Contact Us: 1-440-250-1900

Rolled Ring Forgings | What Is the Process?

Rolled ring forgings are used in a wide range of industries. Rolled ring forgings are an appealing metalworking option thanks to their strength, versatility, and cost effectiveness. But how do they get that way? Rolled rings are able to hold so many advantages thanks to their forging process. Keep reading to find out everything you need to know about this metalworking method!

3 Steps of the Rolled Ring Forgings Process

The forging process performed to create rolled rings is extremely difficult and complicated. To help make it easier to understand, we broke it down into 3 simple steps.

Step 1: A thick and circular piece of metal is heated. It is then pierced to form a hollow ring. This ring should somewhat resemble a donut.

Step 2: The ring is heated to recrystallization temperatures. It is then placed onto an idler roll. Squeezing, stretching, and in some cases, pounding, then occurs until it forms into a thin ring.

Step 3: The shaping on the idler roll continues until the forgings possess the desired diameter and wall thickness.

This is the process that creates rolled ring forgings. The final ring products can range from tall cylindrical shapes to small washer-like parts. They can be created using basically any type of metal or alloy. The diameters can range from 1 to 300 inches. Weights can range from 1 to 3000 pounds. No matter how complex or customized the shape is, the rolled ring forging process creates extremely dependable and sought after parts. Some specific components include valves, bearings, flanges, gears, clutches, drives, and so on.

If you need rolled ring forgings for your next project, we can help. Ferralloy, Inc. is the best in the metalworking industry. We provide high quality, competitively priced metal components to a variety of industries throughout the global marketplace. Visit our foundry online today to learn more!

Ferralloy, Inc. Ships Seamless Rolled Rings

The company shipped two seamless rolled rings produced from 4140 grade alloy steel to a customer in the industrial processing industry today.  The customer in California is rebuilding a processing equipment machine which required two 78″ OD x 72″ ID x 5″ High machined to size.

Ferralloy, Inc. produced the seamless rolled ring forgings and then machined them on Vertical Turning Lathes to complete the requirement. 

Rolled Ring Forgings are available up to 110″ diameter in rough or finish machined form.

seamless-rolled-ring-shipment

Closed Die Forging | What is Closed Die Forging?

Forging is a favorable and effective manufacturing process. It is able to form high quality metal components for countless industries. Forging is able to do this because it can be subdivided into specific forging processes. The forging process used depends on the specific needs of the project. Closed die forging is one of the many types of forging. Keep reading to find out the process, advantages, and applications of closed die forging!

What Is Closed Die Forging?

Closed die forging is a forging process. It is sometimes referred to as impression die forging. This process involves two or more dies that contain a precut profile of the desired component. The heated raw material is placed at the bottom of the die. The dies then move towards each other until the raw material is formed into its required shape and size.

Why Is It Used?

Most metals and alloys can be forged through the closed die process. Closed die forgings of steel, stainless steel, titanium, aluminum, and other alloys can produce an unlimited variety of 3-D shapes in a wide range of weights and sizes. As a result, this is one of the best processes for complex shapes that require elaborate designs.

What Are Its Applications?

Closed die forging is used for applications that require high quality components. People turn to closed die forgings when their project requires strength, reliability, and resistance to fatigue. Because of this, closed die forging is an appealing manufacturing process for numerous industries. Some specific parts that are formed by this type of forging can be found throughout the automotive, aerospace, and defense industries.

Ferralloy Inc. can meet any and all of your forging needs! We’re a leading global provider of forgings to major companies in numerous industries. We produce rolled ring, cold headed, open die, and closed die forgings in a variety of alloy steel grades. Connect with our metal manufacturing company online today!

What Is the Difference Between Castings and Forgings?

There are several different methods and techniques that can be used in manufacturing a variety of different metal components. Based on the purpose and ultimate use of the metal part, different procedures are used to create the highest quality piece possible. While determining the best process, some arrive at the question of whether they need castings or forgings. Which would be more effective for their metal component and most cost effective? Keep reading to find out the differences and find out which process would be more beneficial to your business!

What Are Castings?

Valve Sand Castings

The casting process is where the metal is heated until molten and then poured into a die to form a specific shape. This process is beneficial when the shape of the component is intricate or when the component needs to be a very large size. Another advantage of castings is that machining costs can sometimes be cut down because the component can be made to certain specifications.

What Are Forgings?

Forging is a technique where metal is heated up and then hammered and manipulated into the final desired shape. Forgings are generally stronger than castings, but there are some limitations to manufacturing capabilities of forging. Components can not be very intricate or complex when forging. Usually if a component needs to be forged and also needs to meet certain size requirements, the component needs to be machined after it has been produced.

