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Get Quality Machined Casting Surfaces

Producing a quality machined castings surface does not only deal with the metal used, but it is also affected by a lot of factors. It’s always a group effort that includes the customer, materials used, the process performed, and the efficiency of the producer. Since the areas that you need to finish machining require that you have a sufficient amount of metal, allowing for tolerances and removing the entire cast surface may be practical.

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How to Get the Perfect Machined Casting Surfaces

Processing Requirements

The machined castings factory is required to create the area selectively oversized to deliver sufficient material so it will be easier to machine over the entire area. This additional material is commonly known as the machine stock or finish allowance. If there is an adequate finish allowance, after you have already run the cutter over the surface, some imperfections on the surface may remain. Thus, you’ll need to scrap these parts to produce a perfect surface.

Eliminate the Porosity Issue

In heavier portions of the machined castings, porosity comes into play. It is always important to remember that cutting deep into the parts will only lead to exposure of porosity. The good thing about machined castings is that it holds tight tolerances well in such a way that you no longer have to remove certain parts of the material. As a result, you can always guarantee that you stay clear from the possibility of getting porosity issues.

Additionally, porosity issues are always present in machined castings. It’s only the process of handling or the means employed that matters. This is why it is essential that you get a supplier that carefully and meticulously works with the production factory.

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Where to Get Quality Machined Castings Surface

Examples of machining processes include cutting with the use of single-point or multipoint cutting tools, grinding, and non-traditional machining processes that utilize chemical, electrical, and other sources of energy. Aside from the fact that machining can seal surfaces and threaded holes, it also allows the production of fine and detailed components that are impossible to create through the use of casting techniques alone.

To know more about machined castings, contact Ferralloy today!

Process Capability of Closed Die Forging

Closed die forging usually is precision-machined to achieve net shape or near-net shape finished products. When you use forging, less post-forging operations are needed because near-net shape products are formed and created. Otherwise said, you’ll save a substantial amount of time and effort when you use this type of process.

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Closed Die Forging Process

Basics of Closed Die Forging

Also known as the impression-die forging of titanium, aluminum, steel, or other types of alloys, closed die forging can practically produce a wide array of 3D shapes that differ in weight from ounces to tons. This type of forging is primarily created on hammers, mechanical press, and hydraulic presses with powerful capacity that can reach up to 50,000 pounds.

What it Contains and Yields

As the name suggests, two or more closed dies comprising impressions of the shape are merged together as forging stock that endures plastic deformation. Since the die contours control the metal flow, closed die forging can produce closer tolerances and more difficult shapes as compared to open die forging processes.

Best Thing About Closed Die Forgings

One of the best things about forging is its adaptability and versatility with its components because the manufacturer can use any form of raw metal or even alloys using this method. It doesn’t matter if the user needs small or medium-sized metal parts – closed die forging can quickly produce them.

Forging Process

Closed die forging involves the most complex components with long and thin portions that integrate small webs and relatively high vertical projections like bosses and ribs. Likewise, it also includes simple elements to forge secure disc-like configurations, block-like shape solids, and spherical shape configurations. While most of these parts are commonly symmetrical, others integrate all kinds of design components such as pockets, cavities, holes, protrusion, flanges, and a whole lot more. These are used to produce a very non-symmetrical forging. Additionally, portions of the materials used can be easily curved and bent in one or more planes.

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Ferralloy, Inc. is your comprehensive engineered product resource, contact us today for more inquiries!

Basic Information About Rolled Ring Forging

Seamless forged rings, commonly known as rolled rings, have a donut shape and can be in any sizes, from large parts over 10 feet in diameter to small or washer-like rings. Rolled ring forging is usually near starting blank or net shape products, which undergo extra grinding, machining, and forming to create end products. Below are the basic pieces of information you need to know about rolled ring forging.

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Straightforward Information About Rolled Ring Forging

Benefits

Rings that are designed and created from a wrought blank or solid forged may have the same properties without having subjected to circumferential grain flow. However, the near starting blank rolled ring forging process creates less scrap as compared to machining and cutting rings from a compact wrought blank or block, leading to a more affordable product for the customers.

Additionally, the rolled ring forging process can fabricate and build parts at certain geometry with solid tolerances and exceptional surface smoothness and concentricity. These qualities can, from time to time, lead to extra cost savings if the forged tolerances and surface reach the actual design the engineer requires.

