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Steel Castings | Should I Use Steel Castings for My Next Project?

Casting offers exceptional capacity for design detail. While there are many types of materials that can be used for castings, steel and iron are two of the more popular options. While cast iron and steel may appear similar on the surface, they are actually more different than you think. Let’s take a look at the difference between the two and why you should ultimately use steel castings for your next project.

Impact Resistance

One of the most significant advantages steel has over iron is its impact resistance. Steel is excellent for withstanding sudden impacts without bending, deforming, or breaking due to its toughness. While iron might be easier to work with, steel has an optimal mix of both strength and ductility, making it extremely tough. This makes steel desirable for many mechanical and structural applications.

Carbon Content

Iron and steel are both ferrous metals comprised of primarily iron atoms. However, pure elemental iron it too soft the be used in most applications. When mixed with carbon, it becomes harder and more useful. That carbon composition is the main distinction between cast iron and steel. Cast iron typically contains more than 2% carbon, while cast steel often contains between 0.1–0.5 percent carbon.

Should I Use Steel Castings for My Next Project?

Steel is the most widely used metal in the world and for good reason. Its impact resistance and durability make it a popular choice, especially in the casting world. At Ferralloy, we offer top quality steel castings that can be used for your next project. Contact us today to learn more.

 

Should I use steel castings for my next project?

Investment Castings | Which Materials Are The Best?

Investment castings can be used to make a wide range of products and prototypes. It’s important when using investment castings to make your product or prototype to use the right materials. Aluminum alloy, titanium alloy, steel, and superalloys are all quality materials used. Let’s take a deeper look into each one.

Aluminum Alloy

Aluminum alloy is the most used material in investment castings, especially in the fields of aerospace, avionics, electronics, military command equipment, and pump and valve applications. Improved strength and premium quality aluminum-silicon-magnesium alloy castings means casters can now offer castings for demanding applications, such as airframe components.

Titanium Alloy

Titanium alloy castings are made for products that require high fracture toughness and metallurgical integrity. Titanium golf club heads form a substantial part of the titanium investment casting market.

Steels

The variety of steels used in investment castings have increased drastically as designers and engineers have realized its durability and potential. From bicycle can forks to gearbox parts for automotive applications, to various gears and cam components, to even golf club heads, steel covers them all.

Superalloys

Superalloys are replacing sheet metal. Not only are they are more cost-effective, but they also provide a high rigidity monolithic component with superior service characteristics.

Are You In Need Of Investment Castings?

No matter what metal you want to go with, we can help you with all your investment castings needs. Contact us today to learn more about all the services that we provide.

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Steel Castings | What is Near Net Shape Manufacturing?

When it comes to metalworking, there are several different methods a professional can use to create durable components. Sometimes a manufacturer is able to get a product so close to its final stage that finishing is not a requirement. This is the opposite of net shape manufacturing. Learn more about near net shaping and why it may be an option for the next time you need steel castings:

What is a Near Net Shape?

A near net shape is an industrial term that refers to a particular manufacturing technique. This name means that a product that comes out of its initial production and is very close to the final shape. The final shape is also known as the net shape. Net shape manufacturing is the opposite of near net shape. Near net shape manufacturing allows there to be less traditional finishing. Finishing includes machining and grinding.

Why Would I Choose Near Net Shape Manufacturing?

Near net shape manufacturing is a great option for those looking to save money where they can. This is because near net shape manufacturing does not require finishing steps. So, when you do not need any time of machining done, you are able to save in production costs. It also takes less time to produce near net shapes.

Do You Need Steel Castings for an Upcoming Project?

At Ferralloy, we dedicate our time to creating durable and reliable metal workings. If you are in need of steel castings or other metal components, we can assist you. So, if you want to know more about our services, contact us today to learn more.

what do i need steel castings for

Steel Forgings | Should I Choose Forging over Gravity Fed Casting?

Metalworkers can create strong and durable metal components using a variety of methods. However, some methods are sometimes better suited for certain projects better than others. Gravity fed castings and steel forgings are extremely different methods. But, how to they measure up against each other?

What Are Gravity Fed Castings?

Gravity feeding is a method of casting that uses the natural force to move a material into a mold. Gravity casting allows for there to be great of dimensional accuracy as it creates a smooth surface. You can even cast supplemental parts into a gravity fed casting. Lastly, they are easily reproducible. This is key when it comes to large industrial projects. By having the ability to use a mold over and over again, you can keep costs lower. It also ensures that you have consistent products throughout.

