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Gravity Casting | Gravity Casting Process

Gravity casting is a casting process used for non-ferrous alloy parts. Sometimes referred to as Permanent Mould, the process is typically used on aluminum, zinc, and copper base alloys. Let’s take a deeper look at the process and some of its benefits.

The Process

There are three stages to the gravity casting process.

The first step is the heating of the mold and coating it with a die release agent. The release agent spray also serves as a cooling agent after the part has been removed from the die.

In the second step, the molten metal is poured into channels in the tool to allow the material to fill the entire mold cavity. The metal is either dosed or hand poured by using ladles. Usually, there is a mold “down sprue” that allows the alloy to enter the mold cavity from the lower part of the die. This reduces the formation of turbulence and subsequent porosity and inclusions in the finished part.

After the part has cooled, the die is opened by either using a mechanical tool or manually.

Advantages

There are many advantages to gravity casting. It offers good dimensional accuracy, a smoother cast surface finish than sand casting, and improved mechanical properties compared to sand casting. Gravity casting also provides faster production times compared to the other processes.

Does Your Project Require Gravity Casting?

Gravity casting is ideal when using non-ferrous alloy parts such as aluminum and zinc. Contact us today to learn more about this, as well as the other services we provide.

What is gravity casting?

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

Heat Resistant Castings | Everything You Need To Know

When it comes to different types of projects involving metal parts, it’s important to consider the sensitivity of the metals you’re using. Depending on the project, you must make sure that the parts can withstand the processes you intend to use. One example of a process to be wary of is extreme heating. In the case of extreme heating, heat resistant castings would be best. Many industries benefit from this type of casting. These include air craft and aerospace, oil and gas, road construction, coal mining, steel production and processing, off road equipment, food equipment, railroad, biowaste and more.

What Are Heat Resistant Castings?

heat resistant castings

Heat resistant castings are castings that don’t melt or corrode during high-end industrial operations involving high temperatures. In fact, they have the capability of performing in conditions above 1200°F. Heat resistant castings are usually higher in alloy content than other types of castings. They mainly consist of nickel and chromium. Nickel is usually present in amounts of up to 70 percent. Chromium is usually present in amounts of 10 percent to 30 percent. Other elements, however, are used as well. These include iron, carbon, silicon, manganese and molybdenum.

If you have a project coming up that requires parts to perform at temperatures above 1200°F, Ferralloy Inc. assist you. Here at Ferralloy Inc., we can supply you with all of the parts you need for your heat resistant castings. Our products include trays, baskets, fans, furnace rolls, retorts, skid riders, muffles, roller rails, piers, grids, pickling hooks, walking beams, radiant tubes, fixturing, corrugated boxes, generator tubes, chain guides, pusher heads, heating elements, burner nozzles, hanger bars, tube support and enameling hangers. And if you need us to, we can make recommendations about which products are best for your specific wants and needs. So don’t hesitate any longer to start your project! Contact us today!

heat resistant castings help

Zirconium | History of Zirconium

Have you heard of the metal zirconium? It’s a chemical element that is a strong solid at room temperature. It does not exist in a pure state in nature and requires complex physio-chemical processes to get there. When it is in pure form, it’s a corrosion resistant metal that can handle high water temperatures. In addition, it can create different alloys that can handle highly corrosive environments, such as strong alkalis and mineral acids. This is why it’s very useful for parts that will be exposed to extreme environments.

what is zirconium

Brief History of Zirconium

Martin Heinreich Klaproth was the German chemist who discovered zirconium. This discovery took place in 1789 as Klaproth was analyzing jargon from the island of Ceylon. Upon finding the element, he decided to name it “zirkonerde (zirconia).” In 1808, Humphry Day tried to isolate the element using electrolysis, but was unable to do so. Later, Jons Jacob Berzelius was finally able to successfully isolate it.

In 1824, it was prepared in an impure form by Berzelius. This preparation was done by mixing potassium and potassium zirconium fluoride in a tube. The first industrial process that was able to produce metallic zirconium was called the crystal bar process. This process was surpassed by the easier and cheaper kroll process later on.

Learn More About Zirconium Today!

By now, you should be more familiar with the history of zirconium. But if you want to learn even more about this metal, Ferralloy Inc. can educate you. Our team is extremely knowledgeable about the different metals and alloys and would be more than happy to assist you.

Here at Ferralloy Inc., we provide industries with all of the materials and components they need to complete various projects. If you’re interested in finding out how zirconium might benefit your project, contact us today! You can also visit our website to learn more about our services and how they can help you.

Alloy Castings | Which Metal Alloys Can Be Used for Cast Parts?

