Contact Us: 1-440-250-1900

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

Global Sourcing | 6 Interesting Facts About Nickel’s History

Your project starts with its materials. And, the better the materials, the better the project. Global sourcing allows Ferralloy to create components that are durable and can withstand wear and tear. Nickel is a great option for many projects. Read to find out a little more about this powerful metal:

  1. Nickel was discovered by a Swedish chemist by the name of Alex Fredrik Cronstedt. It was found in the mineral niccolite – hence the name.
  2. The name comes from the German word Nickel, which translates to “Old Nick” or the “Devil’s copper.”
  3. Peruvian natives believed nickel to be a form of silver. This is because the metal did not rust. But, the Chinese also used a zinc-nickel alloy called “pai-t’ung” back in 200 B.C.
  4. Metalworkers alloy nickel with other metals to create strong components that are resistant to corrosion. So, you can find these combinations in vaults and machine parts.
  5. The world’s largest supply of nickel is in Ontario, Canada. And, scientists believe it originated from a large meteor that hit Earth in ancient times.
  6. Nickel is a transition metal. Using a periodic table, you can see that nickel closely relates to metal including iron, cobalt, copper, and zinc.

Want to Learn More About Our Global Sourcing?

We always make our products to the highest of standards. And, our global sourcing allows us to provide you with quality materials that result in strong and durable products. So, if you’re looking to supply your next project with nickel-based products, contact us with any inquiries!

why is global sourcing good for nickel materials

Investment Castings | What Are Gravity Fed Castings?

If you have a project that requires unique components, investment castings may be the way to go. With a high degree of design flexibility, investing castings offer applications for an array of industries. But, how do you make investment castings? One popular method is a gravity fed process.

How Do You Make Castings?

Investment castings are an age-old practice that continues to evolve and produce even better products. Investment castings involve a unique mold which workers use for a series of coating and hardening. This allows for remarkable surfaces that are unique and workers can easily recreate. Castings can be made with an array of materials, including heat-resistant options.

What is the Gravity Process?

A gravity casting is fairly self-explanatory. Simply because gravity is used to fill the mold from a vertical position rather than gas pressure or a vacuum process. But, the process starts with a preheated mold. This helps the material to flow easily and reduce damage to the casting. Then, workers or a machine coats the mold to prevent the material from sticking. The material is then invested, or poured, hardened and removed. There is no need to apply extra force. This is repeated until the order fulfilled.

Why Use the Gravity Process?

A typical purpose of gravity fed castings is large production orders. This makes it easy to repeat the molding process for several castings. It also offers less trapped gas within the mold, giving it more integrity. However, workers determine the best process to use for a casting depending on the goal of the component.

Want to Learn More About Investment Castings?

Ferralloy dedicates its expertise to create high-quality metalwork for an array of projects. If you think investment castings are a component you need for your next project, please contact us today to discuss your options!

what are gravity fed investment castings

Alloy Castings | What are Super Alloys and Why Would I Use Them?

The integrity of any project requiring metal work lies on the integrity of the material used. There is a reason super alloys are named “super.” Their strength and stability make them ideal for particular products and alloy castings. If you are looking to create strong and high performing castings for your next industrial project, super alloys may be an option. Read why they are continuously growing in popularity:

What are Super Alloys?

Super alloys – also known as high-performance alloys – are alloys that offer paramount strength. They do not only have great mechanical strength. But, they are able to withstand high temperatures without deforming. And, super alloys are made even stronger every year. New chemical processes raise the temperature limit for different super alloys.

When Would I Use Super Alloys?

Super alloys have become more available in recent years. So, this has made them more popular. And, new super alloys are always under development to create stronger alloy castings. When a piece of metalwork needs to maintain strength while reaching high temperatures, a developer may want to use super alloys.

The aerospace and marine industries use super alloys for turbine engines. And, over the years, the heat resistance of super alloys has been growing. However, super alloys can be susceptible to environmental factors. Thermal fatigue, hot corrosion, and oxidation – all of which can weaken chemical bonds – may affect surfaces of certain super alloys. But, protective materials cam coat super alloys to prevent such issues from occurring.

