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Inconel | Should I Use Inconel Parts for My Next Project?

Inconel is a family of austenitic nickel-chromium-based superalloys. Because of its components, it is ideal for some of the toughest conditions in manufacturing. You might be thinking, “why should I use Inconel?” Well, if what you are doing falls into any of these categories, this particular alloy is perfect for you.

Rapid Temperature Changes

Some manufacturing processes involve rapid temperature changes. Most Inconel alloys retain excellent oxidation resistance at high and low temperatures allowing for near-cryogenic lows and heat treatment highs.

Heat Treat Applications

Compared to most stainless steel alloys, a basket made from nickel-chromium-based superalloys won’t lose shape as easily when holding parts through a rigorous heat treat application. That’s because it is known for being resistant to extreme heat. It retains enough of its strength in high temperatures that it can still hold a moderately sized load.

Exposure to Saltwater

Due to its extraordinary resistance to sodium chloride at a variety of temperatures, it’s frequently used in marine applications. Some stainless steel alloys can also be used in saltwater, however, Inconel is more useful in extreme temperatures in excess of 1,000°F

Jet Engines

Jet Engines are unique in that they have to withstand extreme temperatures both high and low frequently during use. Since these alloys great under both extremely high and low temperatures it is ideal for jet engines.

Should I Use Inconel Parts for My Next Project?

If any of your projects fall into any of the above three categories than Inconel might be right for you. Contact us today to learn more.

 

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Alloy Castings | Where Can I Buy the Best Alloy Casting?

Casting is a simple, inexpensive and versatile way of forming aluminum into a wide array of products. Items such as power transmissions, car engine, and even the cap atop the Washington Monument were all produced through the aluminum casting process. Here are some other facts about alloy castings.

The Casting Process

Casting is the original and most widely used method of forming aluminum into products. While technological advances have been made, the principle remains the same. Molten aluminum is poured into a mold to duplicate the desired pattern.

There Are Three Common Methods

The three most important methods in the casting process are die casting, permanent mold casting, and sand casting. The die casting process forces molten aluminum into a steel die under pressure. Permanent mold casting involves molds and cores of steel or other metal. Sand casting is the most versatile method for producing aluminum products. Compared to die and permanent mold casting, sand casting is a slow process but is usually more economical for small quantities, intricate designs, or when a very large casting is required.

Where Can I Find Castings?

The automotive industry is the largest market for aluminum and alloy castings. These castings make up more than half of the aluminum and alloy used in all cars. Cast aluminum transmission housings and pistons have been commonly used in cars and trucks dating all the way back to the early 1900s.

Where Can I Buy the Best Alloy Castings?

At Ferralloy we offer the best, and highest quality alloy castings on the market. Contact us today to learn more and find out how we can help you with your alloy casting needs.

 

Where can I buy the best alloy castings?

Investment Casting | Where Can I Buy High-Quality Investment Castings?

It’s important when looking for investment castings to make sure it is used with high-quality materials. Materials used in investment castings range from alloys to steel and aluminum. Let’s take a look at some of the best materials used in investment casting.

Superalloys

Gas turbine engine blades and nozzle guide vanes are the two most popular pieces that use superalloys. They are exposed to very demanding conditions and as a result, the nickel-base superalloys keep the everything cool internally.

Steels

The amount and variety of steel used has increased greatly since designers and engineers have realized the potential for investment castings. The aerospace, armament, automotive, food, petrochemical, nuclear, textile, valve and pump, and other general engineering industries all now use this technique. From gearbox parts and bicycle cam forks to golf club heads and various gear components, investment casting with steels covers them all.

Alloys

Titanium alloy investment castings are produced for static structural applications requiring metallurgical integrity with high fracture toughness. A significant portion of the titanium alloy investment casting market is made up of golf club heads and long hollow compressor blades.

Aluminum alloys are the most widely used investment castings in electronics, avionics, aerospace, pump and valve applications and military command equipment. Originally aluminum alloys were meant for small castings, but much larger sizes are now regularly cast.

Where Can I Buy High-Quality Investment Casting?

When looking for high-quality investment casting materials, look no further than Ferralloy. We offer the highest quality materials for your next project. Contact us today to learn more about how we can help with your investments castings needs.

Where Can I Buy High-Quality Investment Casting?

Investment Castings | Which Materials Are The Best?

Investment castings can be used to make a wide range of products and prototypes. It’s important when using investment castings to make your product or prototype to use the right materials. Aluminum alloy, titanium alloy, steel, and superalloys are all quality materials used. Let’s take a deeper look into each one.

Aluminum Alloy

Aluminum alloy is the most used material in investment castings, especially in the fields of aerospace, avionics, electronics, military command equipment, and pump and valve applications. Improved strength and premium quality aluminum-silicon-magnesium alloy castings means casters can now offer castings for demanding applications, such as airframe components.

Titanium Alloy

Titanium alloy castings are made for products that require high fracture toughness and metallurgical integrity. Titanium golf club heads form a substantial part of the titanium investment casting market.

Steels

The variety of steels used in investment castings have increased drastically as designers and engineers have realized its durability and potential. From bicycle can forks to gearbox parts for automotive applications, to various gears and cam components, to even golf club heads, steel covers them all.

Superalloys

Superalloys are replacing sheet metal. Not only are they are more cost-effective, but they also provide a high rigidity monolithic component with superior service characteristics.

Are You In Need Of Investment Castings?

No matter what metal you want to go with, we can help you with all your investment castings needs. Contact us today to learn more about all the services that we provide.

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Forging Rings | Why Does Corrosion Occur in Metal?

When you are working on an industrial project, you need to be able to rely on your materials. And, they need to last as long as possible. But, corrosion can lessen the integrity of metal elements. So, whether you are in the market for forging rings or other metal components, here is what you should know about corrosion:

What is Corrosion?

Corrosion is a natural process that causes the deterioration of refined metals. Over time, a chemical or electrochemical reaction will cause the metal to break down. This can reduce the durability of a metal component. It will “eat” away at the surface and eventually internal structure.

What Causes Corrosion?

There is an array of chemicals that can react with metals and alloys, causing oxidation. Even oxygen can play a role in corrosion. Rust is a very common form of corrosion. For example, iron can oxidize. It will then get a burnt orange and flaky surface. This is called rust. For structural alloys, moisture in the air can lead to corrosion.

How Can I Prevent Corrosion?

The first step to preventing corrosion is by creating high-quality, corrosion-resistant materials. Metalworkers make corrosion-resistant fabrications with materials that naturally are less susceptible to chemical deterioration. A special coating can also be put on to protect from oxidation. A professional can supply a prevention recommendation.

Are You in Need of Forging Rings?

Whether you are looking for forging rings or other reliable metal components, we can assist you. And, if you are in need of corrosion resistant fabrications, a specialist can direct you! So, contact us today for more information about our abilities.

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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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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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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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