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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!

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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!

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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!

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Castings | Why Should I Use Gravity Fed Castings?

We experience the power of gravity every day. And the metalworking industry knows how to implement natural forces. And, it creates durable products for industrial purposes. Gravity castings, also known as permanent mold castings, are one of those forces that metal workers can use to the industry’s advantage.

There are some obvious benefits to using a gravity fed casting. To start, in comparison to sand casting – a method that uses sand as the mold material – gravity castings offer a smoother cast finish. A gravity fed casting also show as in having better mechanical properties in comparison to sand casting. This is because there is less gas that gets trapped within the material. However, you cannot produce some complex molds with gravity fed castings that you can with sand castings.

Additionally, a gravity fed casting allow for better dimensional accuracy. This is in addition to high production rates because of their reusable ability. Note that the process has the possibility to be more expensive than other options (depending on the variables of your needs). But, you are able to get more out of your casting. This makes them a great choice for projects that have demand for several strong components. During the process, the mold aids in the casting material to solidify quicker. This will happen after the metal worker performs a low pressure or tilt pour.

Are You in Need of Castings for Your Next Industrial Project?

The integrity of your next project relies on the durability of its metal components. Contact Ferralloy today to learn about our high-quality, globally sourced materials and products.

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Investment Casting | The History of the Term “Machining”

Precision is key when creating reliable metal components. Whether you are looking for an investment casting or something else, machining for an industrial project is a way to ensure accuracy of cuts. But term machining has not always meant the same thing in the metalworking industry.

As the technology of machining has changed, the definition of the term has as well. In the 18th century, a machinist simply would mean you could build or repair machines. This was done mostly by hand with forging and filing.

Later on – around the mid-19th century – “to machine” came around, as the practice became more widespread. This would include the use of more efficient tools like drill presses and sharp cutting tools.

Now, the term “machining” involves an array of modern day metalworking technologies. This can include electrical discharge machining, electrochemical machining, ultrasonic machining, and more. However, people refer to more traditional technology as “conventional machining.”

So, What is Machining?

Machining is the process used to cut and manipulate raw material for a finished product. It is a great way to ensure precision for unique shapes. Metalworkers use cutting, drilling, forming, grinding, and more to create a final component that is durable and accurate details.

Is Your Next Project in Need of Investment Casting?

Machining sometimes entails difficulties. So, it is important that metalworkers understand the investment casting process and machining process. At Ferralloy, we are experts on both. If you are in need of reliable castings and/or machining, we can assist you. Contact us today for more detail!

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Ring Rolling | What Shapes Can Ring Rolling Produce?

There are several types of metal rolling – all of which allow metal workers to create large and small pieces. And, certain methods of ring rolling provide extremely strong and reliable components for an array of industry needs. But, one of the perks of ring rolling is the variety of shapes it can make.

Shear

Shear rolled rings means that a solid, cylindrical shape is created. It is hefty and reliable as it retains all of its volume during the rolling process. This is a very simple yet useful piece of metalworking. What is also great is that ring rolling creates completely seamless materials. This makes them even more reliable.

Flatten

If you are looking for a flattened rolled ring. Imagine if you took a shear shape and pressed down to flatten it out like a thick coin. It is important to note that parts produced with ring rolling give the material a grain with orientation. This allows for even more strength.

Punch

A punch is another step from a flattened shape. You can think of it as though you punched a hole through the flattened component. To create rolled rings, metal workers use an idler roll (which will shape out the middle) and a drive roll (which will shape the outside in conjunction with the idler role).

Looking for Ring Rolling for Your Next Project?

The integrity of your project relies on the durability of your metal components. If you’re in need of ring rolling for your pieces, contact us at Ferralloy to discuss how we can supply your project!

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Alloy Castings | Interesting Tantalum History and Facts

You have your basic metals and alloys – titanium, stainless steel, aluminum and more. And they’re great! But, behind the classics, are some renowned metals and alloys with properties that ensure the integrity of alloy castings. Tantalum is one of those materials.

History of Tantalum

Scientist found tantalum in 1802 in Sweden. It was originally thought that columbium (now niobium) and tantalum were the same. But, scientists were able to dispute that later. The first metallic form of tantalum came about in 1864. Then, in the early 1900s, it was used to create light bulb filaments and would later be replaced by tungsten.

Physical Properties

Tantalum is a dark blue-gray in color. What’s great about it in terms of metalwork is that it is dense and very hard. But workers can still fabricate it easily. It’s ductility also makes it a great component to conduct heat and electricity. However, it’s greatest physical proper is that it is extremely resistant to corrosion by acids.

Where Does It Come From?

