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Understanding Forged Carbon Steel and Why You Need to Use It

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

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Advantages and Options of Carbon Steel

Advantages of Choosing Carbon Steel Forgings

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

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

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

Options of Carbon Steel Forgings

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

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Get Quality Steel Forgings

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

Basics of Classic Rolled Ring Technique

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

Hot Radial Rolled Ring

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

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

Cold Rolled Ring

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

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

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Looking for Highly Engineered Rolled Rings?

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

Why is Stainless Steel Used in Investment Casting?

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

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Nitty-Gritty Facts About Stainless Steel Casting

Common Material Grades Used

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

Application of Stainless Steel Castings

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

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

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

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Know More About Other Investment Castings

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

Benefits of Using Forged Rolled Rings

The forged rolled rings process begins with a heated circular mass of metal that is ready to be molded after being formed and pierced to form a hollow “doughnut”. This is then heated to a high temperature and placed over the mandrel roll.

The roller then moves under extreme pressure towards the constantly rotating drive roll that reduces the thickness, increasing the diameter of the final product. It can produce everything from flat washers to tall cylindrical parts.

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Process and Benefits of Forged Rolled Rings

What is the Process?

When it comes to the rolled rings process, it can be broken down into six steps. In the first step, the billet is cut to the proper size and is then upset to achieve the right properties. After that, the center is punched to create the ring that is rolled.

After the donut is ready for ring rolling, the ring is placed on an idler roll and is manipulated by axial rolls and the drive roll. The ring diameter slowly increases as more pressure is applied and once the desired size is reached, the process is done.

Benefits of Forged Rolled Rings

When it comes to this kind of forging, there are a lot of benefits. Given the rolled rings process, one of the biggest benefits is how strong the final product is. Any material that is forgeable can be used to make rolled rings.

That includes alloy, stainless steel, carbon, and aerospace metals. The ability to use several different materials makes them not only more cost-effective, but also allows them to be used in many different industries including power generation, chemical, and refinery industries.

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Where to Get Forged Rolled Rings?

Are you looking for state-of-the-art rolled rings that are processed with utmost precision and accuracy? Schedule an appointment today!

Why Use Alloy in Seamless Rolled Ring Forging

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

This additional alloying material creates steel fatigue resistance, as well as, strength and stability of the rings. Moreso, there are three diverse types of exotic alloys. Below is a short yet in-depth discussion of these types.

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Types of Alloy Rolled Rings

Waspaloy

It is a nickel-based superalloy with an age-hardening feature that gives this seamless rolled ring forging useful strength. This type of exotic alloy works best on provisions with solution-annealed conditions. Although it is a bit difficult to wield, it’s still known to be reasonably impermeable to oxidation and possess high-standard corrosion resistance.

Therefore, it is useful for functioning in extreme environments. Waspaloy alloy rings are often used in turbine disks, shafts, rings, seals, and gas turbine blades.

Inconel

This type of exotic alloy is a family of the non-magnetic stainless steels. They can sustain their structural integrity despite being exposed to excessive temperatures. Additionally, they are resistant to oxidation and are typically used in applications that need materials that yield corrosion caused by stress-corrosion cracking and high purity water.

Inconel is normally used in industries involved in commercial gas turbines, in making jet engine parts, chemical or food processing, and aerospace.

Hastelloy X

Hastelloy X is an alloy composed of molybdenum, iron, chromium, or nickel, making it both resistant to extreme temperatures and oxidation. They provide good ductility and are definitely easy to fabricate. These types of seamless rolled ring forging are found in the combustion zone parts of the gas-turbine engines like flame holders, combustor cans, spray bars, and transition ducts.

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Looking for the Finest Seamless Rolled Ring Forging?

Contact Ferralloy today for more information!

What Exactly are Stainless Rolled Rings?

Rolled ring forgings have several types such as stainless steel, alloy, and carbon. This article will explain what is a stainless rolled ring, its advantages, and why it is beneficial to use. If you are debating which forging material to use for your next project, you should consider stainless steel.