Shapes Produced

The rolled ring forging process can produce a lot of shapes such as punch, flatten, and shear. Shear rolled rings means that a solid, cylindrical shape is produced. It is large, weighty, and reliable as it holds all of its volumes during the rolling process. This is a very simple yet useful piece of metalworking. To create punch or flattened rolled rings, metal workers use a drive roll that shapes the outside in conjunction with the idler roll and an idler roll that shapes out the middle.

Types

Rolled ring forging has numerous types such as stainless steel, alloy, and carbon. The materials commonly used are tool steel, titanium alloys, stainless steel, nickel alloys, copper or copper alloys, cobalt alloys, carbon steel, aluminum alloy, or alloy steel.

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Know More About the Rolled Ring Forging Process

If you’re keen enough, you’ll realize that rolled rings are present almost anywhere you are. Learning the basic pieces of information about rolled ring forgings, especially when you have a business that uses these products, can be very beneficial. Contact Ferralloy today!

Industries That Use Rolled Ring Forgings

The reason why industries purchase rolled ring forgings is that they soon realize that it can be ordered in different sizes and shapes, making it very convenient and practical on their part. Since the rolled ring process is so flexible, almost any material that is forgeable can be used to make rolled rings, including alloy, stainless steel, carbon, and aerospace metals. The ability to use several different materials makes them not only more cost-effective but also allows them to be used in many different industries.

Oil and Gas Production

Rolled ring forgings are perhaps the most ideal and well-known product when we talk about oil and gas production. It is frequently used in pressure vessel connections and forged flanges. Aside from these, rolled rings are likewise used in surface gas and oil exploration, subsea connections, and hydraulic fracking or fracturing.

Heavy-Duty Manufacturing

As experts would say, rolled ring forgings are the basic factor used in almost every heavy-duty manufacturing industry. These rolled rings can be found in the food and chemical processing, as well as, in the gear and bearing parts of the machines. Since these forgings are often used in extreme environments, it will work well with machines and other equipment that are subject to friction, pressure, and high-temperature conditions. For instance, heavy-duty manufacturing use rolled ring forgings in robotics, mining, shipbuilding, cooling and heating systems, wind turbines, and paper mills.

Automotive and Aviation

Rolled ring forgings are used in several ways as primary components in aviation parts like jet turbines and jet engines. Likewise, these materials are often used in helicopter gearboxes. As for the automotive industry, these forgings are used in nearly everything. To name a few, rolled ring forgings are used in couplings, gears, drives, clutches, bearings, and a whole lot more.

Want to Use Rolled Ring Forgings in Your Industry?

At Ferralloy, our experts have the ability to offer and provide you with the most reliable and strongest rolled ring forging you can find. If you’re in dire need of a rolled ring forging, we’ll be glad to assist you. Just reach out to us through this link!

Understanding Forged Carbon Steel and Why You Need to Use It

Carbon steel forgings are designed and shaped by means of a steel forging process. This type of steel forging comprises an unspecified amount of alloy, without the need of employing any minimum required percentage. Various kinds of alloys found within this steel forging are zirconium, cobalt, chromium, tungsten, titanium, nickel, and a lot more. However, it is important that there should be a sufficient amount of steel alloy as it can lower the melting point to create better steel forging.

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Advantages and Options of Carbon Steel

Advantages of Choosing Carbon Steel Forgings

Every knowledgeable forging manufacture understands the essence and importance of producing cutting-edge and durable forgings for every project need. Some of the many benefits of opting for carbon steel forging are tight grain structure, economical, product efficiency, and impact strength.

Carbon steel forgings often have a tight grain structure, making it mechanically strong to withstand friction and other effects. Hence, this type of steel forging does not require a number of expensive alloys just to achieve high strength components. With this, you may infer that this forging is definitely economical as compared to others. Additionally, it uses an open-die process to produce final products with extremely cost-effective resources.

As for product efficiency, forgings can be designed in various sizes, which make the product more efficient and flexible. Likewise, it has exceptional strength quality that allows the end product to withstand heavy load, impact, and stress.

Options of Carbon Steel Forgings

Subject to the type of project your needs, there are several available options when it involves carbon steel forgings grades. All of these grades can be treated to enhance its ductility, strength, and machinability. The most common option is medium carbon steel wherein it is composed of about 1.65% manganese and 0.54% carbon content. This grade stabilizes the good wear resistance, strength, and ductility. Additionally, the end product is often used for cars, forging, and large mechanical parts.

