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Forgings | Which Industries Use Forgings?

Thanks to possessing a wide-range of benefits, forged parts are one of the most popular metal components in the world. As a result, countless industries rely on these parts. Which industries use forgings? Keep reading to learn about the 5 most common industries that use forged parts!

5 Common Industries That Use Forgings

1) Automotive Industry

The automotive industry has greatly benefited from the forging process, specifically either hot or cold forging, thanks to their high-demand for complex shapes. Some specific forging parts used by the automotive industry include: engine parts, steering parts, automatic and manual transmission systems, etc.

2) Power Generation and Transmission Industry

The power generation and transmission industry highly relies on this type of metal component. In fact, about 43% of all parts used in this industry are manufactured through forging. Turbine components, shafts, discs, seamless pipes and fittings, are just a few of the many examples of forgings in this industry.

3) Medical Industry

A vast number of medical equipment parts are forged. Examples of forgings in the medical industry include: extremities parts, implants, trauma parts, and medical machine parts.

4) Aerospace Industry

A number of forged parts are also used in the aerospace industry. Examples for this industry includes: inner-outer rings, engine discs, exhaust, compressor parts, spinner, as well as other engine, transmission, and structural parts.

5) General Production and Manufacturing Industry

Another industry that benefits from forged parts is the general production and manufacturing industry. This is mainly due to their structural integrity. Some examples include: washers, gaskets, welding products, bars, etc.

These are just a few of the many industries that benefit from using forgings. If your interested in utilizing forgings for your next project, we can help. Ferralloy, Inc. is a leading global provider of forgings to major companies across all industry verticals. We have the resources to provide you with forgings machined complete to your engineered specifications. Contact our metalworking company online today to learn more!

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!

Cobalt Alloys | Uses and Characteristics

Steel, aluminum, titanium, zirconium, the list of raw materials used for metal components can go on and on. With so many options, deciding on the right type of material for your project can get overwhelming. It’s important to understand the properties, benefits, and applications of different types of metals to see which best fits your specific needs. Keep reading to learn all about the popular metalworking material like cobalt alloy.

What are Cobalt Alloys?

Cobalt alloys are metal alloy. But it’s not just any metal alloy. This alloy is a cobalt-chromium “superalloy”. It was designed specifically for high wear resistance and superior performance in hostile environments. It’s resistant to cavitation, erosion, corrosion, galling, and abrasion. The combination of Cobalt and Chromium also enables the metal to have an extremely high melting point. It is typically used in temperatures ranging from 600 – 1112 °F (315 – 600 °C). Molybdenum or tungsten and a small amount of carbon are also sometimes added to cater to specific applications. Cobalt alloy was developed in the early 1900s as an alternative for cutlery that stained easily.

What are Cobalt Alloys Applications?

Due to its favorable properties, there are numerous cobalt alloy applications. Some of the major applications include saw blade facing and acid-resistant machine parts. It has greatly improved the production of poppet valves, valve seats, and exhaust valves for internal combustion engines. This alloy is also preferred for M2HB machine gun and machine gun barrels, medical parts (e.g. artificial hip joints, bone replaces, dental cast structures, etc.), and turning tools for lathes.

If you are interested in using cobalt alloys or any other type of metal for your next project, contact us! Ferralloy Inc. has the infrastructure and facilities to supply countless forms and grades of raw materials at a competitive price and delivered just-in-time. Give us a call at 440-250-1900 or visit our foundry online today!

Stainless Steel Castings | What Industry Needs Them?

There are so many different types of metals you could use for your project, so picking the best one can be difficult. We are experts in the metalworking industry and can provide you with the exact piece your project requires. A commonly used metal is stainless steel. Keep reading to find out if stainless steel is the right metal for your component.

Stainless steel from Ferralloy Inc!

What is Stainless Steel?

This metal is a versatile material with its most known characteristic being that it is resistant to corrosion. What makes this characteristic possible is the minimum of 10.5% Chromium that the stainless steel contains. The Chromium makes a thin layer of oxide on the steel’s surface, which prevents corrosion from occurring. For this reason, stainless steel is very popular in settings that are susceptible to corrosion. Not only is it resistant to corrosion, but it is also a very strong metal and able to sustain both low and high temperatures. There are three main types are: austenitic, ferritic, and martensitic, all of which vary in their characteristics. Making sure you utilize the right one is important, considering each type of stainless steel has a best use in slightly different applications.

What Industry Needs Them?

This material is used in many different industries for different purposes. For example, the chemical and oil and gas industries use this metal for tanks, pipes, pumps, and also valves. The building and construction industry also utilizes stainless steel as reinforcing bars in their projects. It is used for exhaust systems in the automotive industry because of its ability to handle high temperatures while maintaining it’s corrosion resistant property.

Ferralloy, Inc. supplies high quality products and services to a diverse metalworking customer base. We are experts in the metalworking industry and can manufacture your project requirements with your exact specifications. Contact Ferralloy, Inc. for all your metal needs today!

Fabrication to Casting Conversion

Ferralloy, Inc. was recently contacted by a large automotive parts manufacturer to design a cast heat treating basket that would replace their current fabricated design.

Metal fabrications from Ferralloy Inc.

The customer provided Ferralloy, Inc. with their specific requirements such as operating temperature, the need to build in outside pockets for lifting and also to consider their need to stack the baskets on top of each other.

Steel castings can be ordered from Ferralloy Inc.

The resulting design gives them more strength, better heat resistance values and an estimated life expectancy increase of more than 100%.