Contact Us: 1-440-250-1900

Forgings | What Are the Different Types of Forging Processes?

Forging is a manufacturing process involving the shaping of metal using localized compressive forces. When it comes to forging, there are four main ways to forge a part. Those four are impression die forging, cold forging, open die forgings, and seamless rolled ring forging. Let’s take a look at each type of the four main forgings.

Impression Die Forging

Commonly referred to as closed-die forging, impression die forging pounds or presses metal between two dies that contain a precut profile of the desired part. Impression die forging uses steel, aluminum, titanium and other alloys to produce a variety of 3-D shapes that range in weight from mere ounces up to more than 25 tons.

Cold Forging

While most forging is done hot, cold forging is done at colder temperatures. Cold forging encompasses many processes — bending, cold drawing, cold heading, coining, extrusions and more, to yield a diverse range of part shapes. These include various shaft-like components, cup-shaped geometry’s, hollow parts with stems and shafts, all kinds of upset and bent configurations, as well as combinations.

Open Die Forging

Open-die forging can produce forgings from a few pounds up to more than 150 tons. This process is referred to as open die because the metal is not confined laterally by impression dies during forging. Open die forging is ideal for parts over 200,000 lbs. and 80 feet in length.

Seamless Rolled Ring Forging

Seamless rolled ring forging is typically performed by punching a hole in a thick, round piece of metal and then rolling and squeezing the donut into a thin ring. Ring diameters can be anywhere from a few inches to 30 feet.

Are You Looking for Forgings?

Whether it’s impression die, cold, open die, or seamless rolled ring, at Ferralloy we have the forgings for you. Contact us today to learn more.

 

Who sells forgings?

Inconel | What Are Some Popular Uses for Inconel?

Inconel is a material that is specifically optimized for some of the toughest use conditions found in manufacturing. While it might be more expensive than other metals, it’s worth it. It has some of the highest tolerance for extreme heat and doesn’t lose as much tensile strength at 2,000°F as most varieties of steel. Let’s take a look at some of the popular uses for Inconel.

Heat Treated Applications

Due to it’s resistance to extreme temperatures and its ability to retain enough strength at high temperatures, it is the ideal basket material for heat treat applications. Compared to most stainless steel alloys, a basket made from Inconel won’t lose shape as easily when holding parts through a rigorous heat treat application.

Jet Engines

Jet engines are incredibly unique in that they have to withstand extreme temperatures. At peak cruising altitude for a plane, the average air temperature is -69.3°F. The combustion process can exceed temperatures of 2120°F though. While cooling technologies are used, the temperatures still easily exceed the tolerances of many metals. Inconel 600 retains high oxidation resistance and tensile strength despite rapid changes in temperature from the combustion process and cooling technologies employed in the aerospace industry.

Exposure to Saltwater

Inconel is often used in marine applications because of its extraordinary resistance to salt. As a result, it can be ideal for situations and products that use salt or are located near the ocean.

Are You Looking for Inconel Products?

If you are in the market for materials that are resistant even to the most extreme of temperatures, contact us today.

 

Who offers inconel?

Furnace Rolls | Gas Furnace Types

Furnace rolls work in some of the harshest environments. They will typically see temperatures in excess of 500 degrees Fahrenheit for years at a time. Materials used are made to withstand this criteria, so they are also difficult to machine. Let’s take a look at some of the different types of gas furnaces that furnace rolls are found in.

Modulating (or Variable Speed) Furnace

This furnace adjusts its flame incrementally so that the true temperature never varies more than 1 or 2 degrees from the thermostat’s target temperature. In terms of comfort, it is the most comfortable gas furnace you can buy. Modulating gas furnaces are among the most energy-efficient furnaces and are rated at 98% efficiency.

Two-Stage or Dual-Stage Furnace

The two-stage furnace is not as complex than the modulating furnace but better than the single stage furnace. Rather than a simple on/off operation, its flame can be on/high, on/low, or off. Adding this second flame setting makes a dramatic difference in energy costs.

Single Stage Furnace

With a single stage furnace, the gas flame is either on or off. Because of that, the furnace waits for the temperature in the house to get cold before firing on. Then, the furnace rams the house full of heat until the thermostat shuts the system down.

Are You Looking for Furnace Rolls?

No matter what the use, Ferralloy offers high-quality furnace rolls at competitive prices for your next project. If you are looking for furnace rolls, contact us today to learn more.

 

What can furnace rolls do?

Castings | What’s the Difference Between Molding and Casting?

Casting and molding are fundamental techniques in the metalworking process. Many industries rely on casting and molding to produce their signature products. Let’s take a look at the difference between moldings and castings to help you decide which one is best for your next project.

Molding

Molding is the process by which we take an object and create an impression of it in some sort of material. Generally, an initially soft material is poured or spread around the object and allowed to harden or set, creating a negative imprint of the object. Moldings can be made in either one piece or multiple pieces. While the type of molding material used depends on the size and shape of that object, some popular options include plaster and silicon.

Casting

Casting is done once a mold of an object is available. If the mold is made up of multiple pieces, it is put together securely and the casting material is applied. Casting creates an exact replica of the object that was molded, with only some slight sanding needing to be done. Various types of metals are commonly used in the casting process, including aluminum, copper, magnesium, iron, and zinc.

Are You in Need of Castings?

At Ferralloy, we offer molding and casting at competitive prices. No matter what the project is, we will work with you to make sure that you get the completed product in a timely manner and that it meets all your specifications. Contact us today to learn more about the products that we offer.

