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Forging Inconel Alloys

Corrosion is one of the biggest and most common problems faced by industries using forged materials. To avoid this concern, manufacturers ventured into using Inconel alloys. It turned out to be useful and effective. Hence, Inconel alloys are still widely used by forging industries to produce quality and oxidation-resistant end products.

 

What is Inconel?

Inconel® Properties and Applications

What is Inconel?

Inconel is a nickel component. It contains iron and chromium and is often resilient to high temperatures and corrosion, making it a good forging material. The only downside is that it’s not that affordable to produce. While it is consistent and hard-wearing, it is one of the more expensive materials you can use.

However, it is worth the cost since it can produce extremely tough materials. More so, it does not easily break down or falter.

What Makes Inconel Alloys So Exceptional?

Inconel alloys can preserve their structural formation despite being exposed to high temperatures. Aside from this, it can also resist oxidation. Inconel alloys are extensively used by industries that need material properties that do not easily yield to stress-corrosion cracking, high purity water corrosion, or caustic corrosion.

Although every Inconel variety has distinctive traits that make it functional in diverse situations, the majority of these alloys are applied or used by chemical industries. For example, Inconel 718 is repeatedly used in the aerospace industry such as rocket motors and spacecraft. On the other hand, Inconel 600 and 601 are exceptional tools in the food processing and chemical industries.

What is Inconel?

What are Inconel 600, 601, and 718?

Inconel 600 a nickel-chromium alloy with stable high-temperature oxidation resistance. It is also resistant to chloride-ion, stress-corrosion cracking, corrosion by high-purity, water, and caustic corrosion.

In contrast, Inconel 601 also has the same properties and use as that of the Inconel 600, the only difference is that it has additions of aluminum. Lastly, Inconel 718 is a corrosion-resistant nickel material that’s known for its excellent rupture strength, fatigue, and tensile.

Irrespective of the type of Inconel material you’re looking for, you’ll be able to find the Inconel alloys you are looking for at Ferralloy Inc. We are a quality-driven organization committed to process improvement and customer satisfaction.

Understanding Forged Steel

Many people have never heard of foraged steel, but little do they know it’s used all around them. Most things made out of metal can be made stronger with forged steel! Forging was originally implemented to produce different kinds of steel ends with distinct properties. Currently, hydraulic hammers, and other forging machines and processes, make it possible for the development of steel forgings.

What are Steel Forgings?

Process and Categories of Steel Forgings

Process of Producing Forged Steel

The forging process begins by heating the steel to a high temperature, making the material more malleable and ductile. Next, it will be formed to the desired shape by applying the right amount of pressure to the steel. With the precise processing methods, steel forgings make it possible for a billet of steel to permanently be shaped without compromising its quality.

Additionally, steel forgings require a forge oven, forge furnace, or any forging heating system to sufficiently deliver the precise temperature needed. Furthermore, the deformation and thermal cycle process allow for rain refinement and metallurgical recrystallization to strengthen the finished product. This process is important to improve impact toughness and quality.

Categories

Steel forgings can be divided into 3 categories: the cold, warm, or hot forging of steel. Cold steel requires room temperature forging require a room temperature forging. The process often involves a self-heating method in which temperature may reach up to 150 degrees Celsius. This category requires high forming forces and low formability.

As for warm forgings, the temperature reaches between 750 and 900 degrees Celsius. However, just like cold steel forgings, this category needs higher forming forces but only has limited formability.

Lastly, hot forgings may reach up to 1250 degrees Celsius. Since the temperature is often above the recrystallization level, this forging category only requires low forming forces and still has good formability results.

What are Steel Forgings?

More Information about Steel Forgings

Aside from the forging process and categories involved, there is still a lot of information you need to know before purchasing forged steel. Additionally, you should know the advantages, disadvantages, properties used. At Ferralloy Inc., our friendly experts will lay down all the facts you need to know. Contact us today!

Characteristics of Open Die Forging

Open die forging is a type of drop forging technique of deforming a metal according to the desired shape. Without any limitation, it can utilize pressure and power inflicted. Some experts even call it free forging since the process involves fewer restrictions. 

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Features of Open Die Forging

Simple Production Equipment

One of the most notable characteristics of open forging is that it requires only the necessary production equipment. Because of this, the production cost is lowered. In contrast with other forging processes, open die forging bar any possible defects such as porosity, gas holes, or shrinkage. 

High Mechanical Properties

Unlike closed die forging, this type of technique involves basic shaping and flexible operation. Because it uses higher mechanical properties, open forging always acts as an essential part of heavy-duty machinery.  

