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Advantages of Using Steel Castings

The word “casting” is used to define or refer to the part made by the machine casting process, which dates back more than 5,000 years ago. When it comes to history, this process is performed to make significant and complex metal components that would have been difficult when using the traditional manufacturing method. Because of this development, steel casting emerged.

what are the advantages of steel castings?

Why Use Castings?

Strength and Durability

Most manufacturers choose to use stainless steel castings for valve bonnets because of their incredible durability and strength. You can expect these types of valve bonnets to function well and remain in excellent condition for a long period of time, even when you use them in extreme temperatures.

Metallurgical Versatility

Castings allow you to choose among different chemical compositions and organizational control that fit your project’s requirements. In other words, castings offer strong metallurgical variability and adaptability.

Furthermore, compared to any other cast metal, you can obtain a wide array of physical and mechanical properties by simply making variations in its carbon and alloy content or heat treatment.

Economic Benefits and Greater Reliability

You can depend on cast steel parts for day-to-day use because they are designed with an isotropic material that intensifies engineering reliability. When you factor in its design flexibility and shorter delivery time, castings can give you the economic efficiency you’re looking for.

Design Flexibility

With steel castings, you can select from a wide range of alloys that can provide your designers the flexibility to configure your cast according to their needs. Aside from the fact that maximum design freedom to produce complex shapes and hollow section parts is never impossible when using steel castings, these can also be configured in a sturdy and repeatable manner.

Since steel castings’ design flexibility allows you to make quick changes as needed, your delivery time is dramatically shortened.

what are the advantages of steel castings?

Are You Looking for Steel Castings?

If you want to explore your options and invest in steel castings, contact the team at Ferralloy, Inc. today!

How Much Do You Know About Inconel?

Do you know what type of alloy is known to have oxidation – and corrosion-resistant materials? Inconel, a brand name for specific nickel-chromium alloys, is well-suited for service in extreme environments subjected to pressure and heat.

It is often used by industries that use forged materials exposed to extreme heat because of this capability. However, did you know that it’s extremely hard to weld on its own?

where can i get iconel?

Weld Inconel with TIG Welding

What is Titanium Inert Gas (TIG) Welding?

Titanium belongs in the family of reactive metals; meaning, it possesses a resilient affinity for oxygen. At room temperature, this metal reacts with oxygen to produce titanium dioxide. The passive and impenetrable coating combats further interaction from the surrounding particles. With titanium inert gas welding, manufacturers can secure the weld area from water vapor and oxygen.

How Does TIG Welding Enhance Inconel Welding?

As stated earlier, Inconel is generally complex to weld since the welds tend to crack because of too much heat and pressure. Nonetheless, certain types of Inconel are specially designed to be weldable.

In welding Inconel, industries must use an Inconel 625 filler metal. This is usually the most common weldable type of Inconel. According to metal experts, this type is useful in welding two pieces of Inconel together. Another good part of using Inconel 625 is that it can also be welded with other metals. For instance, most welding industries use stainless steel and Inconel to produce durable and heat-resistance metal.

For welding Inconel, you have to expect an ill-defined weld pool that may seem dirty and substandard for welders used to steel; however, this is normal. The important thing is that it welds a resilient and highly corrosion-resistant product.

where can i get iconel?

More Information About Welding Inconel with TIG Technique

The TIG technique offers the welder to gain more control over the materials. Additionally, this technique uses a clear-cut welding arc and is well-fitted for automation. Contact Ferralloy Inc. to learn more!

Titanium Seamless Rolled Ring Forging

A process used widely and performed to the highest level by Ferralloy is seamless rolled ring forging. It plays an important role in the manufacturing of certain components. Forging is a method of manufacturing inherently stronger components for machinery.

When apparatuses are needed to develop wind turbines or high-quality gears are required for mechanical parts, the ring forging process is used to manufacture superior pieces. The forging process uses different metal and alloy types to comply with the highest standards – among the most commonly used is titanium.

what are seamless rolled ring forging?

Why is Titanium Used in Seamless Rolled Ring Forging?

Applications

Titanium can be used for a wide range of metal parts, from tubing to bolts to fasteners. And this metal alloy is used for good reasons. The list of titanium benefits is a long one. Titanium seamless rolled ring forging is applied in water treatment, desalination, power generation, marine, chemical processing, aerospace military, and medical technologies.

Features

Aside from the fact that titanium rolled ring forging has many applications, its features are exceptional. It provides efficient low thermal expansion, low elasticity module, non-toxic and non-magnetic, high melting point, exceptional oxidation capabilities, and exceptional bearing to cryogenics property. Other notable features are:

  • Excellent corrosion resistance
  • Outstanding strength-to-weight percentage
  • Low density
  • High-heat resistance

Main Properties

What makes titanium a special forging material is its properties. According to forging experts, the following are titanium’s main properties that make it an exceptional material for forging processes.