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Get Quality Steel Forgings

At Ferralloy, our team has the capability, resources, and experience to exceed your steel forging expectations. If you have any queries about steel forgings, contact us now!

Benefits of Utilizing Global Sourcing in the Production Process

As product demand increases making whatever product be more competitive in the trade and retail market, it is essential that you hire a company with global sourcing goals and capabilities. Since extensive global sourcing awareness and expertise can be the solution to marketing and manufacturing needs, every company must know how to speak the global sourcing language.

Generates Substantial Cost Savings

Studies show that appropriate sourcing can dramatically produce substantial cost savings. For instance, the purchasing cost of a company that source globally method can lead up to 10%- 15%. Industries that have used this sourcing methods have enjoyed tons of advantages that boost their earnings.

Additionally, manufacturing costs are mostly lower and industries can often purchase goods at a lower unit price. For industries with not much to spend, this can be an ideal solution to exploit their bottom line. Nevertheless, it is important to remember that there are still other factors, aside from global sourcing, that may affect a probable cost-savings increase.

Contiguity to Raw Materials

Another notable advantage of sourcing is that you have the chance to get more proximity when it comes to raw materials. You no longer have to reach out and avail the services of remote companies and industries just to get the raw materials. Moreso, global sourcing also offers state-of-the-art manufacturing technology and substantial knowledge of local languages and cultures, making it even easier on your part.  With the availability of advanced technology, you are guaranteed that the manufactured products are in perfect built, design, and condition.

The most common benefits of globally sourcing are knowing how to do business efficiently in the new market, evolving and searching for alternative supplier sources that may encourage competition, and decrease costs. It possesses an essential role every time you need to search for scarce resources and skills that are hard to find in your area. Hence, your manufacturing volume and other technical services will radically increase once sourcing is used properly.

Searching for a Global Sourcing Partner

At Ferralloy, our global sourcing permits us to deliver quality materials that result in strong and durable products. For more inquiries, contact us now!

A Simple Guide to the Uses of Investment Casting

Investment casting is one of the most prevalent metal parts used by most industrial companies. These cast components embrace countless benefits that make them an alluring alternative to a wide range of businesses and industries. Investment casting provides the ultimate design flexibility for highly complex parts made from a large choice of alloys. Furthermore, the investment casting process is relatively simple, allowing high production rates and consistent dimensional accuracy to be achieved.

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Simple Facts Should Know About Investment Casting

What is Investment Casting?

Investment casting, otherwise 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. This 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.

What are its Common Uses?

The uses of investment castings are immeasurable. Nonetheless, companies or industries engage in aerospace, power generation, firearm, automotive, military, commercial, food service, gas and oil, and energy industries use these metal components a lot. For instance, the firearms industry turns to cast parts for firearm receivers, triggers, hammers, and other precision parts. Investment castings are even used by beverage industry equipment manufacturers and international pressure relief valve manufacturers in the oil and gas industry. As a consequence, it’s safe to say that regardless of your industry, if your business can benefit from the advantages of investment cast parts and components, they might be the perfect metal option for any of your projects.

Why Use Investment Casting?

There are several explanations for why individuals choose to use this casting. Among the reasons why companies and industries use castings are the following:

  • It produces very smooth surfaces with no parting line, requiring only minor machining.
  • It can create exceptionally complex parts that would otherwise be extremely difficult or impossible.

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At Ferralloy, Inc., we supply machined investment castings to quality-controlled companies and industries. Contact us today!

Basics of Classic Rolled Ring Technique

Do you ever wonder how the procedure of creating rolled rings work and the techniques used for producing bearing rings? The process begins with the piercing of a circular preform of metal so as to produce a ring-like structure. As soon as this is formed, the ring is rotated and heated until its desired wall diameter and thickness are achieved.

Hot Radial Rolled Ring

This advanced and innovative rolled ring technique is normally used for manufacturing medium-scale bearing ring under high temperature via the hot radial rolled ring (HRRR) mill. During the rolling process, the HRRR mill’s main roll part makes the active rotation as well as the linear feed while its mandrel part creates a passive rotation.