Manual Operation

Nowadays, forging techniques are controlled by manual operations. Another feature why industries purchase equipment made through an open die forging process is that manual operations hold the dimensions and net near shapes. Hence, the accuracy of product sizes has become relatively low. 

Main Equipment Used

Open forging primarily uses two main types of equipment. These are the hydraulic press and forging hammer. To be more specific, the steam hammer and air hammer are used. Also, a hydraulic press is used to reshape the metals into its desired form. It uses static pressure produced by a liquid solution. 

Production

Open forging uses both machines and labor to produce quality materials that are worth the investment. Because it uses work, the production cost decreases. Hence, open forging is a metal forging technique that’s suitable for single and accurate production.

what is closed die forging?

Learn More About the Open Die Forging Process

Open die forging involves numerous processes such as welding, cutting, mismatch, torsion, bending, etc. Also, it uses a technique called elongation. It is a process commonly performed to produce components for rod and shaft parts. 

If you want to know more about the forging applications and which product to choose, experts at Ferralloy Inc. will help you! Contact our experts today through this link!

Understanding What Forged Steel Really Means

Forgings involve a complicated process. Manufacturers and other industries concerned should be well-equipped with every forging knowledge to fully deliver exceptional products. This article will tackle the benefits, types, significance, and history of forged steel.

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Forged Steel Basics

History

Forgings began several decades ago. It was only in the 1800s when modern methods and processes were developed. The first types of forged steels were discovered and known to have been developed in China and Persia. Traditionally, this method is performed by a smith. Today, anyone with enough experience and tools can manufacture and produce quality forged steel.

What is Forged Steel?

Modern forged steel is manufactured by using hydraulic hammers and other specialized machines. When understanding forged steel, you have to consider many things before you start.

According to specialists on forgings, forged steel is an alloy of iron and carbon compacted under extreme temperature and pressure. By this, the manufacturer can produce a product with strong and durable components. 

Benefits

Forgings are used in different ways by different industries. Everything from pharmaceuticals to manufacturing uses the benefits of forged steel. Anything that is made of metal is designed and manufactured through forging. These metals are made to be weight-conscious and durable by forged steel.

Types

There are three basic forged steel – squeezed-in steel, upset steel, and drawn out steel. Squeezed-in steel utilizes closed dies that compress the steel into a definite shape and creates flow in all directions. Upset steel decreases the length of the metal and increases the width. Drawn out steel is the opposite as it reduces the width and increases the size.

Significance

One of the perks of choosing forgings is that the metal components become more robust and more durable. The pressure in manufacturer the steel strengthens the materials used in a way that it can withstand extreme temperatures. Hence, to make exceptional forged steel, the metal must be heated to high temperatures and kept at room temperature.

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Learn More About Forgings

At Ferralloy Inc., we make sure that the products we sell are only of good and exceptional quality. To know more about forgings and what we can offer, contact us through this link!

Do You Know About Lost-Wax Casting?

Lost-wax castings are commonly known as precision castings or investment castings. It is a procedure of designing and building an object with the use of a variety of metals. From simple to complex objects, lost-wax casting use metals like bronze, brass, silver, or gold to create an original pattern or model.

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The Lost-Wax Casting Process

A Little Bit of History

Investment castings are known to be the oldest metal-forming procedure that dates back in 4000 BC. Even though it is the oldest known technique, innovations and technique evolutions made it possible to offer exceptional metalwork. Likewise, it is extensively used to produce objects for art, dentistry, and jewelry. 

Making the Mold

The investment castings process starts with carving a mold out of wax. To get exceptional metalwork, you need to look for a casting industry that can handle your design’s size and complexity. The experts’ skill and the equipment used should be in line with what you want your finished product to be.

Upon making and casting the mold, it will be intensively polished to comply with the exact measurements and dimensions. It is then used to create another wax mold that will be heated and transformed to create a more flexible mold. 

Assembling the Wax Pattern

To guarantee product quality, investment castings use different methods such as coordinate measuring, ultrasonic, and dye penetrant. These methods will be used according to where the metal components will be used. Dye penetrant testing is a nondestructive method, and it includes cleaning the surface of a product, then applying a colored penetrant or dye. The wax pattern will primarily depend on which way will be used.

Finishing the Metalwork

The casted components are sandblasted, machined, ground, or files to attain the desired surface finish and final geometry. If necessary, the cast components are likewise heat-treated to improve the mechanical properties of the metalwork.

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Know More About Investment Castings

If you want to know more about the products designed through investment castings, contact our experts at Ferralloy Inc. today!