  • Hydrogen storage
  • Superconductivity
  • Shape memory
  • Low damping resistance, modulus of elasticity, thermal conductivity, non-magnetic, and density
  • High-temperature easy oxidation, strength, and heat resistance

Likewise, titanium rolled ring forging offers tensile strength close to yielding strength, good performance at low temperatures, and exceptional corrosion resistance.

what are seamless rolled ring forging?

Where to Look for Titanium Seamless Rolled Ring Forging

Are you interested in using these metal components for your next project? At Ferralloy Inc., we are a quality-driven organization that is committed to constant improvement and customer satisfaction.

When to Use Investment Casting

Are you familiar with the metal-forming process known as investment casting? If not, you should learn about this process if you want to excel in the metalworking field. Castings investment is a process that allows workers to create products with remarkable surfaces. The process begins by creating molds and patterns. Then, workers use wax to make patterns, allowing easy reproduction of these patterns.

 

What is Castings Investment?

Properties, Considerations, and When to Apply Investment Casting

Properties and Considerations

In manufacturing metals by investment casting, you need to take into account the important properties and considerations. For one, this is a manufacturing process that makes possible the casting of highly complex parts. Despite the complexity, the results can still achieve a good surface finish. Below are some of the common properties and considerations you need to learn if you want to master the art of investment casting.

  • According to experts, this metalworking process is highly complicated and relatively expensive if you don’t know what you’re doing because some parts of the process may require automation.
  • The good thing about castings investment is that you can practically use any metal. Components manufactured by this complex are customarily small. However, the weight of the component may reach up to 75lbs.
  • Another advantage when using investment casting is that it can create parts and components with high dimensional accuracy. It can produce end products with tolerances as low as .076mm and very narrow sections. 

When is Investment Casting Used?

Manufacturers often use investment casting when machining of internal passageways cannot be employed. Likewise, it is also applicable when progressive tool maintenance costs are not the goal. The following are other reasons why investment casting is used.

  • Excessive upfront tooling costs connected to sand casting are adequate
  • Sand casting is not acceptable because wall thickness is too thin
  • The exceptional as-cast surface result is desired
  • Small to medium dimensions, generally less than 454 kg or 1,000 lbs.
  • Various and/or convoluted internal passageways in design
  • Metal components are asymmetrical or shaped with accurate detail
  • Tight tolerances and external shaping are desired

What is Castings Investment?

Where to Get Metal Components Manufactures by Castings Investment?

Using the correct material and process for your metal components is important. Schedule an appointment at Ferralloy Inc. to know more about the castings investment process!

Why Forging Rings is a Priceless Asset

Are you into forging? If yes, you probably have researched how to forge the best rings. If you haven’t and want to be an excellent blacksmith, you need to learn how forging rings work. Since forging rings is one of the essential techniques in blacksmithing, it’ll become your priceless asset in the future. Below are the reasons why forging rings is considered to be a priceless asset.

What are forging rings?

Perks over Learning How to Forge Rings

Cost-Effective and Flexible Production

Other metalwork procedures like special performance castings need longer lead times, complicated process controls, and pricey materials. With forging processes like ring rolling and open-die processes, you can easily adapt to different production run lengths and set up less lead time.

Better Heat Treatment Response

Another remarkable factor about forging rings is that it offers a great heat treatment response. Other methods like castings need close control cooling and melting processes to prevent alloy segregation. If this is not prevented, it will lead to a non-uniform heat treatment response that will compromise finished products’ straightness. When it comes to forging rings, the intricate process responds better to heat treatment, resulting in exceptional dimensional stability.

Use of Various Materials

Ring forging can be very useful since it can be used in several 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.

Strength

The strength factor of this process is the most notable advantage why blacksmiths often choose the metalwork process. Experts say that forgings have more strength than other components. It can maintain the power of the metal despite temperature fluctuations.

What are forging rings?

Learn More About Forging Rings

At Ferralloy Inc., we only provide excellent quality metalwork and always aim to offer better business cooperation with every customer. If you want to know more about forging rings and where to get products made according to this forging process, schedule an appointment with us today!

Learning About Machined Castings in 5 minutes

The machined casting process is a critical part of metalworking. Implementing a precise and efficient process holds the ability to create various complex parts in a wide selection of metals for countless industries. Sometimes, castings can be utilized in the exact form that they leave the mold. They often, however, need to be machined for the part to be further perfected.

What are machined castings?

Basic Information About Machined Castings

Why is Machining Used?

Machining helps create very fine and detailed objects that would have been impossible to manufacture through a mere casting technique. Furthermore, machining can seal surfaces and threaded holes without compromising the quality of the product.

How Does Machined Casting Work?

