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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!

Steel Castings | Why Use Steel Castings?

Steel is one of the most versatile metalworking materials available in the world today. It can be found throughout numerous industries and in countless forms. One particular type of steel component that is exceptionally well-liked is cast steel. Despite these castings not being as popular as other metal parts, steel castings are used for vital components in the mining, railroad, construction, truck, military, and oil and gas industries. Why are steel castings so important to so many projects? Keep reading to find out!

3 Advantages of Steel Castings

1. Design Flexibility

Design flexibility is one of the biggest advantages of steel castings. Their flexibility grants the designer the freedom to choose whichever shape and size they desires. It is extremely simple to form and change the shape of components, and all in a timely manner.

2. Metallurgical Versatility

Another great advantage of steel castings is their strong metallurgical adaptability and variability. Cast steel obtains a wider range of physical and mechanical properties than any other cast metal. All that this casting needs to do is simply vary the carbon and alloy content, fluctuate the heat treatment, and gain good weldability and workability.

3. Large Weight and Size Range

The next advantage of this type of casting is its large weight and size range. Steel castings can be as small as a few ounces or as large as hundreds of tons. Their quantities can also vary from one to thousands per order.

Design flexibility, metallurgical versatility, and large weight and size ranges are just a few of the many advantages of steel castings. If you think that your next project can benefit from this type of casting or any other metal component, contact us. Ferralloy, Inc. is a global supplier of castings, fabrications, forgings, machining, and other related products and services. Contact our metalworking company online today!

What is Zirconium? | Properties and Uses

There are a wide range of zirconium components in the metalworking industry. There are ingots, forgings, plates, sheets, rods, tubing, and so many other parts that are all made out of this metal. But what exactly is Zirconium? Keep reading to find out everything you need to know about this popular metalworking material!

Properties

Zirconium was first discovered in 1789 by Martin Heinrich Klaproth and took the world by storm thanks to its unique properties. It is a transition metal with a grayish-white luster. This solid metal is difficult to ignite and its compounds have a low inherent toxicity. One property that makes it particularly appealing is that it is exceptionally resistant to corrosion by many common acids and alkalis, seawater, and numerous other agents. It is also known to become magnetic at low temperatures when alloyed with Zinc. You can find Zirconium on the atomic table as the number 40 with the symbol Zr.

Uses of Zirconium

Zirconium’s intriguing properties make is a popular choice for parts and components in numerous different industries. For example, since it does not absorb neutrons, it is an ideal material for tubes and other parts in nuclear power stations. In fact, 90% of this metal is used in this way. Some other industries that use this metal for a variety of applications include solar power, chemical process, petrochemical, oil and gas, pharmaceutical, geothermal, mining, utilities, and many more.

If you are interested in using zirconium in one of its many forms, we can help. Providing different industries with metal parts that meet their specific requirements is what we do. Whether you need blanks cut to size, cold drawn shapes, or custom castings or forgings, we can fulfill your order accurately, competitively priced, and on a timely basis. Contact us today or visit our foundry online for a quote or to learn more about our services!

Inconel | Why Should I Use Inconel Alloys?

Countless types of metals and alloys are used in metalworking. Due to the high number of choices, deciding which type of material to use for your next project can sometimes feel overwhelming and confusing. Today, we will explain the benefits of Inconel alloys to help you figure out which alloy is best suited for your specific needs. Keep reading to find out all of the reasons why you should consider using this type of alloy.

Benefits of Using Inconel Alloys

Different Inconels have different compositions. Each variation of Inconel posses its own unique traits that make it effective in different circumstances. Inconel 600, for instance, creates effective parts in the chemical and food processing industries thanks to holding a higher resistance to oxidation and various forms of corrosion. Meanwhile, Inconel 625 possesses high levels of strength without ever having to go through heat treatment, making it an appealing option for aerospace and marine engineering industries.

Inconels are mostly made out of nickel and chromium. Because of this, there are numerous properties that make this metal an appealing choice of material, no matter the specific alloy. For example, all of these alloys are resistant to oxidation and are able to withstand high temperatures and mechanical stress without losing any of its structural reliability. Other metals such as aluminum and steel usually deform when put under extreme heat. This makes this type of metal perfect for extreme environments that experience lots of pressure and heat.

After learning about all of the benefits of Inconel alloys, it’s no surprise why it’s a popular choice for metal components in the food processing, oil refinery, chemical, aerospace, and nuclear industries. If you’re interested in using Inconel components, we can help. Ferralloy, Inc. has the infrastructure and facilities to supply raw material in numerous grades and forms. Visit our metal foundry online today!

Machined Stainless Steel Components

Ferralloy, Inc. is producing machined stainless steel components from 316L grade material for a manufacturer of high end machines in the Beverage Delivery Sector of the food equipment market. These components are coarse and fine thread screws which are used in the assembly of the equipment as well as solenoid valve bodies which meter the flow of the beverage which is finely calibrated.  Additional stainless steel fittings are produced to the tight tolerance requirements as outlined by their engineering department.  The components for this customer are produced and stocked in Ferralloy, Inc.’s warehouse and then shipped to them  under a Kanban program which meets their production needs without the need for excess inventory.

machined stainless steel components

Rolled Ring Forgings | What Is the Process?

