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What are the Perks of Choosing Rolled Rings?

From pharmaceutical companies to machine shops to nuclear industries, it is safe to conclude that rolled rings are widely used in several industries. This type of forging is a procedure that starts with a circular form of metal. Such metal has already been pierced to make a hollow donut shape. The rolled ring is placed in a high temperature, then rotated to decrease its wall thickness while increasing the finished metal product’s diameter. Below are the perks of using a rolled ring forgings. 

Use of Various Materials

Rolled rings can be formed from numerous forgeable components such as aerospace metals, carbon, stainless steel, or alloy. Its versatility allows the rings to be more responsive and flexible. This is precisely why the industries engaged in refinery, chemical, and power generation choose this process. 

High Temperature Tolerant

Rolled rings forging is easier to manage and control when it comes to heat exposure. Unlike any metal components, rolled rings do not require extensive care when the heat is applied. The troubles of preventing such parts from deforming and melting rarely exist. With such procedure, manufacturers and other industries are guaranteed that it can withstand maximum heat.

Reliability and Cost-Effectiveness

Since rolled rings can withstand high temperatures, it can be inferred that the finished product is reliable with more resistance and strength capability. Aside from reliability, it is also known to be cost-effective. Rolled rings are formed and created at a lower cost than other components. It requires less machining as it closely matches the shape of the finished metal.

Strength

The strength factor of rolled rings forging is the most notable advantage of choosing such metalwork or process. Experts say that forgings have more strength than other components. It can maintain the power of the metal despite temperature fluctuations.

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Get Rolled Rings Forging at Ferralloy Inc.

At Ferralloy Inc., we are committed to providing you only the finest and efficient work. Also, our rolled rings are created by the best and dedicated manufacturers that offer precision machining. Contact our team today to learn more about us!

What Exactly is Inconel 600 and How is it Used?

Inconel is an alloy of nickel that also contains iron and chromium. It is resilient to both high temperatures and corrosion, making it a valuable material. The only disadvantage is that it is it’s not that affordable to produce. While it is reliable and durable, it is one of the more expensive materials you can use. However, it is worth the cost because the content is extremely tough. Likewise, it does not break down or falter often.

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Facts you Need to Know About Inconel 600

What is Inconel 600?

Inconel 600 a nickel-chromium alloy with stable high-temperature oxidation resistance. It is also resistant to chloride-ion stress-corrosion cracking, corrosion by high-purity, water, and caustic corrosion. Hence, this type of alloy is ideal for furnace components, chemical and food processing, nuclear engineering, and sparking electrodes.

What Makes it so Exceptional?

The chromium content allows the alloy to resist sulfur compounds and other oxidizing conditions. The chromium content found in Inconel 600 makes it ideal for a commercially pure nickel under an oxidizing environment. It is relatively un-hampered by the majority of alkaline and neutral salt solutions.

What are the Characteristics?

  • Below are the following characteristics which make Inconel 600 worth an investment.
  • Suffers from selective oxidation only due to reduction of conditions and alternating oxidations
  • Highly resistant to carburizing gases, nitrogen, and ammonia bearing atmospheres
  • High strength and scaling resistant because of the elevated temperatures
  • Exceptional resistance to high purity water 
  • Has the ability to resist organic acids such as stearic, formic, and acetic

Where is Inconel 600 Applied?

Inconel 600 is used and applied by several industries. It is involved in process equipment such as fluorinated and chlorinated hydrocarbon productions. Manufacturers of a heat exchanger and reactor vessels like using this type of alloy, especially in the construction of vinyl chloride and other substances.

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How is Inconel 600 Used?

Inconel is excellent when it comes to dealing with rapid temperature changes too. It can withstand the cold just as well as it faces the heat. Since the material does not corrode, it is very commonly used in various marine applications too. 

To know more about Inconel, contact Ferralloy today!

Lubricant Choices in Closed-Die Forging

Closed die forging includes a controlled plastic deformation process of alloys and heated metals to achieve the desired shape. Without an appropriate forging die lubricant, effective and economical closed die forging is unattainable.

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Factors Affecting Closed Die Forging Quality

Factors that Ensure Optimal Life of a Forging Die

The life of a closed die forging is affected by many factors. The most common of which is the proper method of application of die lubricant at appropriate intervals. Likewise, the forging result may also be affected by the reduction of friction during the forging process. Friction can sufficiently be reduced by using suitable die lubricants and polished dies.

