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Why Use Cobalt Alloy Parts?

There are many different types of superalloys containing various levels of titanium, silicon, sulfur, phosphorus, molybdenum, manganese, chromium, carbon, boron, aluminum, iron, nickel, and cobalt. Most of them contain four to six elements to produce quality parts and components, and cobalt alloy the largest often used in forging valves in the combustion engine and other parts of a gun. It not only offers high corrosion resistance, but it’s also the predominant alloy that provides exemplary strength.

What are cobalt alloys?

Cobalt Alloy Parts will Enhance your Next Project

Wear Resistant

As a cobalt-based “superalloy,” it holds a wide range of benefits. Some of its biggest advantages include its strength, resistance to tremendous wear and tear, and ability to work under extreme temperatures. Not only is it able to function in a wide range of temperatures, but it has the ability to maintain its core strength and wear resistance, no matter the temperature, as well. As a result, this material is ideal for the environment with temperatures ranging from 600 to 1112˚F (3315 to 600˚C). Another one of its benefits is that you can introduce other elements to this alloy to meet your exact specifications, making it more adaptable and convenient.

Accurate Manufacturing Process

Cobalt alloys are produced by a range of different processes or methods. These methods include wrought or hot forging, hard-faced deposit, powder metal, and finally, casting. Using cobalt alloy can be a bit difficult to machine and grind as compared to when using steel. As a result, high-performance processing equipment and specialized machining tools are required since it is often machined by grinding instead of cutting.

What are cobalt alloys?

Know More About Cobalt Alloys and Their Applications

Ferralloy Inc. is producing machined investment castings to the Rc 52 hardness grade of every cobalt-based alloy. The parts and components produced are used as holes by a large international company in the oil drilling equipment industry. This type of material is also being used to produce sleeves in the valve industry. The sleeves are pressed into their safety relief valves to dramatically reduce wear which occurs when abrasive fluids are pumped through the valves.

To get more info about the different applications of cobalt alloys, contact our team today!

How Much Do You Know About Inconel?

Do you know what type of alloy is known to have oxidation – and corrosion-resistant materials? Inconel, a brand name for specific nickel-chromium alloys, is well-suited for service in extreme environments subjected to pressure and heat.

It is often used by industries that use forged materials exposed to extreme heat because of this capability. However, did you know that it’s extremely hard to weld on its own?

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Weld Inconel with TIG Welding

What is Titanium Inert Gas (TIG) Welding?

Titanium belongs in the family of reactive metals; meaning, it possesses a resilient affinity for oxygen. At room temperature, this metal reacts with oxygen to produce titanium dioxide. The passive and impenetrable coating combats further interaction from the surrounding particles. With titanium inert gas welding, manufacturers can secure the weld area from water vapor and oxygen.

How Does TIG Welding Enhance Inconel Welding?

As stated earlier, Inconel is generally complex to weld since the welds tend to crack because of too much heat and pressure. Nonetheless, certain types of Inconel are specially designed to be weldable.

In welding Inconel, industries must use an Inconel 625 filler metal. This is usually the most common weldable type of Inconel. According to metal experts, this type is useful in welding two pieces of Inconel together. Another good part of using Inconel 625 is that it can also be welded with other metals. For instance, most welding industries use stainless steel and Inconel to produce durable and heat-resistance metal.

For welding Inconel, you have to expect an ill-defined weld pool that may seem dirty and substandard for welders used to steel; however, this is normal. The important thing is that it welds a resilient and highly corrosion-resistant product.

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More Information About Welding Inconel with TIG Technique

The TIG technique offers the welder to gain more control over the materials. Additionally, this technique uses a clear-cut welding arc and is well-fitted for automation. Contact Ferralloy Inc. to learn more!

What to Know About Custom Machined Forgings

Machined forgings involve various metalworking processes that manufacture parts with a strength greater than other metalworking techniques. Once the piece of the metal is shaped during the forging process, the internal grain structure of such metal becomes uninterrupted throughout the part, producing results with exceptional reliability at high-stress points and inconceivable strength.

what is machined forgings

Benefits of Opting for Custom Machined Forgings

“Cannot Fail” Applications

Materials used in custom machined forgings are aluminum, nickel, titanium, stainless steel, micro-alloy steel, re-sulfurized steel, alloy steel, and carbon steel. With these materials, the parts created through this process are mostly used in several “cannot fail” applications such as parts used by chemical industries, mining companies, automotive industries, and aerospace.