What Are Steel Forgings?

Forging is a completely different metalworking method than casting. However, a workers use a force is when making forgings – it’s just not a natural one. During the forging process, a cold or hot material is rolled, pressed, hammered, or squeezed into a shape. This allows for a very strong finished product.

Is One Better Than the Other?

Both methods have their advantages. So, choosing a method depends on the need of a material. Casting is a smart option when a shape is very complex as using a molten version of a material makes it way more pliable. However, often times forgings are stronger than castings because of the type of force used. It is best to consult a professional when choosing.

Is Your Next Industrial Project in Need of Steel Forgings?

Ensure the integrity of your next industrial project by using only the strongest steel forgings. With a dedication to creating high-quality components, Ferralloy can suggest an array of amazing materials that will work for you. Contact us today to learn more about our metalworking services!

why should i choose steel forgings over castings

Seamless Rolled Ring Forgings | What Are the Best Types of Steel?

Forged parts are not all made using the same material. Rather, you are able to choose from a plethora of materials, ranging from aluminum to steel and everything in between. The choice of which particular material you use for your forgings is based on the specific application and need of the part. Frequently, companies turn to steel for seamless rolled ring forgings. However, once you decide on steel, you still have another decision to make: which type of steel? Keep reading to learn about three popular types of steel so you can decide which is best for your specific needs.

3 Types of Steel for Seamless Rolled Ring Forgings

  1. Carbon Steels

Carbon steels possess properties that are similar to iron. Within carbon steels, there are additional classifications: low carbon steel, medium carbon steel, and high carbon steel. The lower the carbon content, the cheaper and easier it is to shape. Meanwhile, the higher the carbon content, the stronger the part.

  1. Alloy Steels

Alloy steels have great strength, hardness, wear resistance, and enhanced toughness. However, additional heat treatment may be required in order to achieve these attractive properties.

  1. Stainless Steels

Stainless steels contain a higher amount of chromium than other types of steel. As a result, seamless rolled rings forgings that are made of this type of steel are corrosion resistant and do not rust.

No matter if you are interested in using seamless rolled ring forgings made out of carbon steel, alloy steel, stainless steel, or any other type of steel or material, Ferralloy, Inc. can provide it for you. We supply top-notch seamless rolled ring forgings in diameters up to 110” from carbon, alloy, and stainless steel, as well as many other materials including titanium and nickel alloys. Get your metal parts delivered on time and at a competitive price by contacting Ferralloy, Inc. today!

where can i get high quality seamless rolled ring forgings

Steel Forgings | What You Need to Know

In the metalworking world, there are a variety of different materials that can be used to create forged parts. Inconel, cobalt alloys, titanium, nickel, and steel are just a few of the countless forging materials that you can utilize for your next project. Which one you choose all depends on the specific application of your desired part. As a result, it’s essential to have a basic understanding of each particular forging material. That way, you can pick the one that best suits your needs. To help you get started, we outlined some important things that you should know about a popular type of forging: steel forgings. Keep reading to learn about why you might want to consider steel forgings for your future project.

Advantages of Steel Forgings

There are three main types of steel: carbon steels, alloy steels, and stainless steels. Even though each specific type of steel possesses a few unique properties, all steel forgings can be extremely advantageous. With the right forging technique, steel parts will possess a wide range of properties that can be extremely beneficial to your project. We listed the four most appealing advantages of steel forgings below.

  1. Good Toughness
  2. Advanced Strength
  3. Superior Surface Quality
  4. Fine Austenitic Grain Size

Thanks to these advantages, steel forgings are used in countless applications. Some of these applications include manufacturing cranes, cables, shafts, hydraulic presses, and axles as well as various other parts in the automotive, production, and chemical manufacturing industries.

Do steel forgings sound perfect for you next project? Then contact us! As an international company servicing the global marketplace, Ferralloy, Inc. can provide you with the best forged parts to your exact specifications, in a variety of materials, and at a competitive price. Visit our foundry online to learn more about high quality metal products today!

Forgings Rolled Rings | Most Common Materials

One of the best things about forgings rolled rings is that they can be manufactured by a wide range of materials. The choice of metal is based on the specific application of the rolled ring forging. As a result, it is important to know the specific physical and chemical properties of individual metals so that you can pick the one that is most beneficial for your project. To help you get started, here is a closer look at some of the most common materials used for forgings rolled rings.