Its guide roll’s placement is fixed at the main roll’s exit side while the signal roll can be found at the opposite side of the guide roll. The ring rolling process ends when the ring’s diameter touches the guide roll. Techniques when it comes to rolled rings are challenging; thus, it is essential that you know which technique to use and how it specifically works in order to prevent any sub-standard or low-quality products.

Cold Rolled Ring

This classic technique of producing quality rolled rings is considered as an advanced rotary forming technique that’s created to manufacture seamless rolled ring forgings in a high-temperature room through a cold-rolled ring mill. The main CRR mill has a mandrel part that makes linear feed, the main roll part that creates active rotation, a measured roll that measures the ring’s diameter, a guide roll that moves according to ring’s expansion, a frame part, and a power and control system.

During this process, a blank or a pre-turned ring is rolled between two rolls that may have specific profiles or may have no shape. The rolling process ends when the ring’s diameter meets the target value.

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Looking for Highly Engineered Rolled Rings?

At Ferralloy, Inc., we can provide you with quality and highly engineered products. Our substantial growth in the industry, allows us to provide you with excellent and first-rate rolled ring forgings, investment castings, machined components, and specialty products. Contact us today!

Closed Die Forging vs Open Die Forging

Most manufacturers use the closed die forging technique when they need to forge metallic parts that are small or medium-sized. The fact that multiple elements and factors are being merged during the process of forging leaves us no reason to wonder why this technique is able to generate results that are geometrically accurate. However, before resulting in a closed die forging technique, it is essential to first determine the difference between open die or closed die forging.

Common Information to Know About Die Forging

What is it?

Free forging, commonly known as open die forging, is the method of deforming the metals between the several dies. It is called open die forging since the multiple dies do not entirely enclose the metal. These dies often hammer the metal through a chain of movements. It tends to alter the dimension of the metals until the dies reach the desired shape.

On the other hand, closed die forging is also called an impression forging. It takes advantage of a specific amount of pressure to force the metal piece into an encircled or bounded die. This process uses an induction heating furnace with medium frequency to heat the metal to reach the desired pattern.

Advantages and Disadvantages

In whatever you purchase or manufacture, one of the important factor to look into are the advantages or disadvantages of the product. Die forging is the perfect method to achieve maximum tolerance. When it comes to open die forging, it is cost-effective since it uses less material waste. Additionally, it offers reduced chances of voids in your final forging, can increase strength to achieve longer product life, improved microstructure, and has an excellent fatigue resistance.

In contrast, closed die forging offers excellent net shapes, tighter tolerances, and better surface finish. It is resorted to so there can be no material limitation and it will be economically beneficial when it comes to large runs.

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Want to Know More About Closed Die Forging?

If you need more details about open and closed die forgings, contact Ferralloy, Inc. today!

Why is Stainless Steel Used in Investment Casting?

Stainless steel casting is among the few methods of the investment castings process. It is made by pouring molten stainless steel into a molder to solidify and achieve a solid and compact stainless steel material in the desired pattern. Same with other steel cast alloys, this material is a common component for casting production. When corrosion resistance and the properties of steel are needed in a certain product, stainless steel casting is the perfect option.

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Nitty-Gritty Facts About Stainless Steel Casting

Common Material Grades Used

Among the several stainless steel material grades used, the common ones are the 304, 304L, 316, 316L, 17-4 PH, and 2205 Duplex. 304 is the most extensively used austenite steel. It is commonly referred to as A2 stainless steel. Experts on investment castings also use 304L when slightly lower mechanical components are required. It is widely used by companies because of their versatility.

Application of Stainless Steel Castings

The reason why experts on investment castings use stainless steel is because of its unique physical properties. It is exceptionally resistant to corrosion, abrasion, and heat. Hence, it can be used in various ranges of industries, especially those which require materials that can withstand the severe environment. Stainless steel is used in building or construction purposes, pipe fitting, medical equipment, marine, kitchenware, and food machinery or processing.

According to investment castings professionals, stainless steel is one of the common materials used in building and construction. Modern construction uses more stainless steel when it comes to facades, roofing, and cladding. The reason for this is that it is known to have anti-vandal characteristics, low maintenance cost, and beautifully aesthetic.

As for stainless steel used in pipe fittings, it comes in various shapes and sizes. As conferred by investment castings professionals, stainless steel is used in this industry because it tends to be very convenient despite being durable and stable.

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Know More About Other Investment Castings

If you want to know more about the applications of stainless steel castings, contact us today!