Want More Information on Our Alloy Castings?

Ferralloy goes above and beyond the industry standard for our customers. And, we can help you find the best materials for your next project. Whether you’re looking for super alloys or an alternative, we want to provide you the best information on alloy castings, so please contact us today!

does ferralloy offer super alloy castings

Castings Investment | The History of Investment Casting

Dedicated to improving, the metal casting industry strives to improve its processes and technologies. But, there is one industrial process that has stood the test of time. Derived from lost-wax casting, castings investment – or investment casting – is still used to produce precise patterns.

What is Investment Casting?

Investment casting is a process of metal-forming and allows metal workers to create products with remarkable surfaces. The process begins by creating a mold and creating patterns. Then, workers use wax to make patterns. Later, they can reuse this wax. But, these patterns allow for easy reproduction.

Then, the investing of materials beings with a series of coating and hardening. Materials are invested – jargon for poured – into the mold decorated with unique patterns. Lastly, dewaxing, heating, pouring, removal and cleaning round out the process.

How was Investing Casting Used in the Past?

Thousands of years ago investment casting started off as lost-wax casting. Workers made ornaments and jewelry with casting. Beeswax was used to make patterns and molds. Modern day castings investment involves a very similar process. But, with more industrial materials.

What Makes Investment Casting a Popular Process?

Investment casting is extremely versatile. This begins with the materials that can be cast. Workers can use glass, aluminum, steel alloys and carbon steel. Workers may also use materials like titanium. The customizability gives customers an array of options. They can choose which materials best suit their project. Also, metal workers take the ceramic molds used in investment castings to upwards of 1,500F. This allows for a stronger finished product.

Want to Know More About Castings Investment?

Using the correct material for your next project is important. Ferralloy can provide customers with thorough information and the highest quality products. You can learn more about castings investment and how we can assist you by contacting us today!

why is castings investment a good option

Ring Rolling | 3 Essential Benefits

There are many different types of forging processes. There is open die forging, closed die forging, and rolled ring forging, to name a few. While all three methods possess their own set of benefits, the specific purpose of this post is to discuss ring rolling. Ring rolling is a hot forging process that utilizes two rollers, one driven and one idle, to shape the metal until it becomes the shape and size of the desired part. This type of forging holds countless benefits that help create parts that are used in a wide range of industries in various applications. What are the advantages of the ring rolling process? Keep reading to find out!

should i use the ring rolling process

3 Advantages of the Ring Rolling Process

Advantage #1: Versatility

One great benefit of this forging process is that it can create metal parts of various heights, diameters, and weights. Even the shapes of the components can be varied. This versatility enables parts to be created for specific needs and applications.

Advantage #2: Strength and Durability

Ring rolling is extremely effective in creating parts with high developmental and structural strength. Additionally, the produced components are also extremely durable, which numerous industries find very advantageous.

Advantage #3: Cost-Effective

Many companies and industries turn to ring rolling because it is one of the most cost-effective forging processes. This is not just due to it’s versatility, but because of the enhanced strength and durability as well.

what are the advantages of ring rolling

Are you interested in utilizing the advantages of the ring rolling process for your next project? If yes, contact us today! Ferralloy, Inc. can supply you with rolled ring forgings in diameters up to 110” and in various materials ranging from carbon to stainless steel. We can even vary the metallurgical properties of your part to cater to your specific application.  Visit our international company online to order your metal components today!

Seamless Rolled Rings | What You Need to Know

The metal components that you use can make or break your project. As a result, it’s essential to choose a part that isn’t just good for your project, but rather one that is perfect for your project. One of the most popular metal parts that play an essential role in countless projects are seamless rolled rings. These rings can be used in numerous products (i.e. valves, flanges, bearings, robotics, gears, couplings, machines, clutches, and drives) throughout countless industries. What are seamless rolled rings? Keep reading to find out everything that you need to know about this indispensable metal part!

What Are Seamless Rolled Rings? 