Rolled ring forgings are used in a wide range of industries. Rolled ring forgings are an appealing metalworking option thanks to their strength, versatility, and cost effectiveness. But how do they get that way? Rolled rings are able to hold so many advantages thanks to their forging process. Keep reading to find out everything you need to know about this metalworking method!

3 Steps of the Rolled Ring Forgings Process

The forging process performed to create rolled rings is extremely difficult and complicated. To help make it easier to understand, we broke it down into 3 simple steps.

Step 1: A thick and circular piece of metal is heated. It is then pierced to form a hollow ring. This ring should somewhat resemble a donut.

Step 2: The ring is heated to recrystallization temperatures. It is then placed onto an idler roll. Squeezing, stretching, and in some cases, pounding, then occurs until it forms into a thin ring.

Step 3: The shaping on the idler roll continues until the forgings possess the desired diameter and wall thickness.

This is the process that creates rolled ring forgings. The final ring products can range from tall cylindrical shapes to small washer-like parts. They can be created using basically any type of metal or alloy. The diameters can range from 1 to 300 inches. Weights can range from 1 to 3000 pounds. No matter how complex or customized the shape is, the rolled ring forging process creates extremely dependable and sought after parts. Some specific components include valves, bearings, flanges, gears, clutches, drives, and so on.

If you need rolled ring forgings for your next project, we can help. Ferralloy, Inc. is the best in the metalworking industry. We provide high quality, competitively priced metal components to a variety of industries throughout the global marketplace. Visit our foundry online today to learn more!

Ferralloy, Inc. Ships Seamless Rolled Rings

The company shipped two seamless rolled rings produced from 4140 grade alloy steel to a customer in the industrial processing industry today.  The customer in California is rebuilding a processing equipment machine which required two 78″ OD x 72″ ID x 5″ High machined to size.

Ferralloy, Inc. produced the seamless rolled ring forgings and then machined them on Vertical Turning Lathes to complete the requirement. 

Rolled Ring Forgings are available up to 110″ diameter in rough or finish machined form.

seamless-rolled-ring-shipment

Closed Die Forging | What is Closed Die Forging?

Forging is a favorable and effective manufacturing process. It is able to form high quality metal components for countless industries. Forging is able to do this because it can be subdivided into specific forging processes. The forging process used depends on the specific needs of the project. Closed die forging is one of the many types of forging. Keep reading to find out the process, advantages, and applications of closed die forging!

What Is Closed Die Forging?

Closed die forging is a forging process. It is sometimes referred to as impression die forging. This process involves two or more dies that contain a precut profile of the desired component. The heated raw material is placed at the bottom of the die. The dies then move towards each other until the raw material is formed into its required shape and size.

Why Is It Used?

Most metals and alloys can be forged through the closed die process. Closed die forgings of steel, stainless steel, titanium, aluminum, and other alloys can produce an unlimited variety of 3-D shapes in a wide range of weights and sizes. As a result, this is one of the best processes for complex shapes that require elaborate designs.

What Are Its Applications?

Closed die forging is used for applications that require high quality components. People turn to closed die forgings when their project requires strength, reliability, and resistance to fatigue. Because of this, closed die forging is an appealing manufacturing process for numerous industries. Some specific parts that are formed by this type of forging can be found throughout the automotive, aerospace, and defense industries.

Ferralloy Inc. can meet any and all of your forging needs! We’re a leading global provider of forgings to major companies in numerous industries. We produce rolled ring, cold headed, open die, and closed die forgings in a variety of alloy steel grades. Connect with our metal manufacturing company online today!

Why Should I Use Investment Castings?

Investment castings are one of the oldest and most popular type of metal components. The process to create these parts involves pouring molten metal into a ceramic mold. The metal solidifies within the mold and then the metal casting is broken out. Aircraft, aerospace, oil, road construction, coal mining, steel production and processing, heat treating, railroad, food equipment, and countless other industries have discovered the benefits of this type of casting. What are these benefits? Keep reading to learn about the advantages of investment castings!

4 Advantages of Investment Castings

1) Wide Choice of Materials

Almost every type of alloy can become an investment casting. This includes popular metals such as steel, copper, nickel, iron, cobalt, stainless steel, etc. Having a wide selection of materials allows you to select the type of metal that will yield the best performance for your specific need.

2) Accurate and Consistent

These castings are extremely accurate and near net shape. Since components are created by using the same wax pattern, this accuracy can be maintained from casting to casting.

3) Intricate Design

Investment castings are a designer’s dream. Logos, product ID’s or numbers, and letters can easily be added to the inside and/or outside of components. It is also easy to add holes, slots, blind holes, splines, gears, and thread profiles.

4) Low Tooling Cost

Tooling is a significant cost factor for all other types of parts, but not for investment castings. Thanks to the casting process, a long-lasting and high quality part that requires little tooling is produced.

Investment castings can be extremely beneficial. But they can also extremely difficult to manufacture. The production of these components requires expert knowledge and experience. If you are interested in using investment castings for your next project, look no further than Ferralloy Inc. We guarantee to provide the best products, delivered on time, and at a competitive price. Call us at 440-250-1900 or visit our foundry online for any of your metalworking needs today!