The many unique properties of stainless steel make it an excellent choice of material for all different types of metal components, specifically forged rolled rings.

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Knitty-Gritty Facts of Stainless Rolled Rings

What is it?

Stainless rolled ring forgings are steels that are known for being heat and corrosion-resistant. It often contains a small amount of 10% – 12% chromium alongside other alloy materials. These stainless rings are typically known as the best alternative to ASTM A276 & A240. Additionally, these are normally used for food and chemical processing applications.

What are the Advantages?

Just like any other stainless steel materials, stainless rolled ring forgings have a lot of advantages to offer. For one, there is no need for a thorough inventory since there’s no need for the stock plate in varying thicknesses.

Additionally, rolled rings offer superior structural integrity to achieve superior quality. Aside from this, it is also cost-effective and does not generate too much waste. With stainless steel, the length production and layout time and expensive handling are removed.

Moreso, stainless rolled ring forgings provide ease of fabrication and aesthetic appearance. The easily maintained and bright appearance of stainless steels grants your forged rolled rings a modern and attractive appearance. Likewise, stainless steel can be forged and machined as readily as traditional steels without sacrificing any of its unique advantages.

What are the Types of Stainless Steel Used?

To know which type of stainless rolled ring you want to use, it is essential that you know what are the types used. The common types used in stainless rolled rings are precipitation hardening (PH), austenitic, and martensitic stainless steel.

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Want to Know More About Stainless Rolled Ring Forgings?

Since the stainless steel used varies, it is imperative that you gain simple know-how of what it is and its applicability. Contact Ferralloy now to know more!

Seamless Rolled Ring Forging Process

If you’re keen enough, you’ll see that rolled rings are present anywhere you are. These rings are used in endless products and merchandise that you depend on each day such as drives, clutches, machines, gears, flanges, washers, bearings, and valves, just to enumerate a few. These donut-shaped items vary in sizes from large parts for about 9-ft. in diameter to smaller ones. How are these durable, versatile and highly sought after metal components made? Read on to know more about seamless rolled rings.

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Procedures involving Seamless Rolled Ring Forging

Completion of Forging Process

The billet or ingot is cut to the desired size then upset to attain the ideal mechanical properties. The center is then punched to mold a ring rolling donut. Once the preferred size is done, the donut-shaped part is now ready for ring rolling. After this, the process starts with ID & OD pressure applied to the ring part. Eventually, the ring diameters will increase as the pressure applied to the ID & OD increases. Axial rolls control the ring height. When the desired size is achieved, the seamless rolled rings process is complete.

What Materials Are Used for Seamless Rings?

Seamless rolled rings can be made from any forgeable material. These materials include alloy steels, stainless steel, carbon, Haynes, Inconel, superalloys, 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.

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Get Your Seamless Rolled Rings Today!

Using seamless rolled rings can be very advantageous. What makes these rings valuable is the fact the metal components are cost-effective, versatile, and strong. As a result, the product requires fewer machining operations, reduced weight, and lower costs for raw materials. Clearly, forgings have come a long way since 4000 BC. Start using the modern power of forged rolled rings for your next project by contacting us.

Ferralloy, Inc. is an international company that serves the global marketplace and offers competitively priced, engineered products that are produced in both North America and Asia. Connect with our forging experts online today to learn more!

The Basics of the Machined Casting Process

Whatever business you may be in, efficiency is always a good thing. It doesn’t matter if your industry is service or manufacturing-oriented. Countless process efficiency always provides a wide array of benefits above “business as usual.” Hence, it is always imperative to determine the ways on how to efficiently better the ways of production. Check out the process of making machined castings:

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The Machined Casting Process

The Basics

To attain various specific metal components, there are certain developments that the metal undertakes. For products like a machined investment casting component, it is required to undergo a procedure after the part is cast known as machining. Aside from knowing what machining is, there are numerous diverse tools and processes within machining that are precise to the component and its purpose. Depending on what the machined investment casting components will ultimately be used for, the type of machining it undergoes could vary.