 

What's the difference between castings and moldings?

Closed Die Forging | What Materials Are Commonly Used?

While closed die forging is applied for almost all the metal materials, in actual production, only part of the materials are used for the different characteristics. The material used is one of the main factors that affect the cost of the forgings. Let’s take a look at some of the common materials used in closed die forgings.

Aluminum

Aluminum is popular due to its low density, high strength, and easy machining. It is widely used in the automotive and aerospace industries. While it is commonly used in the aerospace and automotive industries, it is a challenge for domestic forging due to the fact that it is easily deformed.

Steel

Steel is by far the most common material used when it comes to closed die forging. Alloy steel, carbon steel, and stainless steel are all used depending on what the forging is used for. Stainless steel material is often used for components that require corrosion resistance and rust resistance. Alloy steel and carbon steel are the most widely used in closed die forging process for its competitive price and easy deformation.

Brass

While brass is used in closed die forgings, it is the most expensive of the three materials that we have discussed. Brass forging is most commonly used for valve and pump fittings.

Are You Looking for Closed Die Forging?

At Ferralloy, we offer closed die forgings made of many different materials. Contact us today to learn more about how we can make closed die forgings for your next project.

 

Where can I find closed die forging?

Investment Casting | Do I Need Investment Castings for My Next Project?

The investment casting process is a metal casting process where a disposable wax replica, or “pattern”, which is identical to the casting desired, is produced from an injection molding type of tool. If you are thinking about using investment casting for your next project, here is some important information.

Why Is It Called Investment Casting?

The term “investment” refers to the process of the ceramic slurry application. When an object is dipped into a liquid, and that liquid stays on the surface, that is called investing, and hence this is where the name comes from. The process is sometimes also called the “Lost Wax” process as well as “Precision Castings”.

What Alloys Can Be Used?

Most all ferrous and non-ferrous materials can be investment cast. Although aluminum can be investment cast, it is not as popular due to its ability to be permanent mold cast due to its inherent low melting point. The more popular alloys include different variations of steel, copper, cobalt, and nickel.

What is the Accuracy?

Typically, a linear tolerance of plus/minus 0.010” for the first inch and then another plus/minus 0.005” for each inch after that is standard in terms of accuracy. The smaller the casting, the more dimensionally accurate it can be investment cast.

Do I Need Investment Castings for My Next Project?

If you are in need of investment castings for your next project, look no further than Ferralloy. We offer high-quality parts for any project you might need them for. Contact us today to learn more.

Do I Need Investment Casting for My Next Project?

Titanium Tubing | Where Can I Get High-Quality Titanium Tubes?

Titanium tubes are classified into two categories, commercially pure and alloys with additives such as aluminum and vanadium. Within each category, there are grades given to the titanium. This blog will go into the different grades of titanium to give you a better idea of what kind of titanium you need for your titanium tubing.

Commercially Pure Titanium Grades

Grade 1 titanium is the first of four commercially pure titanium grades. It’s the softest and most ductile and has the greatest formability, excellent corrosion resistance and high impact toughness. As a result, this grade of titanium is the material of choice for any application where ease of formability is required and is commonly used in tubing. Grade 1 titanium can be found in the medical industry, architecture, marine industry, and automotive parts.

Grade 2 titanium is called the “workhorse” of the commercially pure titanium industry. It has many of the same qualities as Grade 1 titanium but is slightly stronger.

Grade 3 titanium is the least used of the commercially pure titanium grades, but not because it’s not valuable. While it is actually stronger than grades 1 and two, it possesses higher mechanicals than the others Grade 3 is used in applications requiring moderate strength and major corrosion resistance.

Grade 4 is by far the strongest of the four grades. It is known for its excellent corrosion resistance, good formability, and weldability and has become increasingly more popular in the medical industry.

Are You Looking for High-Quality Titanium Tubing?

If you are looking for high-quality titanium tubes, look no further than Ferralloy. No matter what you are looking to do, we have the titanium to do it with. Contact us today to learn more.

 

 What is titanium tubing?

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?

Heat Treating Baskets | Should I Use Heat Treating Baskets?

Material handling baskets, such as heat treating baskets, can have a large impact on the efficiency of the parts finishing processes. A well-designed basket is effective at keeping parts safe from damage. While many manufacturers rely on plastic baskets, steel fabrications for material handling baskets can have several significant benefits. Let’s take a look at some of those benefits.

Heat Resistance

Unlike plastic, steel is significantly more resistant to heat. The melting point of a basic stainless steel alloy is about 2,550 degrees Fahrenheit. The strongest plastic polymer out there has a melting point of 750 degrees. The high-temperature tolerance of steel allows these baskets to take on oven-like temperatures with ease without degrading or losing tensile strength like a plastic container would.

Larger Load Capacity

Steel has a greater strength than plastic. The higher strength of steel allows baskets to handle loads that would crush a frame made of plastic. One of the weakest steel alloys on the market it’s still four times stronger than one of the toughest polymers on the market.

Lasts Longer

As we talked about earlier, steel has a greater strength and heat tolerance than plastic. That means that no matter what you are using the basket for, the steel version will be more durable and last longer than one made of plastic.

Should I Use Heat Treating Baskets?

Steel heat treating baskets are much better to use than their plastic counterparts. If you are looking at using a heat treating basket for your next project, contact us today.

 

Should I Use Heat Treating Baskets?

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?