Do You Want to Know More About Steel Castings?

To get more information about steel castings or a quote on your next project, contact the leading supplier of quality castings to major companies throughout the world – Ferralloy, Inc.