Pay Attention to Part Details

To cast better aluminum, use fillets in place of sharp corners. Disparity shrinkage at the sharp corners will lead to persistent shrinkage porosity, which may develop during the machining process. Gussets and ribs must be used in place of immense sections. A regular blending of light into substantial sections is suggested.

Understanding the Lifespan

If you think that aluminum die casting is the perfect option for your production requirements, you should know by now the maintenance and lifespan than aluminum die casting require. Since the life of the die is difficult to determine since it is heavily dependent on several factors, you’ll need to keep a selection of aspects in mind, which includes the desired part quality, aluminum alloy utilized, heat treatment, mold configuration, and tool steel used.

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Know More about Machined Castings

Ferralloy, Inc. is an international company serving the global marketplace, offering competitively priced, engineered products produced in North America and Asia. Schedule an appointment today!

What Materials are Used to Make Closed Die Forgings?

Although closed die forging is enforced for almost all the metal materials, especially in physical production, only a portion of the materials is used for several characteristics. The prevailing materials used are one of the main factors that affect the cost of the forgings. Check out the prevailing materials used in closed die forgings to determine which best suits your goal.

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Different Closed Die Forging Materials Used

Brass or Copper

Brass or copper is also popularly used in closed die forging, which is the most expensive of the common materials that will be discussed. Brass or copper forging is more often than not the most frequently used material for pump and valve fittings.

Aluminum

This type of material is commonly used by forgers because of its easy machining, high strength, and low density. It is extensively used in the closed die forging process, particularly for the aerospace and automotive industries. While it is commonly used in the automotive and aerospace industries, it is a daring process for domestic forging due to the fact that it is straightforwardly deformed after forging. However, the typical heat treatment can assist in the hardness improvement of other properties.

Steel

Among the prevailing materials used in closed die forging, steel is by far the frequently used material due to its quality and durability. Stainless steel, carbon steel, and alloy steel are all used subject to what the forging will be used for. Carbon steel and alloy steel are the most extensively used in forging because of its easy deformation capability and competitive price.

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Do you Need More Information About Closed Die Forging?

One of the best things about forging is its versatility and adaptability 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 easily produce them. If you need more information about open and closed die forgings, Ferralloy, Inc. is the leading global supplier of engineered products and services to a diverse metalworking customer base. Schedule an appointment with us now to know more!

How are Seamless Rolled Rings Used in Aerospace Industry?

Seamless rolled rings come in a variety of sizes and shapes depending on what they are being used for. They are typically rolled by a process called ring rolling. Ring rolling is done on rolling mills. They can be produced in configurations ranging from flat, washer-like parts to tall, cylindrical shapes, with heights ranging from less than an inch to more than 9 feet. Additionally, these rings are now used in the aerospace industry. Below are the facts you need to know.

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Aerospace Industry and Seamless Rolled Rings

How are they Linked?

The aerospace industry is that type of industry that leaves unequivocally zero room for error. It requires impeccable precision and precise tolerance. Discs, forging rings, and seamless rolled rings to aid in powering helicopter rotor and jet engine assemblies. More so, the forged rings offer greater strength than a flame-cut plate, castings, or weldments, creating them to have the ideal fit for aerospace companies.

How does Seamless Rolled Ring Forging Work?

The process of producing seamless rolled ring forging begins with a circular preform of metal that was previously upset and pierced through the open die forging process to create a hollow donut-shaped component. The heat that is above the recrystallization temperature is applied to the donut before it is placed on the mandrel or idler roll. The donut is continuously rotated as the idler roll is moving under pressure toward a drive roll. As the donut is being rotated, its wall thickness is being reduced and its diameters are being increased.

Benefits of Seamless Rolled Rings

Seamless rolled rings have been used by different industries for a number of reasons. 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 a lot of 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. Furthermore, these rings can maintain their strength despite the fluctuating temperature.

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Do You Need More Information About Seamless Rolled Rings?

If you’re curious to know more about the benefits that seamless rolled rings forging has in store for you, contact us today!