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Seamless Rolled Rings | Should I Use Seamless Rolled Rings for My Project?

In metalworking, rolling is a metal forming process in which metal stock is passed through one or more pairs of rolls to reduce the thickness and to make the thickness uniform. Seamless rolled rings give your forging the best strength, fatigue resistance, and freedom from inclusions. Let’s take a look at where you can find seamless rolled rings and if you should use them for your next project.

Advantages

Seamless rings offer an improved strength, fatigue resistance, and freedom from inclusions. They also have a cost advantage. This forging process results in an end product that requires fewer machining operations, reduced weight and lower costs for raw materials.

Applications

Rolled Ring forgings can be commonly found in jet engines, jet turbines, helicopter gearboxes, paper mills, windmills, and other extreme environments.

Process

The process of creating seamless ring forgings start with the punching of a hole in a thick or round piece of billet, generally made of steel. The piece is then heated, rolled, and squeezed into a ring. It can be produced in configurations ranging from flat, washer-like parts to tall, cylindrical shapes, with heights ranging from less than an inch to more than 9 feet. The simplest and most commonly used shape is a rectangular cross-section ring.

Should I Use Seamless Rolled Rings for My Project?

If you are thinking of using seamless rolled ring forgings for your next project, consider using Ferralloy. We offer high-quality forgings at competitive prices. Contact us today to learn more or to place an order.

 

Should I Use Seamless Rolled Rings for My Project?

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

Investment casting is a manufacturing process in which a wax pattern is coated with a refractory ceramic material. It is one of the first forms of metalworking and is still popular today for many reasons. There are more benefits to investment casting than other metalworking techniques. Here are just a few of the reasons why you should use investment castings for your next project.

Flexibility

Investment casting produces near-net-shape configurations. This offers engineers design flexibility in many types of alloys and the capability of producing precise detail and dimensional accuracy in parts weighing from many pounds to just a few ounces.

Reduction of Production Costs

With the exception of tooling for the wax molds, no large capital equipment is needed to produce this type of casting. The reduction or even elimination of machining operations significantly reduce the cost of production.

Reduction of Assembly

Several parts can be made as one casting. This eliminates the need for fabrication such as welding or mechanical fasteners, thus reducing assembly, handling and inspection costs. Reduction of assembly operations can greatly reduce prices.

Many Alloys to Choose From

Investment castings allow for a ride range of alloys to be used. Aluminum, stainless steel, steel, cobalt alloy, nickel alloy, and iron can all be used. Since there are so many options when it comes to the material that can be used, it provides the ability to have a wide variety of material characteristics to suit almost any application.

Are You Thinking About Using Investment Castings for Your Next Project?

If you are thinking of using investment castings look no further than Ferralloy. We offer some of the finest castings available. Contact us today to learn more about how we can help you with your next project.

 

Should I use investment castings for my next project?

Cobalt Alloys | Should I Use Cobalt Alloy Parts for My Next Project?

Cobalt alloys are a group of cobalt-chromium ‘super-alloys’. They are designed for high wear resistance and excellent chemical and corrosion performance in hostile environments. Let’s take a deeper look at this type of superalloy and why you should use it for your next project.

Chemical Properties

There are several different types of these superalloys all containing various levels of titanium, silicon, sulfur, phosphorus, molybdenum, manganese, chromium, carbon, boron, aluminum, iron, nickel, and cobalt. Most of them contain four to six of these elements. Cobalt is the largest alloy found in cobalt alloys. Chromium is also an extremely important. It not only offers high corrosion resistance, it’s also the predominant carbide former and it provides strength.

Manufacturing Processes

Cobalt alloys are produced via wrought or hot forging, hard-faced deposit, powder metal, and casting. It is more difficult to machine and grind than steel and requires high-performance processing equipment and specialized machining tools.

Applications

Cobalt alloys are found in many different products. Some of those include:

• Saw teeth, hard facing, and acid-resistant machine parts
• Poppet valves, valve seats, and exhaust valves of an internal combustion engine
• M2HB machine gun and machine gun barrels
• Medical applications including manufacturing of artificial hip joints, other bone replacements and cast structure of dental prosthesis
• Turning tools for lathes

Should I Use Cobalt Alloy Parts for My Next Project?

If you are thinking of using cobalt alloy parts for your next project, contact us at Ferralloy today. We can help with all your superalloy and other metal needs and offer high-quality products.

 

Should I Use Cobalt Alloy Parts for My Next Project?

Investment Castings | Where Can I Find the Best Investment Casting?

The investment castings process can produce the most intricate shapes in pretty much any alloy. It is the only metal working process that provides the design freedom to easily cast complex intricate shapes and assemblies. Here is more information why you should use investment casting and where you can find the best investment casting.

Reliability

Investment casting provides reliable process controls and repeatability that are maintained from casting to casting.

Better for the Environment

Investment castings are produced from nine wax patterns. In most cases, the wax can be reclaimed and used again. The wax pattern allows you to see your part before it’s cast, eliminating expensive and wasteful revisions. This allows for less metal to be used.