Understanding Carbon Steel Rolled Rings

Creating carbon steel rolled rings is a process that uses carbon steel. It contains up to around 1.2% carbon while other present elements are in quantities too small to impact its properties. With this material, carbon rolled rings are commonly used for pressure and structural vessel applications. To understand more about carbon steel rolled rings, below are the facts you need to know.

seamless-rolled-rings

All About Carbon Steel Rolled Rings

Why Choose Carbon Steel

Manufacturers engaged in rolled ring production will tell you that carbon steel is among the most cost-effective option when it comes to steel. Since it is cost-effective, the rolled rings process can attain the high strength a stainless steel can offer. However, you can still achieve good quality products that can be hardened through tampering and quenching.

Carbon Steel Grades

High-grade carbon steel rolled rings is often used in applications that don’t require high temperature or high strength environments. Below are the carbon steel grades you need to familiarize yourself with.

  • A Grade – This type of carbon steel is ideal for oil field applications since it is corrosion resistant. It comprises alloy substance such as nickel or manganese. Thus, it can enhance the toughness and hardenability of the metal produced.
  • High Carbon Steel – Akin to A Grade carbon steel, this type also comprises manganese to improve hardenability and toughness. It can be heat treated or welded for higher durability.
  • Low Carbon Steel – This is commonly known as re-sulfurized carbon steel as it contains sulfur to provide exceptional machinability.
  • Plain Carbon Steel – The least expensive type but provide a good welding factor. It comprises high carbon content and low alloy content. Hence, plain carbon steel can offer excellent surface hardness and good toughness.

Capabilities of Carbon Rolled Ring

Carbon rolled rings utilize a foolproof forging process that creates seamless rolled rings with outstanding circumferential grain flow and ample internal structure. Also, the precision rolling procedure offers exceptional surface smoothness and concentricity.

forged-rolled-rings

Want High-Quality Carbon Rolled Rings?

Ferralloy Inc. is a solutions provider that offers high-quality carbon steel rolled rings. Products are delivered according to the preference and most demanding requirements of clients. Contact us today!

How the Investment Casting Process Works

To produce many specific metal components, the metal undergoes certain processes to achieve the shape and quality. For products like investment castings components, it needs to undergo a rigorous process called machining. This process is very complicated and crucial to the quality of the metalwork. You also need to remember that there are various tools and techniques within machining specific to the component and its purpose. 

Depending on what the investment casting component will ultimately be used for, the rigid and complex process it undergoes may still vary. To find out more about how the investment casting process works, below are the applications and types used. 

Machined Investment Casting Applications

Investment castings are essentially used in power generation and aerospace industries to produce a variety of components. The process in investment casting includes the operation of machining the metal after it has been manufactured. This is to have it made and delivered to the company’s exact specifications. In the power generation and aerospace industries, it is imperative to guarantee that any accurate measurement is achieved in machined investment casting. 

Types of Machining

The tools, techniques, and technology involved in machining vary between different tools used for cutting. There are times where machined investment casting needs a specific texture or an exact measurement. Likewise, in each case, an additional device is utilized. A few of the different machining operations types include turning, drilling, boring, reaming, and milling. 

A single edge cutting tool is used to eliminate excess material from a rotating component to produce a cylindrical shape when it comes to the turning process. As for the drilling process, a round hole is being created. A single bent tip is used to advance the precision of an already roughly made hole. 

The reaming process involves the removal of a small amount of excess metal from an already drilled hole. Lastly, milling is a rotating tool with several cutting edges utilized to create a straight surface.

Looking for Quality Investment Castings?

Ferralloy Inc. has the experience and authority to offer this service and product to you. As an industry leader, Ferralloy, Inc is equipped and experienced in delivering high-quality metal components at competitive prices. Contact our metal component manufacturing company today!

Near Net Shapes of Seamless Rolled Rings

Seamless rolled rings offer numerous advantages, such as using less material to be machined to achieve the final machined part. However, one of the most notable factors why industries opt for these rolled rings is the near net shape factor. Aside from the cost reduction, companies or manufacturers who use the seamless rolled rings process can maintain constant durability and strength in the product. 

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Benefits of Near Net Shapes

Cost Reduction

By using seamless rolled rings, your company can reduce costs in several ways. For instance, the process involves less wear factor in the machining equipment and requires lesser machinery hours. Additionally, there is less input component needed to design and create the ring.

Since near-net designs of seamless rolled rings substantially reduce costs, it became popular in aerospace industries. Because of the high cost of several aerospace supplies and resources, enterprises engaged in this sector often look for cost-effective substitutes.