Are Castings or Forgings Better?

Which metal component production method is better? This will completely depend on what the component will ultimately be used for. Both castings and forgings have their advantages, so depending on what the component will be used in will determine which production method will serve you better. If you have questions about what type of metal component you should be purchasing for your company give Ferralloy, Inc. a call today! We are metalworking industry leaders and have the technical authority to deliver the highest quality castings and forgings! Whatever your metal need is, we can meet it and exceed your expectations!

Dryer Drum Tires

Ferralloy, Inc. is shipping 2 sets of rolled ring forgings to a customer in the cement industry.  The seamless rolled rings sets are 80 x 70 x 7” and 78.5 x 72.5 x 6.5”, rough machined to a surface finish of 125 RMS from 4140 material.

Rolled ring forging process is a specialty of Ferralloy Inc!

These forged rings are components of a dryer drum used in the cement industry to process cement powder.

For more information about the processes behind cement manufacturing see this link!

Steel Forgings | What Are the Different Types of Forgings?

To create the high quality and durable steel forgings ordered by our customers, Ferralloy employs different processes depending on the component specifications. One of these processes, Forging, can be subdivided into more complex processes that are utilized according to what the metal piece will need to become. What are the most popular types of forging?

Steel forgings from Ferralloy Inc are high quality components

Open Die Forging

The reason that this process is referred to as open die forging is because the metal is not confined by any impression dies during the forging process. The process uses hammers and different tools to press and pressure the metal into the desired shape of the steel forgings. Open die forgings usually result in irregularities between the different steel forgings because there is no impression that all of the forgings are being molded into. To achieve the correct, final dimensions, the metal normally has to be machined.

Impression Die Forging

This is the opposite of open die forging, also commonly referred to as closed die forging. Where the metal is shaped in the open in open die, in impression die forging there are two or more dies that contain impressions that are brought together around the stock and causes the deformation into the desired shape. In closed die forging the steel forgings can be shaped into more complex components because of the dies that are used to form the metal.

Seamless Rolled Ring Forging

In some ways, this forging process combines elements of both open die and impression die. The metal stock is pierced to create a donut and then shaped, in a somewhat open forging process, into a ring. The rolled ring forging process is used to make high pressure resistant steel forgings, such as gears, engine bearings for aircrafts and flanges, to name a few.

Whatever steel forging or metal component you need, Ferralloy can manufacture it and deliver the highest quality product to your specifications. We are a metal working industry leader, employing the latest technologies to manufacture your metal components at competitive prices. Contact us with any and all of your metal needs today!

Forgings | Difference Between Hot and Cold Processes

 As a company focused on providing only the highest quality metalwork products to the companies and industries in need of castings, forgings and machining goods, we understand the importance of all the different types of processes involved in developing these products. We stay at the forefront of advanced techniques in the production of fabrications relating to the metalworking industry. One of these processes is forging and in this following post we will examine the differences between the different types of metal forgings available for producing high quality metal workings.

What is Forging?

High quality forgings can be found at Ferralloy Inc

It is a good idea to begin with what “forging” is in respects to our metalworking industry. Forging is the process in metal works manufacturing where the metal is pressed, pounded or squeezed under great pressure into different unique parts, known as “forgings”. The metal used in this process is never melted, as it is in other processes relevant in this industry, and the process can be done using different techniques and temperatures; hot and cold.

What is the Difference Between the Different Types of Forging?

The difference between the different types of processes is the temperatures and the effects that the temperatures have on the process and forgings. First, cold forging involves impression die forging or true closed die forging with lubricant or circular dies at room temperature. In cold forging it is easier to impart directional properties, there is increased dimensional control and it handles high stress and high die loads. In this process, little to no finishing work is required and so it helps saves on the costs side of the product manufacturing. But on the flip side, this process is generally restricted to simple shapes being produced in high volumes.

For more complex shapes and configurations, hot forging is required. The metal is deformed at a high enough temperature so that the recrystallization occurs simultaneously with the deformation in order to avoid strain hardening. In order to avoid oxidation of certain metals, a process refereed to as isothermal forging is used, and it simply refers to the deformation taking place in a vacuum. This forging technique allows for a more customized component production, however with this method there is a loss in precision for dimensional tolerance in the process.

Essentially, when manufacturing a metal fabrication is important to consider the desired component and required functionality of the component when determining which forging method to utilize. At Ferralloy we supply high quality products and services to a wide range and diverse metalworking customer base. We are experts in the metalworking industry and can manufacture forgings to your exact specifications. Contact our metalworking supply company today if you have any additional questions on the types of manufacturing processes or products necessary for your metalworking business.