There are several types of tantalum out there. But, not all are great for industrial purposes. The majority of tantalum comes from Australia. But, there are also mines in Thailand and Malaysia. Industry experts predict that there are less than 50 years-worth of tantalum left in the world. This is encouraging people to recycle.

Are You Looking to Use Alloy Castings in Your Next Project?

Alloy castings are a great option for the components of your next project. However, their true integrity lies in the material you choose. Contact us to discuss the details of any metalworking needs you may have!

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Investment Castings | How Can I Ensure Product Quality?

The quality of metal components can make or break a project – literally. So, having high-quality materials and final products is of the utmost importance. At Ferralloy, our expert metal workers use an array of testing and inspection services. These confirm compliance with engineering specifications. They also ensure you are receiving the best of the best in investment castings and more. Get to know just a few of our methods:

Dye Penetrant

When testing finished products, the main goal is to keep the integrity of the component. Dye penetrant testing is a nondestructive method. The test includes cleaning the surface of a product, then applying a colored penetrant, or dye. This shows surface discontinuities in non-porous materials. Workers may use this for joints, forgings, castings, and more.

Ultrasonic

Ultrasonic testing is another type of nondestructive testing. Workers use this method on an array of metal products. It ensures that customers are getting the best components possible. This method works by sending high-frequency wavelengths through an object to detect cracks and other possible flaws. However, with metals, ultrasonic testing is great for inspecting raw materials rather than just complete parts. Plus, a couple more pros about this method are that it is quick and very reliable!

Coordinate Measuring (CMM)

Testers may use coordinate measuring to test geometric characteristics of components. This is reliant on the shape and size of the piece. Then, the readings are shown in a mathematical form. So, the probing system in the machine and data collection allows for precision which results in durability.

In need of Investment Castings for Your Next Project?

Ferralloy dedicates its time and expertise to create the highest quality products for every project you may have. So, if you are looking for investment castings or any of our other quality-tested products, contact us today!

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Alloy Castings | What are Super Alloys and Why Would I Use Them?

The integrity of any project requiring metal work lies on the integrity of the material used. There is a reason super alloys are named “super.” Their strength and stability make them ideal for particular products and alloy castings. If you are looking to create strong and high performing castings for your next industrial project, super alloys may be an option. Read why they are continuously growing in popularity:

What are Super Alloys?

Super alloys – also known as high-performance alloys – are alloys that offer paramount strength. They do not only have great mechanical strength. But, they are able to withstand high temperatures without deforming. And, super alloys are made even stronger every year. New chemical processes raise the temperature limit for different super alloys.

When Would I Use Super Alloys?

Super alloys have become more available in recent years. So, this has made them more popular. And, new super alloys are always under development to create stronger alloy castings. When a piece of metalwork needs to maintain strength while reaching high temperatures, a developer may want to use super alloys.

The aerospace and marine industries use super alloys for turbine engines. And, over the years, the heat resistance of super alloys has been growing. However, super alloys can be susceptible to environmental factors. Thermal fatigue, hot corrosion, and oxidation – all of which can weaken chemical bonds – may affect surfaces of certain super alloys. But, protective materials cam coat super alloys to prevent such issues from occurring.

Want More Information on Our Alloy Castings?

Ferralloy goes above and beyond the industry standard for our customers. And, we can help you find the best materials for your next project. Whether you’re looking for super alloys or an alternative, we want to provide you the best information on alloy castings, so please contact us today!

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Cobalt Alloys | 7 Interesting Facts

Are you thinking about using cobalt alloys for your next project? If you are, then there are a few things that you should learn about this extremely advantageous metal. Keep reading to learn 7 interesting facts that you need to know about cobalt alloys.

7 Facts About Cobalt Alloys 

  1. It was originally created in the 1900s to substitute traditional metal cutlery that was prone to staining and general wear and tear, but its uses have grown throughout the years.
  2. It is a non-magnetic alloy and contains a variety of different elements such as cobalt and chromium.
  3. The combination of cobalt and chromium creates an extremely high melting point, which makes this metal perfect for a wide range of interesting applications from extreme cutting tools to hot section alloy coatings in gas turbines.
  4. Some of its biggest benefits include its toughness, heat resistance, and that it also reduces the amount of machine finishing.
  5. Adding different elements, such as nickel, iron, carbon, magnesium, sulfur, silicon, and titanium, to this alloy enables great control over its individual characteristics so that it will fit your exact needs.
  6. This alloy is commonly used in an intense environment where temperatures can range from 600 to 1112˚F, or 315 to 600˚C.
  7. Cobalt alloys are commonly used for saw teeth, acid-resistant machine parts, valves for internal combustion engines, machine guns and machine gun barrels, medical applications, turning tools for lathes, and more.

Are you interested in using cobalt alloys for your next project? Then contact Ferralloy Inc. today for a quote or to learn more about our services.

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