Reduced Waste Material

Seamless rolled rings allow you to save on waste and recycle disposal costs. Hence, most manufacturing industries always guarantee that the process should produce near net shapes to reduce waste materials costs.

Why Choose Near Net Shape Manufacturing

Near net shape, manufacturing is the perfect solution for those looking to cut back on manufacturing costs. This is because near-net-shape manufacturing does not require finishing steps. So, when you do not need any machining time, you can save on production costs. It also takes less time to produce near net shapes.

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Get Seamless Rolled Rings Today!

Ferralloy Inc. is composed of engineers who are highly skilled in designing and create forged materials. They are used to dedicating their time to create durable and reliable metal works. Among the several developing industries and companies, Ferralloy Inc. is a leader in producing and near net-shaped metal workings with ring geometry. 

To know more about what we can offer, contact our team today through this link. We assure you that only quality and lifelong metal works will be provided. 

What are the Perks of Choosing Rolled Rings?

From pharmaceutical companies to machine shops to nuclear industries, it is safe to conclude that rolled rings are widely used in several industries. This type of forging is a procedure that starts with a circular form of metal. Such metal has already been pierced to make a hollow donut shape. The rolled ring is placed in a high temperature, then rotated to decrease its wall thickness while increasing the finished metal product’s diameter. Below are the perks of using a rolled ring forgings. 

Use of Various Materials

Rolled rings can be formed from numerous forgeable components such as aerospace metals, carbon, stainless steel, or alloy. Its versatility allows the rings to be more responsive and flexible. This is precisely why the industries engaged in refinery, chemical, and power generation choose this process. 

High Temperature Tolerant

Rolled rings forging is easier to manage and control when it comes to heat exposure. Unlike any metal components, rolled rings do not require extensive care when the heat is applied. The troubles of preventing such parts from deforming and melting rarely exist. With such procedure, manufacturers and other industries are guaranteed that it can withstand maximum heat.

Reliability and Cost-Effectiveness

Since rolled rings can withstand high temperatures, it can be inferred that the finished product is reliable with more resistance and strength capability. Aside from reliability, it is also known to be cost-effective. Rolled rings are formed and created at a lower cost than other components. It requires less machining as it closely matches the shape of the finished metal.

Strength

The strength factor of rolled rings forging is the most notable advantage of choosing such metalwork or process. Experts say that forgings have more strength than other components. It can maintain the power of the metal despite temperature fluctuations.

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Get Rolled Rings Forging at Ferralloy Inc.

At Ferralloy Inc., we are committed to providing you only the finest and efficient work. Also, our rolled rings are created by the best and dedicated manufacturers that offer precision machining. Contact our team today to learn more about us!

Tips When Looking for a Forging Manufacturer

Over the years, the forging industry has massively evolved. The use of different techniques and processes in forgings gave rise to various applications in construction, agriculture, automotive, machinery, and so much more. Below are the tips you may want to consider in looking for a forging supplier or manufacturer.

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Guide in Choosing a Forging Manufacturer or Supplier

Know Which Type You Want

Forgings have two most popular forms. These are open die forging and closed die forging. Although both originated in the fundamental forging process that involves beating a piece of metal until the desired shape, strength, and granular level is achieved, these two processes have differences.

Choosing a Company That Delivers On-Time

Did you know that your success as a company depends on the complex relationships that make up your supply chain? Be sure that your supplier supports your success and delivers on-time, all the time. A delay in the delivery will make things complicated and may even compromise your production.

Fact Check of the Company’s History and Reputation

Sellers and manufacturers aren’t hard to find. Some companies focus on low-cost and low-quality solutions. Hence, you can immediately spot them as their products fail to stand the test of time. 

Thus, it’s essential to look for a reputable supplier with a proven history of producing forgings that offer high quality and durability. Your reputation in the industry is at stake if you fail to choose companies that provide quality forgings.

Look for Any Certification

The supplier or manufacturer you chose to provide you with forgings must adhere to industry standards and specifications. In this way, produce durable and resilient forgings that can withstand extreme temperature, pressure, or adverse weather conditions.  

Certified suppliers and manufacturers maintain data-driven systems that are continuously audited. Aside from the fact that they quickly address quality issues by creating quality improvement plans, they also conduct subsequent reviews to monitor and evaluate these plans’ effectiveness.

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Get Quality Forgings at Ferralloy!

Having achieved ISO 9001 certification in both locations, we are a quality-driven organization committed to process improvement and customer satisfaction. Contact us today!