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Advantages of Investment Castings

Investment castings provide limitless advantages. It is often used as a metal component for energy, gas and oil, food service, commercial, military, automotive, firearm, power generation, and aerospace industries. For instance, the firearms industry turns to cast parts for firearm receivers, triggers, hammers, and other precision parts. Castings investment is even used by beverage equipment manufacturers and industries, as well as, international pressure relief valve manufacturers in the oil and gas industry.

castings investment

Advantages and Uses of Investment Castings

What Are the Advantages?

Investment casting is perfect for crafting complex and small geometric shapes that have delicate features with only a single mold. Since it is highly flexible, you can combine it with various wax patterns to make a single unique mold. It allows you to rearrange parts you could not make with a tool or machine. Hence, the results become a worthwhile substitute to wielding.

Smooth finishes and dimensional precision are some of the advantages of this casting process. The manufacturer forms a ceramic shell surrounding even patterns, eliminating any presence of a parting line. The reason for this is there’s only a single mold created. Therefore, this process can lead to a smooth finish and the post-process smoothing can produce better results.

Castings investment also provides excellent design capabilities, tight tolerances, and makes use of reusable materials. In this way, the project can achieve accurate results without having to spend more money. Thankfully, the process takes advantage of reusable materials.

How Are Investment Castings Used?

Investment casting is great for creating prototypes and small products. It has boundless applications across numerous industries, specifically in the industrial and automotive industries. How industries use this process today varies on the metals they need. Nonetheless, refractory metals that can withstand high temperatures work best. The most common metals used are titanium alloy, steel, and aluminum alloy.

castings investment

Get the Finest Investment Casting Product Today!

At Ferralloy Inc., we supply investment castings to quality-controlled companies and industries. If you’re interested in purchasing these castings, you can contact us through this link. Don’t hesitate to get in touch with us. Your business interest is what we prioritize!

Benefits of Alloy and Steel Castings

Depending on the purpose and ultimate use of the metal part, different procedures are employed to create the highest quality piece possible. As for the castings process, it is considered to be one of the best.

The process involves the heating of the metal until it turns molten before being poured into a die to form a specific shape. It is beneficial when the shape of the component is intricate or when the component needs to be a very large size. To know more, below are the benefits of using alloy and steel castings.

where can i get castings?

Why Use Castings?

Advantages of a Steel Casting

Design flexibility, metallurgical versatility, and large weight and size range are the notable advantages alloy castings can offer. Their flexibility grants the designers the freedom to choose whichever shape and size they desire. It is extremely simple to form and change the shape of components, and all in a timely manner.

More so, steel castings obtain 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.

Advantages of an Alloy Casting

Alloy castings are extremely versatile and are able to possess a wide range of characteristics. They can produce near-net-shape parts with a controlled surface finish, dimensional accuracy, and complex geometries.

Additionally, alloy castings can withstand the highest operating temperatures when compared to any other cast alloy. These castings possess outstanding corrosion resistance, thermal and electrical conductivity, EMI and RFI shielding properties, and are fully recyclable.

where can i get castings?

Where to Get Quality Castings?

If you’re interested in utilizing all of the advantages of steel and alloy castings for your next project, contact us. Ferralloy, Inc. is a leading supplier of quality castings to major companies throughout the world. We can provide you with quality and exceptional machined parts in a lot of different ferrous and non-ferrous alloys. Various types of steels are also available to cater to your project.

Forgeability of a Metal

The ability of a metal to undergo deformation without cracking by means of forging is what experts call the forgeability of a metal. With this characteristic, metals can easily be formed with low force and resistance. For instance, closed die forging involves a process wherein the dies move toward each other by covering the metal. The heated raw material is placed at the bottom die to produce a design or shape according to specifications. To know more about the forgeability of the metal, please continue reading.

 

What is Closed Die Forging?

All about Forgeability

Tests to Determine Forgeability

According to experts, there are two primary tests to determine forgeability of a metal – Upsetting test and Hot-twist test. Upsetting test involves cracking while upsetting a cylindrical specimen.  Although this test only provides basic guidelines, it uses different strain and temperature rates to ensure that forgeability can be determined.

On the other hand, the hot-twist test requires the twisting of a metal rod at different temperature rates. Using this method, forgeability can be determined for various materials, including steel.

Extrusion Process

Extrusion is conducted by deforming metal and transporting it into a chamber before the compression process starts. In standard extrusion procedures, a round billet is placed in a chamber and forced through a die opening by a ram. Additionally, this process requires extreme temperature for the material to be completely formed.

