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How Are Steel Forgings Made?

Steel forging involves the heating, deforming, and polishing of steel to create a durable and precise material. These materials are created by forcing materials into customized shapes, either by the die press surrounding a piece of metal or forcing such metal into custom-built patterns. Steel forgings have a broad range of properties and can use different types of materials.

steel forgings made

Properties of Steel Forgings

Limit on Size

Throughout the forging process, shaping a certain type of metal can be very difficult. The reason for this is that forging transpires while the metal is still solid. Because the metallurgists engaged in this project will have a bit of a challenge in altering the shape of the metal, there is a limit on the thickness and size. Hence, the larger the steel section being worked on, the more difficult it is to forge.

Consistency

The great thing about steel forgings is that there is consistency. Because the procedures are deliberate and controlled, each forging goes through the same processes. With steel forgings, it is ordinarily possible to guarantee a consistent material.

Anisotropic

As for the strength of steel forgings, it is not consistent throughout the process; instead, it is anisotropic. In physics, anisotropic is defined as a difference in a material’s physical or mechanical properties. This means that when the steel is worked on, deformation typically occurs.

Durable and Strong

This type of forging produces results that have exceptional strength and are generally tougher than steel produced through other means. Since steel is less likely to break and get altered in contact with other materials, it is often used by industries that require tools and components with increased durability and strength.

steel forgings made

Where Can You Get Steel Forgings?

Steel forgings are widely used by many companies, such as those in the mining, electronics, and aerospace industry. If you’re looking for quality steel forgings, you can give Ferralloy Inc. a call!

The History of Forging

Ever wondered how open die and closed die forging began? The art of forging emerged around 4,000 B.C. – some even say that it began way before this time. Metals like iron and bronze were forged to produce hand tools and other weapons for defense. However, the earliest recorded metal forged by early generations was made out of gold. If you want to know more about the history of forging, please read on.

closed die forging

Centuries of Forging Developments

Before the 19th Century

Limited amounts of natural gold were found in Spanish caves and were said to be used as tools and weapons in the late Paleolithic period. The forging of steel and iron continued in the 19th century and its improvements became the pillars of what has become of today’s forging processes.

19th Century

Forgers and other experts on the forging process were specifically skilled at hand, especially when it comes to open die and closed die forgings. Since bent and twisted iron can only be produced in high heat, the forgers became dexterous in hammer welding and several large shaft forgings.

In 1856, the emergence of the Bessemer steel-making process became a breakthrough in the history of the forging process. People now have an abundant supply of low-cost steel for creating and designing large quantities of forgings.

Historians say that the first cavity steel forging began with the help of the closed die process. It commenced in the United Stated in 1862.

20th Century

The Industrial Revolution and World War II both lead to the development of better forging equipment and processes. Eventually, electrical motors and induction heaters enabled forged rolled rings to be produced quicker, easier, and more effectively than ever before.

closed die forging

Know More About Closed Die Forging

Clearly, forgings have come a long way since 4,000 B.C. Start using the modern power of forged rolled rings for your next project by contacting our accommodating staff at Ferralloy Inc.

Get Raw Materials with Ease

Engineering production units use numerous types of raw materials in their operations for giving an exceptional shape to a new product. Occasionally, it becomes a big challenge to get the essential goods in local markets due to high demands, costs, and other factors. This concern normally affects the entire manufacturing process which results in different problems. Nowadays, global sourcing allows manufacturing companies to attract various organizations which mainly depend on engineering products.

global sourcing

Why is Global Sourcing Essential?

Purchasing Raw Materials is Made Easier

Global sourcing allows manufacturing companies to purchase various types of materials from other countries to enhance their production levels. There are numerous suppliers who provide supply chain management services for a lot of industries to gain major benefits. With this method, engineering firms can focus more on reducing costs on their labor and raw materials for achieving the best results.

Nonetheless, it is important to research the suppliers from the internet before choosing services.