Machined castings refer to the process utilized to cut away certain materials to alter the shape and appearance of a metal product or casting. For instance< cutting using single-point or multipoint cutting tools, grinding, and non-traditional machining processes that utilize chemical, electrical, and other sources of energy.

What are they used for?

When the time comes that your casting applications require machining to improve tolerances, you must get a partner or acquire the services of professional companies whom you can rely on to give a reliable and unfailing high-quality service. Therefore, you should employ the services of companies with skilled machinists! They have the ability to offer quality machined castings for:

  • Wear components
  • Valve bodies
  • Casings
  • Split castings
  • Diffusers
  • Impellers
  • and other specialty components!

So, whether your castings were placed in a sand foundry or other materials used for castings, such a company must have the ability to offer you assembly, finish-machined, and semi-machined results.

What are machined castings?

Where to Get Quality Machined Castings

Therefore, it’s important to guarantee that exact measurements are achieved in machined investment casting, and Ferralloy Inc. has the experience and authority to provide this service and product to you.

As an industry leader, we are equipped and experienced in delivering high-quality metal components at competitive prices. Contact our metal component manufacturing company today to know more about our services!

Tapping Better Resources with Global Sourcing

It’s undeniable that the figures for manufactured products in a low-cost country are significantly lower than those manufactured in developed countries. Many companies in the US enjoy the perks of lower production costs by sourcing the products globally. Besides lower production costs, global sourcing also makes it easier for companies to look for better resources.

What is global sourcing?

How Global Sourcing Makes Everything Better

Reach More Resources

Global reach provides companies with the convenience to reach more unavailable resources within the domestic market but is available overseas. Utilizing such potential already available beyond domestic areas can be great leverage to producing quality materials and components.

Long-running and experienced global companies like Ferralloy Inc. can help you with international procurement services. These companies are oftentimes powered by their active network of global suppliers licensed and certified by the authority.

The procedure of sourcing components from other countries can be simplified with the aid of other industries. Sourcing companies can get materials and other components at the lowest possible price without compromising quality.

No Language Barrier Problems

With the help of global sourcing companies, there remains no language barrier. There will be no miscommunication or lack of contracting differences. The sourcing needs can easily be met while allowing other organizations to benefit from the purchases.

What is global sourcing?

Other Benefits of Global Sourcing

Apart from better resources and no language barrier problems, global sourcing also offers good quality control and greater production capacity. A company can partner with a trusted overseas industry to guarantee that its products are in line with company standards. The global sourcing company can ensure that the entire testing process is carried out.

When it comes to a greater production capacity, there is no question that the selected overseas company has an abundant supply of materials. Aside from the available materials, most outsourced companies have highly-developed manufacturing infrastructures. Once these two factors are present, the large volume production can be achieved quickly.

If you’re looking for an exceptional company that takes on global sourcing, contact Ferralloy Inc. today!

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.

Economic Advantages of Seamless Rolled Ring Forging

The process of seamless rolled ring forging involves the use of many different types of materials. These rings can be made of carbon, stainless steel, or alloy. Alloy steel contains an additional alloying material aside from carbon to improve the heat treat response or mechanical and physical properties of the rolled rings.

On the other hand, stainless steel material is used to create finished products that look elegant and can withstand rust and corrosion. Lastly, companies use carbon material to produce lightweight and heat resistant rolled rings.

what are the economic advantages of seamless rolled ring forging

How Cost-Effective is Seamless Rolled Ring Forging

Material Costs

Rolled ring forging can significantly reduce material costs! Typically, it uses fewer starting metal components to create the desired shapes. For instance, if the process requires a torch cut part, the complete center slug and entire corner stock are lost. With other forging processes, other parts are produced to a size that results in minimal waste.

Efficiency in Production

Using a rolled ring forging process, the same material can be created from several and various sizes of starting billets or ingots. It allows for a broader variety of inventoried material grades. The flexibility of the production process implies that forges materials of almost any grade can be designed and produced rapidly and more economically.

Reduced Reduction Rates

This type of forging eliminates or reduces rejections by yielding to enhanced structural integrity and using forging-quality materials. Additionally, the rolled ring forging process provides weld-free parts created with cleaner and quality material.

Machining Economies

Seamless rolled ring forging can likewise yield tool life advantages, lead time, and excellent machining. The reduced cost comes from forging a size that’s near its actual measurement instead of doing it with an alternative metal component like a bar or plate. With this type of process, it will require less machining to finish the product.

what are the economic advantages of seamless rolled ring forging

Get Seamless Rolled Ring Forging Products at Ferralloy Inc.

If you want to cut on production costs, seamless rolled ring forging is your best option. At Ferralloy Inc., we guarantee you that we only offer high-quality, engineered products.

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. 

what are forged rolled rings?

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!