Intricate Design

When using investment casting, engineers can do a lot to customize your product. Logos, product ID’s/numbers, letters, thru holes, slots, blind holes, external and internal splines, gears, and thread profiles are just some of the intricacies that can be done.

Versatility

Ferralloy works with many different casting alloys. This allows our investment castings to be used for a variety of different industries.

Lower Cost

The initial wax injection mold to produce the patterns is often lower than other casting tooling costs. As a result, you get a more cost-effective product without having to sacrifice any quality.

Are You Looking for Investment Castings?

At Ferralloy, we offer the best investment casting in the business. Our years of experience in this process means that we can supply superior net shape or near net shape parts that need little or no finish work. Contact us today to learn more about our investment casting process.

 

What are investment castings?

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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Forging Rings | Why Does Corrosion Occur in Metal?

When you are working on an industrial project, you need to be able to rely on your materials. And, they need to last as long as possible. But, corrosion can lessen the integrity of metal elements. So, whether you are in the market for forging rings or other metal components, here is what you should know about corrosion:

What is Corrosion?

Corrosion is a natural process that causes the deterioration of refined metals. Over time, a chemical or electrochemical reaction will cause the metal to break down. This can reduce the durability of a metal component. It will “eat” away at the surface and eventually internal structure.

What Causes Corrosion?

There is an array of chemicals that can react with metals and alloys, causing oxidation. Even oxygen can play a role in corrosion. Rust is a very common form of corrosion. For example, iron can oxidize. It will then get a burnt orange and flaky surface. This is called rust. For structural alloys, moisture in the air can lead to corrosion.

How Can I Prevent Corrosion?

The first step to preventing corrosion is by creating high-quality, corrosion-resistant materials. Metalworkers make corrosion-resistant fabrications with materials that naturally are less susceptible to chemical deterioration. A special coating can also be put on to protect from oxidation. A professional can supply a prevention recommendation.

Are You in Need of Forging Rings?

Whether you are looking for forging rings or other reliable metal components, we can assist you. And, if you are in need of corrosion resistant fabrications, a specialist can direct you! So, contact us today for more information about our abilities.

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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.

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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

Alloy Castings | Why Should I Use Vacuum Fed Castings?

When it comes to choosing materials and methods for industrial components, there is a plethora of options. But, you always want the strongest alloy castings possible for your project. Here is why you may want to consider vacuum fed castings:

What is Vacuum Casting?

Some natural processes can aid in the casting process, while others do not. Vacuum casting acts against nature to ensure quality results. This is done by using a vacuum to extract air in a sealed area. Removing the air and atmosphere crates differential pressure. This forces the molten material into the mold from underneath.

What are the Benefits of Vacuum Casting?

There is an array of benefits to using vacuum castings. To begin, you can create more complex molds with this method. The process is also gentler than its counterparts like gravity fed castings. This lessens the risk of slag and inclusions within the mold. Also, vacuum fed castings offer a great surface finish. Plus, vacuum fed castings are easy to automate than gravity fed castings due to the precision that is involved in the process.

Should I Use Vacuum Fed Castings?

The vacuum fed method can be used for a variety of castings, including investment castings. The process is one that provides detail and precision. This makes it a great option for projects that require multiple molds of the same complex designs.

Are You in Need of Alloy Castings?

At Ferralloy, we offer an array of raw materials that we use for durable alloy castings. So, if your next industrial project is in need of castings or other materials, contact us to learn more about our services!

should i use vacuum fed alloy castings

Investment Castings | What is Net Shape Manufacturing?

Creating a strong finished product sometimes takes several steps. So, saving labor and still getting a quality component is key. And, that’s exactly what net shape processing or manufacturing does! So, if investment castings are a necessary component of your next project, understanding net shape manufacturing is smart.

What is Net Shape Manufacturing?

The final shape ­– or as near as possible to final – of a product is the net shape. Net shape manufacturing is a process that creates an object that is complete without needing finish machining or any other finishing actions. Near net shaping is used when net shaping is not.

What are the Benefits of Net Shape Manufacturing?

There is an array of benefits that come with net shape manufacturing. However, the cost effectiveness is arguably the best perk. By eliminating the needs for any extra finishing steps, net shape manufacturing cuts down on processing time and resource use. Additionally, net shape processing has the ability for faster production. It is a very familiar process. Meaning, metal workers commonly use it when it comes to investment castings that are high in demand.

What Materials can be Used?

There is a wide variety of materials metal workers use for net shape investment castings. This includes ferrous and non-ferrous materials. Some of your options are titanium, aluminum, copper, magnesium, and zinc. Steel, however, is not always an option as it requires more reheating and reworking.

Are You in Need of Investment Castings?

Investment castings are in commonplace for the metalworking industry. If your next project requires high-quality and reliable investment castings, contact Ferralloy today!

why would i want net shape investment castings