3 Common Forgings Rolled Rings Materials

Stainless Steel

Stainless steel is one of the most popular materials used for rolled rings. This is thanks to the fact that it has some of the best physical and chemical properties when compared to other metals. A few of these appealing properties include high stability and strength, high resistance to corrosion, high resistance to heat, and durability.

Alloy Steel

 Another appealing rolled ring forging material is alloy steel. Some of the most popular steel alloys are 4140, 4130, and 4340. Alloy steel are used largely due to the fact that they have greater strength, hardness, wear resistance, and enhanced toughness than other types of metals. However, depending on the specific alloy, you may need additional heat treatment to achieve those properties.

Carbon

Carbon is also a widely used material for forgings rolled rings. Carbon and iron possess extremely similar properties. However, adding more carbon makes it difficult to weld or deform and cracks rather easily.

No matter your desired material, Ferralloy, Inc. can provide you with the highest quality forgings rolled rings. We supply rolled ring forgings from all grades of carbon and alloy steels as well as from many other materials, including titanium, aluminum, and nickel alloys. Contact our international company for any of your metalworking needs today!

Steel Castings | Why Use Steel Castings?

Steel is one of the most versatile metalworking materials available in the world today. It can be found throughout numerous industries and in countless forms. One particular type of steel component that is exceptionally well-liked is cast steel. Despite these castings not being as popular as other metal parts, steel castings are used for vital components in the mining, railroad, construction, truck, military, and oil and gas industries. Why are steel castings so important to so many projects? Keep reading to find out!

3 Advantages of Steel Castings

1. Design Flexibility

Design flexibility is one of the biggest advantages of steel castings. Their flexibility grants the designer the freedom to choose whichever shape and size they desires. It is extremely simple to form and change the shape of components, and all in a timely manner.

2. Metallurgical Versatility

Another great advantage of steel castings is their strong metallurgical adaptability and variability. Cast steel obtains a wider range of physical and mechanical properties than any other cast metal. All that this casting needs to do is simply vary the carbon and alloy content, fluctuate the heat treatment, and gain good weldability and workability.

3. Large Weight and Size Range

The next advantage of this type of casting is its large weight and size range. Steel castings can be as small as a few ounces or as large as hundreds of tons. Their quantities can also vary from one to thousands per order.

Design flexibility, metallurgical versatility, and large weight and size ranges are just a few of the many advantages of steel castings. If you think that your next project can benefit from this type of casting or any other metal component, contact us. Ferralloy, Inc. is a global supplier of castings, fabrications, forgings, machining, and other related products and services. Contact our metalworking company 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

Steel Castings | Features and Applications

Steel is one of the most versatile and sought-after metalworking materials. It plays a vital role in various industries. Due to its desirable properties, steel comes in various forms. Which steel component you use depends on your specific requirements and needs. Steel castings are often a popular choice. Keep reading to find out if steel castings can benefit your project!

What are Steel Castings?

A steel casting is a metal component that is formed by pouring molten steel into a mold cavity. The liquefied steel then cools and solidifies within the mold cavity. You can cater the shape of the mold, and hence the casting, to perfectly fit your specifications. The casting process of steel can be difficult. It is less fluid than other metals and more reactive to mold materials. The steel casting process should only be done by metalworking experts for optimal component performance.

Why are They Used?

Steel castings are used for a variety of reasons. They are mainly used when other types of cast irons do not have enough strength or shock resistance. Steel’s physical properties allow the castings to be both strong and ductile. This makes the steel casting extremely tough and limits the chances of fracturing under pressure. Steel castings are also utilized due to their weldability and corrosion resistance.

What are Their Applications?

 Due to its reliability and strength, numerous industries rely on steel castings. Industries that use steel castings range from food processing and electronics to oil and gas.  Some specific industries that use this type of casting include the railroad, construction, drilling, transportation, and mining industries. Examples of items that are steel casting gears, valve bodies, pump casings, mining machinery, marine equipment, engine cylinder blocker, forging presses, and railroad truck frames.

If you’re interested in using steel castings for your next project, contact Ferralloy Inc. today! As metalworking experts, we can provide you with the highest quality castings. Give us a call at 440-250-1900 or visit our foundry online today!