Moreso, proper heat treatment, while the forging process is ongoing, is mandatory. The use of protective anti-scale coating will help reduce scaling on critical surface areas of the material. Lastly, using a correct die material and design can make a difference. 

Types of Forging Die Lubricants

There are numerous types of closed die forging lubricants. Manufacturers often used water with soluble oils, graphite, sawdust, or common salt. The use of these types of lubricants offers several benefits to produce quality forging materials. It is economical, eco-friendly, non-polluting, easy to use, and improve the forging die life and productivity. 

Aside from using water and other mixes, closed die forging manufacturers also use oil without graphite, special oil with graphite, or furnace oil. These types require no purchase hassles, they are the least expensive, and they can improve your material’s die life.

Selection of the Right Type

Choosing the right type of closed die forging lubricant will depend on numerous parameters such as complexity of the forging, size, methods of dispensing the oil, pollution control, cost reduction, and depth of die cavity. 

The selection of the best type will require rigid guidelines and several field trials. Hence, the correct procedure of dispensing the lubricant and appropriate type of oil plays a decisive factor in achieving your desired metal shape. 

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Quality Closed Die Forging at Ferralloy

At Ferralloy Inc., we provide furnace components, extrusions, fabrications, fasteners, forgings, and the like with only the best quality. Contact us today!

What are the Best Applications for Open Die Forging?

Open die forging is known to have the most demanding applications in the metal industry. It is used because of the several features it contributes, such as near net shape materials and improved structural integrity. Read on to know the typical open die forging applications.

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Applications and Benefits of Open Die Forging

Applications

Forging metals is not an easy job. However, experts found a way to make things more accessible without compromising the quantity of the materials. Forging is commonly used in industries like:

  • Shipbuilding
  • Defense
  • Infrastructure and Construction
  • Aerospace
  • Power Transmission and Gearing
  • Metal Processing
  • And More

Types of Applications

Forging is best used in large and bulky pieces with a short run purpose. These generally consist of custom forged shapes, flanges, hubs, discs, cylinders, shafts, blocks, and forged bars. However, it is popularly used in bespoke designed and single run products.

Benefits

The most common advantage of forging is of exceptional strength. It can create hard-wearing materials without compromising the quality of a surface finish. Aside from outstanding durability, forging is also known to produce materials with more exceptional grain size and better fatigue resistance. Because of its better resistance level, metals are not prone to wear and tear.

Additionally, the use of open die forging allows the manufacturer to achieve lesser material waste. It is also more economical because fewer materials are used to make its forging goal. Moreso, this type of forging process includes a shaping process that decreases the presence of voids in the finished products. 

Materials Used

Forging uses a wide variety of forging materials. The materials used will depend on the expected finished product. Most manufacturers use bronze, nickel, copper, aluminum, and tool steel. While others use titanium, Inconel, stainless steel, alloy steel, and carbon steel. 

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Looking for Quality Open Die Forging Material?

At Ferralloy Inc., our reliable team is here to help you find exactly what you are looking for. Reach out to one of our professionals today by visiting our website or giving us a call.

The Impact Strength of Rolled Ring Forging

Techniques in rolled ring forgings are highly advantageous when working with metal to achieve specific steel shapes. Moreso, these techniques can enhance every metalwork structure, especially that each material can be refined in its smallest size. 

Forging uses ingot as an essential component, and this is exposed in hot deformation to achieve a refined metallurgical structure. However, aside from its ability to produce desired steel shapes with precision, these techniques also have high impact strength, making your metal works worth your investment.

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Benefits Offered by Rolled Ring Forgings

High Impact Strength

As stated earlier, rolled ring forgings produce uniform and predictable grain structure. It has a unique flow characteristic that enables every manufacturer to increase directional and impact strength. 

This forging removes gas pockets or internal voids that tend to deteriorate metal components, providing your metalwork a higher chemical strength. Additionally, forging guarantees excellent grain flow orientation to increase impact strength and maximize fatigue resistance.

Variety of Configurations Used

Even though a wide range of configurations are employed in producing rolled ring forgings, small and intricate shapes are the ones that manufacturers commonly provide. Additionally, the process can also create forged rolled rings that can be more than 9 feet tall. 