Apart from these companies, metal parts produced through custom machined forgings are also used in pharmaceutical, medical, marine, power and energy, food and beverage, petrochemical, military, heavy trucking, and agriculture.

Enhanced Metallurgical Properties

In most cases, custom machined castings use selective heating and non-uniform cooling to avoid failure or damage to a particular component. With this customized metalworking process, you are guaranteed that your finished shape will have superior grain flow without internal voids.

You’re probably aware that shrinkage and porosity are often seen in casted products. However, with machined forgings, the occurrence of unexpected failure under high-temperature differences or stress is greatly reduced.

Versatility and Cost-Effectiveness

When you learn about forging processes, you’ll be amazed at the wide array of metals that can be forged into a particular shape. Although each of these options comes with a unique set of characteristics, the forging process can be applied in the production of specific parts that your project requires.

Additionally, when it comes to precision metal manufacturing in high production runs, machined forgings offer a significant cost advantage due to the fact the materials used in the process are cheaper compared with the materials required in other metalworking processes.

what is machined forgings?

Where to Look for a Machined Forgings Product?

At Ferralloy Inc., our team makes sure that we only work with reliable and trusted forging partners. Contact us today for quality products.

When to Use Investment Casting

Are you familiar with the metal-forming process known as investment casting? If not, you should learn about this process if you want to excel in the metalworking field. Castings investment is a process that allows workers to create products with remarkable surfaces. The process begins by creating molds and patterns. Then, workers use wax to make patterns, allowing easy reproduction of these patterns.

 

What is Castings Investment?

Properties, Considerations, and When to Apply Investment Casting

Properties and Considerations

In manufacturing metals by investment casting, you need to take into account the important properties and considerations. For one, this is a manufacturing process that makes possible the casting of highly complex parts. Despite the complexity, the results can still achieve a good surface finish. Below are some of the common properties and considerations you need to learn if you want to master the art of investment casting.

  • According to experts, this metalworking process is highly complicated and relatively expensive if you don’t know what you’re doing because some parts of the process may require automation.
  • The good thing about castings investment is that you can practically use any metal. Components manufactured by this complex are customarily small. However, the weight of the component may reach up to 75lbs.
  • Another advantage when using investment casting is that it can create parts and components with high dimensional accuracy. It can produce end products with tolerances as low as .076mm and very narrow sections. 

When is Investment Casting Used?

Manufacturers often use investment casting when machining of internal passageways cannot be employed. Likewise, it is also applicable when progressive tool maintenance costs are not the goal. The following are other reasons why investment casting is used.

  • Excessive upfront tooling costs connected to sand casting are adequate
  • Sand casting is not acceptable because wall thickness is too thin
  • The exceptional as-cast surface result is desired
  • Small to medium dimensions, generally less than 454 kg or 1,000 lbs.
  • Various and/or convoluted internal passageways in design
  • Metal components are asymmetrical or shaped with accurate detail
  • Tight tolerances and external shaping are desired

What is Castings Investment?

Where to Get Metal Components Manufactures by Castings Investment?

Using the correct material and process for your metal components is important. Schedule an appointment at Ferralloy Inc. to know more about the castings investment process!

Learning About Machined Castings in 5 minutes

The machined casting process is a critical part of metalworking. Implementing a precise and efficient process holds the ability to create various complex parts in a wide selection of metals for countless industries. Sometimes, castings can be utilized in the exact form that they leave the mold. They often, however, need to be machined for the part to be further perfected.

What are machined castings?

Basic Information About Machined Castings

Why is Machining Used?

Machining helps create very fine and detailed objects that would have been impossible to manufacture through a mere casting technique. Furthermore, machining can seal surfaces and threaded holes without compromising the quality of the product.

How Does Machined Casting Work?