Seamless rolled rings are metal parts that are produced through a process called ring rolling. This process takes a circular preform of metal that has been previously upset and pierced to form a hollow “doughnut” shape. The doughnut shape is then heated above the recrystallization temperature and places over the idler or mandrel roll. This idler roll then moves in a series of motions and rotations to reduce the wall thickness and increase the diameters until the rolled ring takes its desired shape. Rolled rings can be produced in configurations that range from flat, washer-like parts to tall, cylindrical shapes and heights ranging from less than an inch to more than 9 feet tall. As a result, seamless rolled rings are great metal parts that be made to your exact specifications.

Get the best seamless rolled rings for your next project by contacting Ferralloy, Inc. today. We can supply you with rolled ring forgings in diameters up to 110” and in a wide variety of materials such as carbon, alloy, stainless steel, titanium, nickel alloys and more. Not to mention, our distribution model ensures that you will receive your deliveries on time so that you can better manage the amount of product that you keep on hand. Learn more about our rolled ring forgings and all of our other metal products by visiting us online today!

Titanium Fasteners | Important Advantages

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. To narrow them down, we will look more in depth at the significant advantages of one specific component: titanium fasteners.  What are these important advantages? Keep reading to find out.

Advantages of Titanium Fasteners

Titanium (Ti) is a highly corrosive element with properties that make it the perfect element to produce fasteners. These fasteners hold their own huge set of benefits and advantages.

Some of the most appealing advantages of titanium fasteners include:

  • These metal parts are typically maintenance free
  • Titanium’s oxide layer protects the fasteners from corrosion
  • These parts are cost-efficient
  • Titanium fasteners are lighter in weight than steel fasteners
  • They are extremely strong, durable, and sturdy
  • These components can withstand high temperatures
  • These parts are biocompatible and non-toxic so it won’t cause any harm to a human’s or animal’s body
  • Titanium can be combined with other metals such as steel, aluminum, manganese, etc. to create an alloy and gain even more advantages

Thanks to these advantages, titanium fasteners are used in numerous different industries. Some specific industries that use this metal component include: aerospace, automotive, chemical, paper, pulp, architectural, consumer, marine, medical, and various other industries.

Are you interested in using these metal components for your next project? Start seeing the benefits of titanium fasteners for yourself by contacting us. Ferralloy, Inc. is a quality driven organization that is committed to constant improvement and customer satisfaction. We are proud to say that we have been providing titanium parts to countless industries and companies throughout the world for almost four decades.  Let us provide you with high quality metal parts. Visit our metal foundry online today.

Stainless Steel Castings | Common Alloying Elements

If you need stainless steel castings, there are numerous of different metalworking methods that can be done to make your part as specific as possible. One of these specific metallurgical processes is adding alloying elements. Alloying elements can change the structure, corrosion resistance, and mechanical properties of stainless steel castings. Furthermore, every different alloying element effects stainless steel differently. Below we explained the effects of 5 common alloying elements used for stainless steel castings so that you can determine which is best for your next project.

Effects of Alloying Elements on Stainless Steel Castings

1. Manganese: Adding manganese to stainless steel improves hot working properties and boosts toughness, strength, and hardness.

2. Nickel: Nickel can help produce stainless steel castings that are incredibly ductile, corrosion resistant, and tough at both high and low temperatures.

3. Chromium: Stainless steel parts with higher percentages of chromium have a higher resistance to oxidation than parts with lower percentages of this alloying element.

4. Carbon: Carbon, along with iron, is the major alloying element that is used to make stainless steel. It is also used to increase the hardness and strength of the metal.

5. Copper: This alloying element enhances the corrosion resistance and formability of the stainless steel castings. Copper can also be added to decrease work hardening in grades designed for improved machinability.

It’s safe to say that alloying elements can have major effects on stainless steel castings. Now that you know the effects that common alloying elements have on stainless steel, it’s time to determine the best option for your specific needs. Learn more about alloying elements, stainless steel, and which metal part is right for you by contacting Ferralloy, Inc. We are a leading supplier of quality castings to major companies throughout the world and can provide you with the exact component you are looking for. Visit our metalworking company online today!

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!