Materials Often Subjected to Global Sourcing

It is essential to know how to purchase the materials needed from other countries that will ultimately help you overcome complex issues. Below are the materials often purchased through global sourcing.

Zirconium

It is a silver-gray metal used in ceramic industries, food packaging, furnace linings, and other applications. Zirconium is a highly resistant product that gives ways for meeting exact needs in the manufacturing process.

Inconel Alloys

These are often purchased by chemical manufacturing companies to improve the structure of a product at maximum temperature.

metal global sourcing

Global Sourcing Keeps the Process Going

Most of the time, companies engaged in casting and forging processes are the ones who greatly benefit from global sourcing. Since these procedures use different kinds of materials, easy access can keep things going. If you want to know more about the benefits of global sourcing, contact Ferralloy Inc. today!

Steel Castings vs. Cast Irons: Which is Better?

Among the most ideal ways to make lasting and quality components are through castings. It allows for a high level of detail, which results in not needing additional fabrication or assembly. When it comes to rolled ring forgings, steel and iron are the two most popular due to their exceptional mechanical properties for a vast range of applications.

Keep reading to find out which is best suited for your specific application!

rolled ring forgings

How Do Steel Castings and Cast Irons Differ?

Steel Castings

Steel castings are components that are formed by pouring molten steel into a mold cavity. The liquefied steels then cool and solidify within the mold. You can create the shape and the casting to perfectly fit your specifications. Although the casting process of steel can be difficult, the results are well worth it.

Moreso, steel castings are mainly used when other types of cast irons do not have enough strength or shock resistance. Its physical properties allow the castings to be both strong and ductile, making it extremely tough. Also, it limits the chances of fracturing under pressure.

Industries that use steel castings range from food processing and electronics to oil and gas. Some specific industries that use this type of casting include the railroad, construction, drilling, transportation, and mining industries

Cast Irons

When it comes to corrosion, iron has better corrosion resistance than steel. It is also often cheaper because of the lower material costs, energy, and labor required to produce a final product. Additionally, cast iron is relatively easy to cast–it pours easily and doesn’t shrink as much as steel.

rolled ring forgings

Other Substances Used in Rolled Ring Forgings

If you don’t know what to use for your next project, allow our team at Ferralloy Inc. to help you decide. Schedule an appointment today for more information about cast irons, steel castings, and other metals used in rolled ring forgings.

Properties and Categories of Steel Forgings

There are various materials that can be used to create forged parts and components. Inconel, cobalt alloys, titanium, nickel, and steel are just a few of the innumerable forging materials. Which one you choose all depends on the specific application of your desired part. Below are the properties and categories of steel forgings you may want to consider for your next project.

steel forgings

What Are Its Properties?

Discussing the properties of steel forgings will give you an idea as to why it’s so commonly used. Because of the properties forged steel possesses, everything is made easier and more precise. Its properties are a bit unique when compared to steel casting.

Range and Uniformity

Although there are some limitations as to the thickness and size of the forgeable steel, it can still precisely follow the design’s consistency. Every forged steel that is manufactured undergoes an accurate and meticulous process that guarantees optimal results.

Persona and Solidity

Most experts say that when a metal is anisotropic, its strength tends to be unpredictable throughout the forging process. Such a persona of steel makes it easier to produce a good resulting grain flow during the fabrication method.

As for its solidity feature, steel forgings are known for their first-rate durability, greater toughness, and superb strength. When it comes in contact with other metals or substances, it is very unlikely to shatter.

What Are Its Categories?

Steel forging can be categorized into two main types:

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 the inflicted pressure and power.

In contrast, closed die forging relates to a process in which a metal is placed between shapes customized to fit the metal. Such metal is then pressed and hammered, causing it to fill and flow in the cavities of the custom-shaped dies.

steel forgings

Learn More About Steel Forgings

At Ferralloy Inc., our commitment to high-quality engineered products and services is evident from our diverse metalworking customer base. For more inquiries, contact our experts through this link!