Machined castings refer to the process utilized to cut away certain materials to alter the shape and appearance of a metal product or casting. For instance< cutting using single-point or multipoint cutting tools, grinding, and non-traditional machining processes that utilize chemical, electrical, and other sources of energy.

What are they used for?

When the time comes that your casting applications require machining to improve tolerances, you must get a partner or acquire the services of professional companies whom you can rely on to give a reliable and unfailing high-quality service. Therefore, you should employ the services of companies with skilled machinists! They have the ability to offer quality machined castings for:

  • Wear components
  • Valve bodies
  • Casings
  • Split castings
  • Diffusers
  • Impellers
  • and other specialty components!

So, whether your castings were placed in a sand foundry or other materials used for castings, such a company must have the ability to offer you assembly, finish-machined, and semi-machined results.

What are machined castings?

Where to Get Quality Machined Castings

Therefore, it’s important to guarantee that exact measurements are achieved in machined investment casting, and Ferralloy Inc. has the experience and authority to provide this service and product to you.

As an industry leader, we are equipped and experienced in delivering high-quality metal components at competitive prices. Contact our metal component manufacturing company today to know more about our services!

Improvements in Equipment of Seamless Rolled Rings

The process of creating seamless rolled rings is one of the most fascinating and complicated parts in the realm of metal forging! Before advancements in technologies, ring-rolling systems were controlled manually by an operator who had to competently negotiate the proper working method.

However, as time flies, the advent of computerized control and modern hydraulics empowered industries to create more automated and precise metal products. To know that your metal products are designed and created with precision, we have outlined the basis of your standards.

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Factors You Need to Look into the Manufacturing of Seamless Rolled Rings

Essential Improvements

In every metal work, it’s important that manufacturers increase the speed and facility of their production, as well as the rate of productivity. Aside from the increase in these areas, it’s also essential to reduce the machining expenses  and requirements. As for the maintenance cost, it should be reduced without compromising the quality of the metal works.

To produce exceptional seamless rolled rings, the improvement must be made from time to time. For instance, the cavities of shaped tools must substantially be updated and improved according to the design. Likewise, the speed of every rolling cycle and accuracy of the machinery should be enhanced.

Preparation

To guarantee that the virtual ring-rolling plant performs and responds accordingly, a good preparation in the credibility and value of the statistically simulated results must be boosted. Additionally, increasing the energy efficiency and allowing the machine to be able to program most of the procedures provides for a more accurate result. 

where is the best seamless rolled ring forging

Quality Materials Used in Seamless Rolled Rings

Seamless rolled rings can be made from any forgeable material. These materials include alloy steels, stainless steel, carbon, Haynes, Inconel, super alloys, aluminum, and more. The ability to create seamless rolled rings out of a wide range of materials is one of the many reasons why it is such an appealing metal part.

Using seamless rolled rings can be very advantageous. At At Ferralloy Inc., our team guarantees that your needs, standards, and expectations are met.

Economic Advantages of Seamless Rolled Ring Forging

The process of seamless rolled ring forging involves the use of many different types of materials. These rings can be made of carbon, stainless steel, or alloy. Alloy steel contains an additional alloying material aside from carbon to improve the heat treat response or mechanical and physical properties of the rolled rings.

On the other hand, stainless steel material is used to create finished products that look elegant and can withstand rust and corrosion. Lastly, companies use carbon material to produce lightweight and heat resistant rolled rings.

what are the economic advantages of seamless rolled ring forging

How Cost-Effective is Seamless Rolled Ring Forging

Material Costs

Rolled ring forging can significantly reduce material costs! Typically, it uses fewer starting metal components to create the desired shapes. For instance, if the process requires a torch cut part, the complete center slug and entire corner stock are lost. With other forging processes, other parts are produced to a size that results in minimal waste.

Efficiency in Production

Using a rolled ring forging process, the same material can be created from several and various sizes of starting billets or ingots. It allows for a broader variety of inventoried material grades. The flexibility of the production process implies that forges materials of almost any grade can be designed and produced rapidly and more economically.