The methods of extrusion involved in forgeability of a metal are direct extrusion, indirect extrusion, hydrostatic extrusion, and impact extrusion.

Metal Flow

Metal flow is an important factor to consider when deforming a metal. It must have a substantial reduction in the cross-sectional part of the process to make sure that the flow is undisturbed. Also, extrusion defects may occur if there are impurities and oxides caused due to the inhomogeneous flow of metal. When this happens, surface defects will thrust or be expelled into the center of the extruded parts.

 

What is Closed Die Forging?

More Information about Closed Die Forging and Extrusion

At Ferralloy Inc., we strive to provide answers for every inquiry! Contact us today if you have any questions and our friendly staff will be glad to answer them!

How were Investment Castings Used in the Past?

Investment casting, otherwise known as a lost wax casting, is one of the oldest metal-forming processes that is still used as of this date. Approximately 5,000 years ago, investment castings started with a basic beeswax-formed pattern. Today, it involves highly complicated processes and technologies using refractory materials and specialized alloys.

what should i know about investment castings?

The History of Investment Castings

Original Use

The use of investment castings in ancient civilization was a bit different from the current method applied today. In the olden times, the craftsman designed the casting from beeswax by using basic tools such as shaving tools, melted wax, and other hot tools. To create the desired form, the craftsman will forge a pattern on the wax shape.

They will then fill the mold with a thin layer of melted wax. As soon as the wax mold is coated in ceramic, a perfect mold of the wax shape can be created. It will then be left to dry out before the craftsman can use it to forge a metal object. Such a process is generally used to create jewelry, decorative objects, and religious objects.

Modern Use

Investment casting is a complex metal-forming development that allows metal workers to create products with intricate and remarkable surfaces. The process starts by creating a mold and producing accurate patterns through the latest technological advancements. The good thing about the modern application of investment castings is that when the workers use wax to make patterns, it can still be reused.

The flexible patterns allow for easy reproduction and stress-free production of wax materials that underwent a series of coating and hardening. Once the materials are invested – jargon for poured – into the mold decorated with unique patterns, it will go through a lot of processes such as dewaxing, heating, pouring, removal, and cleaning.

what should i know about investment castings?

What Makes Investment Castings a Popular Metal-Forming Process?

If you want to know why investment casting survived throughout these decades and remains a widely used process, contact our staff at Ferralloy Inc. We can walk you through its history and help you realize why it’s an important metal-forming process.

Open Die Forging Aerospace Application

Have you ever heard of the term “smith forging”? Before all the advancements in tools and technology, forging was performed by a smith using an anvil and hammer to produce and create forged metal – hence, the term. Smith forging, commonly known as open die forging, is a process that involves a hammer striking and deforming a workpiece securely attached to a stationary anvil.

What is Open Die Forging?

Why do Aerospace Companies Prefer Open Die Forging?

The Basics

Open die forging involves the process of forging alloys without having to enclose the workpiece throughout the procedure. In this process, it is required that the operator knows the proper position and orientation of the workpiece to achieve the desired shape.

The dies or surfaces are normally flat in shape. However, there are instances when dies with a specific shape are used for specialized forging. For instance, a die may have a convex, concave, or round surface. It may also be a cut-off tool or a device to form holes.

Advantages of Open Die Forging

Aerospace companies consider the advantages of open die forging before choosing this metalworking process to produce aerospace parts and components. Below are the advantages:

  • Superior strength
  • Better-quality grain size
  • Constant grain flow
  • Enhanced microstructure
  • Improved fatigue resistance
  • Reduced chance of voids

Progressive open die forging techniques are capable of creating multiple shapes notwithstanding the large parts and components used. Simple shapes like rounds, ingots, and bars are easier to produce because of the constant grain flow and improved fatigue resistance.

The most common subjects used for smith forging are steel and related alloys. Nonetheless, other metals can be shaped as desired. These metals include titanium, nickel, and copper alloys.

Industrial or Commercial Aerospace Parts

The following are the parts and components used by aerospace industries that were produced and forged through an open die forging method:

  • Shafts
  • Seamless rolled rings (bearings)
  • Rotor/Propeller Parts
  • Landing gear components
  • Flat bar
  • Flanges
  • Disks

What is Open Die Forging?

Learn More About Open Die Forging Applications

At Ferralloy Inc., our commitment to the industrial and commercial sectors has made us grow bigger. We make sure to give more importance to the quality and satisfaction of our clients. Contact us today to speak with an expert!

