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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!

Steel Castings | Features and Applications

Steel is one of the most versatile and sought-after metalworking materials. It plays a vital role in various industries. Due to its desirable properties, steel comes in various forms. Which steel component you use depends on your specific requirements and needs. Steel castings are often a popular choice. Keep reading to find out if steel castings can benefit your project!

What are Steel Castings?

A steel casting is a metal component that is formed by pouring molten steel into a mold cavity. The liquefied steel then cools and solidifies within the mold cavity. You can cater the shape of the mold, and hence the casting, to perfectly fit your specifications. The casting process of steel can be difficult. It is less fluid than other metals and more reactive to mold materials. The steel casting process should only be done by metalworking experts for optimal component performance.

Why are They Used?

Steel castings are used for a variety of reasons. They are mainly used when other types of cast irons do not have enough strength or shock resistance. Steel’s physical properties allow the castings to be both strong and ductile. This makes the steel casting extremely tough and limits the chances of fracturing under pressure. Steel castings are also utilized due to their weldability and corrosion resistance.

What are Their Applications?

Due to its reliability and strength, numerous industries rely on steel castings. Industries that use steel castings range from food processing and electronics to oil and gas.  Some specific industries that use this type of casting include the railroad, construction, drilling, transportation, and mining industries. Examples of items that are steel casting gears, valve bodies, pump casings, mining machinery, marine equipment, engine cylinder blocker, forging presses, and railroad truck frames.

If you’re interested in using steel castings for your next project, contact Ferralloy Inc. today! As metalworking experts, we can provide you with the highest quality castings. Give us a call at 440-250-1900 or visit our foundry online today!

What Is the Difference Between Castings and Forgings?

There are several different methods and techniques that can be used in manufacturing a variety of different metal components. Based on the purpose and ultimate use of the metal part, different procedures are used to create the highest quality piece possible. While determining the best process, some arrive at the question of whether they need castings or forgings. Which would be more effective for their metal component and most cost effective? Keep reading to find out the differences and find out which process would be more beneficial to your business!

What Are Castings?

Valve Sand Castings

The casting process is where the metal is heated until molten and then poured into a die to form a specific shape. This process is beneficial when the shape of the component is intricate or when the component needs to be a very large size. Another advantage of castings is that machining costs can sometimes be cut down because the component can be made to certain specifications.

What Are Forgings?

Forging is a technique where metal is heated up and then hammered and manipulated into the final desired shape. Forgings are generally stronger than castings, but there are some limitations to manufacturing capabilities of forging. Components can not be very intricate or complex when forging. Usually if a component needs to be forged and also needs to meet certain size requirements, the component needs to be machined after it has been produced.

Are Castings or Forgings Better?

Which metal component production method is better? This will completely depend on what the component will ultimately be used for. Both castings and forgings have their advantages, so depending on what the component will be used in will determine which production method will serve you better. If you have questions about what type of metal component you should be purchasing for your company give Ferralloy, Inc. a call today! We are metalworking industry leaders and have the technical authority to deliver the highest quality castings and forgings! Whatever your metal need is, we can meet it and exceed your expectations!

The Simple Guide to Investment Casting

If you are in an industry that uses food processing equipment, valve components, power generation equipment, hydroelectric facilities, or furnace parts, chances are that you have heard the term “investment casting”. But what is investment casting? And more importantly, why should you use it?

What is the Investment Casting?

A high quality investment casting can be found at Ferralloy Inc

Investment casting (also known as lost-wax casting) is an industrial process based on one of the oldest known metal-forming techniques. It was developed over 5500 years ago and continues to be an integral part of metalworking to this day. Investment casting takes a wax outline of a part and coats it with a ceramic material. It is then heated until the wax is melted out of its center. Molten metal is then poured into the hollow ceramic mold. The metal hardens, gets broken out, and the part is made.

Why Should I Use Investment Casting?

There are numerous explanations why people decide to use investment castings. Here are the 5 main reasons why you should consider the investment casting process:

  • Practically any metal can be manufactured by this process. This includes aluminum alloys, bronze, tool steels, stainless steels, cobalt alloys, carbon steels, Hastelloys, and precious metals.
  • It can manufacture extremely complex parts that would otherwise be extremely difficult or impossible.
  • It creates very smooth surfaces with no parting line. As a result, only minor machining is required.
  • Very thin sections can be made. Castings with sections as narrow as .015 inches have been manufactured with investment castings.
  • It produces high dimensional accuracy with tolerances as low as .003 inches.

What Industries Use Investment Casting?

Due to their massive benefits, investment castings are used in a wide range of industries. The aircraft and aerospace industries use investment castings for turbine blades, vanes, and structural components such as fan exit cases and struts. Investment castings are also used for valves, fittings, sporting goods, pumps, engines, turbines, military and small arms applications, airframes, missile controls, medical equipment, dental fixtures, gears, jewelry, machine tools, office machines, and numerous other complex parts.

If investment casting is something you are interested in, Ferralloy can help! We are experts in castings, fabrications, forgings, machining, and any of your other metalworking needs. Get the components you need, when you need them by contacting Ferralloy today!