It is very versatile when it comes to thickness and height ratio, giving various industries plenty of options to choose from. A piece of specialized processing equipment can make it possible for manufacturers to produce rings with more significant proportions.

The Difference Between Plating and Casting

Compared to plating and casting, rolled ring forgings have fewer sheetings in the metal components without compromising internal quality. Other benefits of using this technique are the following: 

  • Enhanced metallurgical microstructure
  • Intricate cutting processes are not required
  • Improve metallic yield 
  • Better material cost
  • Superior mechanical resistance properties

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Know More About Rolled Ring Forgings

In a gist, these forgings approximately add about a 30% increase in your metalwork’s toughness and strength. Although the initial tooling expenses are higher and more expensive than plating and casting, you are guaranteed that the quality is never compromised. 

At Ferralloy Inc., we only provide excellent quality metalwork and always seek to offer better business cooperation with every customer. Contact us today for more inquiries!

The Basic Types of Metal Castings Used

Machined castings of metals involve an intricate process wherein molten metal is poured into a mold that has a hollow cavity of the preferred geometrical shape. After such a process, it is processed to form a solidified component. 

The word “casting” is likewise used to define or refer the part made by the machine casting process, which dates back more than 5,000 years ago. When it comes to history, this process is performed to make significant and complex metal components that would have been difficult when using the traditional manufacturing method. 

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Metal Casting Categories You Need to Know

Permanent Mold Casting

Permanent mold machined castings are subdivided into 3 groups depending on its pattern material. These 3 groups are die casting, low vacuum/pressure, and gravity casting. This casting is sometimes called non-expendable mold casting. 

It uses stable and long-lasting molds that are recycled after each production use. Despite using repeatable parts because of the recycled shapes, permanent mold casting can still produce simple and unique castings that, according to its preferential use. 

Expendable Mold Casting

Since there is a non-expendable mold casting, there should also be an expendable mold casting. The latter can be divided into 2 subcategories – permanent pattern and expendable pattern. Expendable models consist of investment castings and lost foam, while stable patterns consist of ceramic mold, shell mold, plaster molding, and sand casting.

These machined castings are used as a provisional non-reusable mold to create the final cast since the frame will need to be penetrated to get the casting out. These molds are often composed of materials such as sand, plaster, shell, or ceramic. 

Generally, these types are bonded using binders known as a bonding agent to enhance the materials’ properties. Likewise, expendable mold casting uses multifaceted and intricate geometries to produce the finished product.

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Where to Get the Best Machined Castings?

In every metal casting production, there should always be factors to consider. Such factors that need to be considered before deciding on the appropriate metal casting are the materials used, required tolerance, required quantity, and shapes or sizes of the metal component. To know more about these factors, contact Ferralloy, Inc. today!

Facts You Need to Know About The Closed Die Forging Presses

Closed die forging is a forging process and sometimes known as impression die forging. This procedure involves two or more dies that comprise 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. Read on to know more about this forging presses.

Advantages of Closed Die Forging Presses

Quality and Efficiency

For industries engaged in manufacturing tools and other parts, a die with a pre-formed impression is required. The company that offers this forging presses likewise offers metal components, tools, and other parts with only the best product quality and efficiency. To meet whatever standard your industry requires mechanical and hydraulic closed die forging presses are enough to surpass your expectations.

Require Less Maintenance

With hydraulic and mechanical forging presses, a metal, alloy, steel, or any type of substance use, different industries may be perfectly built for a specific company need. Additionally, it can even save you more time and money, and it requires less maintenance.

Strong and Durable

In terms of strength and durability, the finished products of the forging presses come first. Because of the advancement in internal structure, the continuity of the grain is maintained. If you’re interested in producing high-performance products that are both strong and durable, use this forging manufacturing technique.

Rejection Rate is Low

If the raw material is of good quality, this forging can create parts that have no internal defects and excellent mechanical properties. This translates into low rejection rates and more economic advantage.

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In Need of a Closed Die Forging?

If you are looking for a closed die forging that will surpass your expectations, get in touch with Ferralloy Inc. today. Our commitment to high-quality engineered products and services is evident from our diverse metalworking customer base. We guarantee that your business interests are upheld at all costs. Request an appointment today!

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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Know More About Closed Die Forging

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!