Development and Characterization of Ring Rolling

Have you ever wondered how the ball and roller bearing races, pressure valves, pipes, and turbines are made? These metal pieces are produced through a process known as ring rolling. This is a specific category of metal rolling wherein a smaller diameter ring is rolled into a reduced cross-section and an accurate ring of larger diameter. Below are the facts about what ring rolling is, as well as its developments and characterization.

What is ring rolling?

Facts to Know About

What is it?

Ring rolling is accomplished by using two rollers, one idle and one driven. The rollers move on either side of the ring’s cross-segment to create an efficient and precise motion. To guarantee the ring will maintain an unbroken width pattern the entire forming process, manufacturers use an edging roller during the industrial metal rolling process.

What are the Characteristics?

The process will retain the same volume of the metalwork. In this way, the geometric reduction in thickness will be reimbursed entirely because of the upturn in the ring’s diameter. Among the many characteristics, the most notable one is the manufacturing of seamless rolled rings. This procedure is used to produce not only flat rings but also rings that are designed to have different shapes and cross-sections.

Another significant characteristic of this process is that it can produce accurate parts and components with little waste of material. Additionally, the process involves an enhanced grain orientation that provides the metal robust strength appropriate for several applications.

What are the Developments?

This technique is gearing towards the new metalwork process with heightened geometries and more complex cross-section geometries. The applied knowledge gathered through the years by experts is insufficient to estimate the precise interface of various process parameters. Nonetheless, experts and manufacturers can still rely on simulation software to produce an accurate ring rolling model and evaluate the material properties and material flow with accuracy.

What is ring rolling?

Complex Facts About Ring Rolling

When it comes to forging, it is ideal that you get advice from specialists. We know this matter involves intricate and elaborate details. At Ferralloy Inc., we make sure that you are provided with detailed information about the engineered products we offer.

Advantages of Using Machined Forgings in Agriculture

Nowadays, agriculture requires massive equipment to optimize a farmer’s workload. With advanced technologies, machined forgings have created a way to speed up the process of the agricultural sector. Check out the advantages forged products can offer.

What are machined forgings?

How Can Machined Forgings Boost the Agricultural Zone

What is Forging?

Before anything else, it’s imperative you know the basics of this intricate field. Forging is a metalwork procedure that yields numerous parts or components with a strength much higher than any other metalwork procedure. Once the metal is shaped, the internal grain structure deforms to align in the forged piece’s new shape. This results in superb reliability and exceptional strength at high points of temperature and stress.

What are the Advantages?

Since machined forging parts and components are robust and reliable, industries often use these products in applications where there should be no room for error. These industries often deal with chemicals, mining, automotive, aerospace, and of course, agriculture.

Forging can polish and enhance the grain structure of the products so that your crops and other vegetation will not be compromised. As several experts would say, forging is superior to machining bar stock and casting. The reason is that the metal’s natural grain flow is designed to imitate the shape of the product.

Economic, machinability, toughness, and strength-wise, machined forgings in heavy construction, off-highway equipment, and agricultural machines make it easier for industries to fulfill their tasks and quotas.

What are machined forgings?

Machined Forgings in Agricultural Implements

Aside from using machined forgings in transmission and engine parts, it is also used for producing quality links, bearing holders, axle beams, yokes, rollers, wheel hubs, ball joints, spindles, shafts, levers, sprockets, and gears. Several farm owners employ key forgings from those parts earlier mentioned, including cultivator shanks, spike harrow teeth, and tie-rod ends.

Notwithstanding the advantages machined forgings can offer in the agricultural sector, they also contribute to other industries. Contact Ferralloy Inc. to know whether your company can benefit from these products.

Reasons to Try Seamless Rolled Rings

Many industries use seamless rolled rings. Moreover, it may even surprise you to know that many industries like aviation and food processing use these rings in their regular line of work! So, why do so many companies from opposite paths of industry opt for seamless rolled rings? Let’s find out.

What are seamless rolled rings?

The Exceptional Process and Materials

Process Involved

The forging process starts with a circular metal component. Next, the component is cautiously pierced to create a hollow ring that looks like a doughnut. Then, the ring is moved and processed to recrystallization temperatures. Finally, after the recrystallization process, it is placed onto the idler roll and under pressure, directed towards the drive roll to produce the desired product.

Types of Rolled Rings

There are three main types of rolled rings:

  • Carbon – commonly used for pressure and structural vessel applications
  • Alloy – used for gear and bearing applications in addition to a variety of industrial equipment applications
  • Stainless Steel – mostly used for food and chemical processing applications.