Forging Rings with Alloy Steel

Forged rolled rings are an incredible metal part for countless applications in numerous industries. While forging rings may be easy, selecting which material to make them out of is not. If you are debating which forging material to use for your next project, you may consider using alloy steel. The numerous properties of alloy steel make it an excellent choice of material for different types of metal components, specifically forged rolled rings. What are the benefits of forging rings with alloy steel? Keep reading to find out.

What are forging rings?

Advantages of Using Alloy Steel

Excellent Seamless Rolled Ring Results

When your clients demand more vigorous seamless rolled rings, using alloy steel materials is the best way to achieve excellent results. Molybdenum, nickel, chromium, and manganese are only a few of the many elements used to enhance the performance of alloy steel after the tempering and quenching process. With alloy steel, finished products possess the following features. However, these features may still depend on the manufacturing and chemistry procedures implemented.

  • Corrosion Resistant
  • Toughness and hardenability
  • Good machinability
  • Tolerates high and low temperatures
  • Wear-resistant

Comprehensive Grain Flow and Internal Structure

Using alloy steel in the forging process offers full circumferential grain flow and excellent internal structure. The process can produce exceptional mechanical properties with the ideal surface smoothness and concentricity.

Aesthetics and Durability

Alloy steel can resist scaling and retain strength even in the highest temperatures. This metal alloy can withstand extreme environments and impacts while still performing its fullest ability. Likewise, forging rings with alloy steel create rolled rings that have high stability and strength.

Additionally, alloy steel can be forged and machined as readily as traditional steels without compromising any of its unique advantages. Lastly, the easily maintained and bright appearances of alloy steel provide forged rolled rings a modern and attractive appearance.

What are forging rings?

More Information about Forging Rings

At Ferralloy Inc., we guarantee that the products you purchase are manufactured by industries that prioritize quality. Schedule an appointment today with our team if you want to know more about the materials used in forging rings.

Achieving Excellence in Global Sourcing

Skillful labors and low-priced raw materials are primarily why companies opt for global sourcing. With these factors achieved, it becomes more cost-effective and favorable for the company. Nevertheless, global sourcing can also provide you with several challenges. Here are some tips to achieve excellence in global sourcing.

What is global sourcing?

Factors to Consider in Global Sourcing

Competitive Advantages

When choosing global sourcing, you must balance the impact on the company’s competitive advantages. For instance, one of the most essential aspects of this factor is the protection of product quality and intellectual property. If you think your company believes that its intellectual property is entirely important, then you should be very selective about your global suppliers. The more you depend on your proprietary information on other companies, especially when it comes to the specifications of your products, the greater the risk of losing it.

Moreso, if your competitive advantages are focused on achieving lower costs, it is critical to guarantee there are no hidden charges. Thus, you need to make sure there is no hidden cost so you can dispose of any realized cost advantage.

Monetary Risks

While the use of global sourcing can lower the cost because of the proximity of raw materials and lower labor costs, there are still monetary risks that can affect it. These risks include the expenses related to time zone differences, costs of transactions, and unanticipated increase in shipping costs. However, there are several financing tools available to global sourcing companies to offset these monetary risks such as forfeiting, factoring, and hedging against currency fluctuations.

Characteristics of the Raw Materials

Several aspects of the premeditated procurement process are distressed and overwhelmed by the characteristics of raw materials and other components. You will have to consider whether the modifications be made before or after the materials are sold, limitations of the supply of raw materials, and if goods are imported as components for manufacturing or simply in raw materials.

What is global sourcing?

Learn More about Global Sourcing

Ferroalloy Inc. is a global sourcing company that understands what its competitive advantages are and all other factors. If you want to enhance, protect, and utilize your company’s best interest, contact us 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?

where can i get iconel?

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.

where can i get iconel?

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!