Reduced Reduction Rates

This type of forging eliminates or reduces rejections by yielding to enhanced structural integrity and using forging-quality materials. Additionally, the rolled ring forging process provides weld-free parts created with cleaner and quality material.

Machining Economies

Seamless rolled ring forging can likewise yield tool life advantages, lead time, and excellent machining. The reduced cost comes from forging a size that’s near its actual measurement instead of doing it with an alternative metal component like a bar or plate. With this type of process, it will require less machining to finish the product.

what are the economic advantages of seamless rolled ring forging

Get Seamless Rolled Ring Forging Products at Ferralloy Inc.

If you want to cut on production costs, seamless rolled ring forging is your best option. At Ferralloy Inc., we guarantee you that we only offer high-quality, engineered products.

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!

What Do You Know About Plaster Casting

Plaster mold castings are machined castings that combine gypsum and enhancing compounds to create a mold. A pure plaster is not very strong; therefore, a combination of plaster and additives are used to enhance castability, permeability, dry strength, and green strength. For instance, magnesium oxide or talc is sometimes added to reduce setting time and avoid cracking.

What are Machined Castings?

Everything You Need to Know About Plaster Casting

What is it Made of?

You’d think this was a simple answer – plaster, right? It gets a little more complicated. Machined castings are made in different ways. The plaster pattern is made of either metal or rubber. Next, it is often coated with an anti-adhesive material to avoid it sticking to the mold.

Molds are Inexpensive

Machined castings can get expensive and large. With plaster castings, it’s easy to change, reuse, and remold. They are also pretty affordable. If you want to get a machined castings quality product without gaps around the mold, and at an affordable price, plaster casting is the perfect option.

Plaster Casting Process

Machined castings require a lot of attention to detail to get the result you want. Once you have determined the parting line, or where the two halves of the cast meet, the plaster is combined and the pattern is covered with an anti-adhesive. The plaster is then poured into the pattern and shaken, allowing the plaster to fill the gap. Finally, it is left alone in the cast for about 15 minutes to set.

Once you feel comfortable with the mold, it is heated at high temperatures to remove all the excess water. As soon as the metal hardens, the plaster is removed from the cast and the finishing process begins.

What are Machined Castings?

Machined Castings that are Worth the Investment

The final step is the most fun! It includes blasting, heat treating, grinding and cleaning. If you want to get quality castings or talk to an expert, contact Ferralloy Inc. now!

Characteristics of Open Die Forging

Open die forging is a type of drop forging technique of deforming a metal according to the desired shape. Without any limitation, it can utilize pressure and power inflicted. Some experts even call it free forging since the process involves fewer restrictions. 

what are forged rolled rings?

Features of Open Die Forging

Simple Production Equipment

One of the most notable characteristics of open forging is that it requires only the necessary production equipment. Because of this, the production cost is lowered. In contrast with other forging processes, open die forging bar any possible defects such as porosity, gas holes, or shrinkage. 

High Mechanical Properties

Unlike closed die forging, this type of technique involves basic shaping and flexible operation. Because it uses higher mechanical properties, open forging always acts as an essential part of heavy-duty machinery.  

Manual Operation

Nowadays, forging techniques are controlled by manual operations. Another feature why industries purchase equipment made through an open die forging process is that manual operations hold the dimensions and net near shapes. Hence, the accuracy of product sizes has become relatively low. 

Main Equipment Used

Open forging primarily uses two main types of equipment. These are the hydraulic press and forging hammer. To be more specific, the steam hammer and air hammer are used. Also, a hydraulic press is used to reshape the metals into its desired form. It uses static pressure produced by a liquid solution. 

Production

Open forging uses both machines and labor to produce quality materials that are worth the investment. Because it uses work, the production cost decreases. Hence, open forging is a metal forging technique that’s suitable for single and accurate production.

what is closed die forging?

Learn More About the Open Die Forging Process

Open die forging involves numerous processes such as welding, cutting, mismatch, torsion, bending, etc. Also, it uses a technique called elongation. It is a process commonly performed to produce components for rod and shaft parts. 

If you want to know more about the forging applications and which product to choose, experts at Ferralloy Inc. will help you! Contact our experts today through this link!