Materials or Components Used

Seamless rolled rings can be made from any forgeable material! Furthermore, these include, but are not limited to:

The ability to create seamless rolled rings out of a wide range of materials is one of the many reasons why so many companies choose to work with them.

What are seamless rolled rings?

Advantages of Using Seamless Rolled Rings

Seamless rolled rings are used by various industries for many reasons. Moreso, some of the common reasons are a broader range of materials, better performance under heat, reduced costs, and greater strength. These rings can be created from numerous forgeable materials, including aerospace metals, carbon, stainless steel, and alloy.

Additionally, unlike the other ring components, it is easier to predict how these rings will react. These rings can maintain their strength despite the fluctuating temperature. To know more about seamless rolled rings, contact Ferralloy Inc. today!

What is Forged Steel?

Whether you’re going for a walk, heading to your office, or riding a bus on your way home, forged steel always makes its appearance. Steel forgings are made out of alloying carbon and iron. Forged steel is produced under extremely high, yet accurate, pressure. It has better ductility than other manufactured steel, possesses fatigue strength, more tensile, has an advanced grain structure, and has less surface porosity.

What are steel Forgings?

Properties and Types of Forged Steel

Properties

Forgings require unique properties to produce quality products. They are composed of specialized alloys like carbon and stainless steel. This offers incomparable strength for the manufacturer of mechanical and industrial parts.

Furthermore, when it comes to forged steel, it has exceptional properties that make it easier to differentiate from other materials. Therefore, it is mostly used in industrial and mechanical applications for its availability and strength.

The only notable disadvantage when using this metal is the size and thickness restrictions for the steel being forged. The reason for this is justifiable – metal forging is a rather tedious process. Despite the limitation, it is possible to retain the exact consistency in all manufactured forged steel. The steel forging process is accurately measured and quite thorough.

Types

Companies classify steel forgings into three types – cold forged steel, hot forged steel, and hardened forged steel. These types differ depending on the forming pressure and temperature during the making process.

  • Cold Forged Steel – the process is done under temperatures up to 160 ºC.  Typically, the low temperature will account for a smoother surface finish.
  • Hot Forged Steel – the temperature for this technique ranges from 900 ºC to 1300 ºC. The temperature is often above recrystallization to produce materials with good formability.
  • Hardened Forged Steel – the temperature ranges from 750ºC to 950ºC. The materials produced are more versatile but have limited ductility.

What are steel Forgings?

Get Forgings with Outstanding Durability at Ferralloy Inc.

At Ferralloy Inc., our specialists see to it that your products are of first-class and exceptional quality. To know more about the products we offer, contact us today!

Understanding Forged Steel

Many people have never heard of foraged steel, but little do they know it’s used all around them. Most things made out of metal can be made stronger with forged steel! Forging was originally implemented to produce different kinds of steel ends with distinct properties. Currently, hydraulic hammers, and other forging machines and processes, make it possible for the development of steel forgings.

What are Steel Forgings?

Process and Categories of Steel Forgings

Process of Producing Forged Steel

The forging process begins by heating the steel to a high temperature, making the material more malleable and ductile. Next, it will be formed to the desired shape by applying the right amount of pressure to the steel. With the precise processing methods, steel forgings make it possible for a billet of steel to permanently be shaped without compromising its quality.

Additionally, steel forgings require a forge oven, forge furnace, or any forging heating system to sufficiently deliver the precise temperature needed. Furthermore, the deformation and thermal cycle process allow for rain refinement and metallurgical recrystallization to strengthen the finished product. This process is important to improve impact toughness and quality.

Categories

Steel forgings can be divided into 3 categories: the cold, warm, or hot forging of steel. Cold steel requires room temperature forging require a room temperature forging. The process often involves a self-heating method in which temperature may reach up to 150 degrees Celsius. This category requires high forming forces and low formability.

As for warm forgings, the temperature reaches between 750 and 900 degrees Celsius. However, just like cold steel forgings, this category needs higher forming forces but only has limited formability.

Lastly, hot forgings may reach up to 1250 degrees Celsius. Since the temperature is often above the recrystallization level, this forging category only requires low forming forces and still has good formability results.

What are Steel Forgings?

More Information about Steel Forgings

Aside from the forging process and categories involved, there is still a lot of information you need to know before purchasing forged steel. Additionally, you should know the advantages, disadvantages, properties used. At Ferralloy Inc., our friendly experts will lay down all the facts you need to know. Contact us today!