When it comes to metal parts, only a few types of components compare to castings. Castings can be produced with fine detail, thin walls, excellent “as-cast” surface finish, shape into external or internal features, and near-net shapes. Furthermore, cast parts allow customers to money thanks to the minimal use of material, machining, and labor. While the question of whether or not to use castings is easy, it may be difficult to decide on which metal alloy to use for your cast parts. To help you out, we listed out a few of the best materials for alloy castings.

5 Best Materials for Alloy Castings

Casting is a suitable type of metal component for a wide variety of alloys. Here are a few of the best ones:

Aluminum Alloys: The benefits of aluminum castings vary depending on which specific aluminum alloy is used but typically consist of good machinability, weldability, and corrosion resistance.

Carbon Steel Alloys: Cast parts that use carbon steel alloys are known for their hardness and having a fair to good weldability and machinability. However, they are also known to have a poor resistance to corrosion. 

Nickel Alloys: Nickel alloys are used for castings largely due to their benefits that include great oxidation resistance, good weldability, and fair machinability.

Cobalt Alloys: Castings that made out of cobalt alloys possess very good resistance to corrosion as well as great castability.

Stainless Steel Alloys: These alloys often are the best option for cast parts that require resistance to oxidation and corrosion.

No matter which material you choose for your alloy castings, Ferralloy, Inc. can provide you with the finest possible part for your next project. We are experts is all casting process and will offer you with the best process option to ensure that your costs are minimized and quality is never compromised. Contact us today for more information about alloy castings or a personalized quote today!

what are the benefits of different types of alloy castings

Alloy Castings | What Are the Benefits Aluminum Castings?

There are numerous different types of castings methods. There are investment castings, sand castings, centrifugal castings, and heat resistant castings. In addition to a wide-variety of processes, there are also numerous casting materials. While castings can be created using just one metal, alloy castings are often seen as the most advantageous with each specific alloy casting possessing its own set of benefits. One alloy casting that is particularly popular throughout many industries are aluminum alloy castings. Keep reading to learn about all of the advantages of using this metal component!

5 Advantages of Aluminum Alloy Castings

Aluminum alloy castings hold numerous benefits thanks to its chemical and physical properties. We outlined the 5 most important advantages of this type of casting below.

  1. Aluminum castings are extremely versatile and are able to possess a wide-range of characteristics.
  2. They can produce near-net-shape parts with a controlled surface finish, dimensional accuracy, and complex geometries.
  3. They create lightweight parts that are still extremely strong and hard.
  4. Aluminum alloy castings can withstand the highest operating temperatures when compared to any other cast alloy.
  5. These castings possess outstanding corrosion resistance, thermal and electrical conductivity, EMI and RFI shielding properties, and are fully recyclable.

Due to their wide-range of benefits, many industries rely on aluminum alloy castings. Specifically, the automotive industry has been the largest market for aluminum castings ever since the early 1900s. However, they can be found in any industry that requires strong, light, and detailed parts.

If you’re interested in utilizing all of the advantages of aluminum alloy castings for your next project, contact us. Ferralloy, Inc. is a leading supplier of quality castings to major companies throughout the world. We can provide you with as-cast or fully machined parts in many different ferrous and non-ferrous alloys. Visit our foundry online today to learn more!

Alloy Castings | What You Need to Know

Countless industries would not be able to function without castings. Formed by pouring a liquid metal into a mold and then allowing it to cool and solidify, these metal components create complex shapes that would be close to impossible to emulate using other methods. While you can create castings using just one metal, such as iron, alloys are an extremely popular casting material as well. Keep reading to find out what you need to know about alloy castings!

What Are Alloys?

Most metals used in castings and other metalworking processes are not metals at all. Rather, they are alloys. Alloys are metals combined with other substances to make them stronger, lighter, or better in some other way. The substances that are paired with the main metal are called alloying agents. The alloying agents can be another type of metal or a completely different chemical element. They are present in much smaller quantities (sometimes less than 1 percent of the total) than the main metal, but have a significant impact on the quality of the castings. 

What Should I Consider When Choosing a Casting Alloy? 

There are numerous different types of alloys that are used to create castings, each with their own advantages and disadvantages. As a result, there are a variety of factors to consider when choosing a casting alloy. Some specific considerations include strength, durability, production volume, corrosion resistance, cost, stability, and so on. For example, if your project requires components that are corrosion resistant with high strength, an aluminum or copper-based alloy could be an effective choice. Which alloy you utilize for your castings depends on which factors are required for your project.

How Can I Get Alloy Castings?

If you’re interested in using alloy castings for your next project, Ferralloy, Inc. can help! We are a leading supplier of quality alloy castings to major companies throughout the world. Contact our metalworking experts for more information or a quote today!