Contact Us: 1-440-250-1900

Forged Rolled Rings for Quality Products

Forged rolled rings offer several advantages, such as using less material to be machined to achieve the final product. However, one of the most notable factors why industries opt for this type of process is the intricate process involved in producing the final product.

What are forged rolled rings?

Process and Advantages of Forged Rolled Rings

Process

In the forged rolled rings’ manufacturing process, the waste of the metal that is punched out is prevented, and the metal piece is forged to become stronger and more durable. A donut shape is formed from metal and then forged into the metal ring that is desired.

The size and diameter are shaped from this donut-shaped metal as it reaches extremely high temperatures to the point that it becomes malleable. This process saves metal waste due to the ring being punched out, making it more cost-effective. Aside from being cost-effective, forged rolled rings can provide strong and durable metal components.

Advantages

  • 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.
  • Reduced Reduction Rates – This type of forging eliminates or reduces rejections by yielding enhanced structural integrity and using forging-quality materials. Additionally, the rolled ring forging process provides weld-free parts created with cleaner and quality material.
  • 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 wider variety of inventoried material grades. The production process’s flexibility implies that forges materials of almost any grade can be designed and produced rapidly and more economically.

What are forged rolled rings?

Looking for Forged Rolled Rings

Companies or manufacturers who use the forged rolled rings process can maintain constant durability and strength. Hence, clients who purchase these items are more likely to have worth-the-investment purchases. Contact Ferralloy Inc. to get forged rolled rings!

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!

Seamless Forged Rings for Bearings

From drive transmission to gearboxes, producing seamless rings is crucial to provide a quality product. At Ferralloy Inc., we guarantee the manufacturers of these seamless rings tightly control the processes and chemistries of production to decrease residual stresses. Furthermore, this will enhance the mechanical properties of the bearings and other custom gears.

What are seamless rings?

Why Opt for Seamless Forged Rings Process?

Quality Standard and Inventory

For bearings or gears ranging up to 125-inch OD, seamless ring manufacturers are devoted to addressing every challenge that comes their way. Backed by the resources and support of exceptional forging manufacturers, we will work closely with you to provide optimal forging products according to your standards. The rings provided by our partners have been used in different applications such as helical gears, herringbone gears, spur gears, sprockets, couplings, clutches, ring gears, internal gear, and spiral or straight bevel gears.

When it comes to inventory, our manufacturing partners carry a comprehensive inventory of raw materials. Through this accessible inventory, delays associated with order processing are eliminated. And because of this, we can provide you with a quick reaction when it comes to market fluctuations.

Exceptional Processing

To guarantee conformance and quality products that perform precise testing according to every customer’s specific standard, we only partner with manufacturers that are ISO 9001:2015 certified. Moreso, these manufacturers’ exceptional processing can provide a complete range of secondary processes for every gearing industry client. The downstream processing includes non-destructive testing, destructive testing, shot blasting, saw cutting, machining, hardness testing, and heat treating. Segmenting, splitting, and parting processing are also made possible.

What are seamless rings?

Looking for Phenomenal Seamless Rings?

Having achieved ISO 9001 certification in both locations, we are a quality-driven organization committed to process improvement and providing engineering support, customer service, logistics, and inventory management services. At Ferralloy Inc., we have excellent product groups that can provide you with quality parts and components that have undergone quality control to comply with first-rate standards. To get quality parts, book an appointment today through this link!

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.

Advantages of Carbon Rolled Rings

Are you interested in utilizing the advantages of carbon rolled rings for your next project? If yes, contact Ferralloy, Inc., because our team can supply you with rolled ring forgings in diameters up to 110” and in various materials ranging from carbon to stainless steel.

where can i find rolled rings?

What Benefits Can Carbon Rolled Rings Offer?

Economical

When using carbon in the rolled ring process, the forged components made from this material tend to be cheaper than other rolled ring materials. Additionally, there are excellent forging tools to enhance the manufacturing process’s efficiency. Aside from being economical, it may considerably reduce the waste produced during the process.

Production of Various Shapes

To produce various shapes of forged components, it is required that the forging process also involves different methods. Since carbon steel forgings are incredibly flexible, it is easier to create them in different shapes. The most common shapes produced by this rolled ring process are hubs, discs, blocks, seamless rolled rings, and flanges.

Challenging Applications

Forged materials are enforced to play a critical role in various challenging applications such as pressure vessels, power generators, aircraft components, and oil rigs. The capacity of carbon rolled ring products to tolerate resistance makes them an excellent option for such applications. Additionally, the forged components produced are available in different sizes and grades.

Metal Grades

Aside from different sizes and shapes, carbon rolled rings have four distinct grades. These metal grades significantly differ from one another on the basis of their hardness, endurance, wear, and strength. This allows companies, using forged components, to choose a category that ideally suits their standards. While there are several alloys that can provide industries with various metal grades, no other alloy can provide the versatility of carbon rolled rings.

where can i find rolled rings?

Where to Find Carbon Rolled Rings?

If you’re one of those industries that want to purchase and secure quality carbon rolled rings, you can contact Ferralloy Inc. today!

Titanium Seamless Rolled Ring Forging

A process used widely and performed to the highest level by Ferralloy is seamless rolled ring forging. It plays an important role in the manufacturing of certain components. Forging is a method of manufacturing inherently stronger components for machinery.

When apparatuses are needed to develop wind turbines or high-quality gears are required for mechanical parts, the ring forging process is used to manufacture superior pieces. The forging process uses different metal and alloy types to comply with the highest standards – among the most commonly used is titanium.

what are seamless rolled ring forging?

Why is Titanium Used in Seamless Rolled Ring Forging?

Applications

Titanium can be used for a wide range of metal parts, from tubing to bolts to fasteners. And this metal alloy is used for good reasons. The list of titanium benefits is a long one. Titanium seamless rolled ring forging is applied in water treatment, desalination, power generation, marine, chemical processing, aerospace military, and medical technologies.

Features

Aside from the fact that titanium rolled ring forging has many applications, its features are exceptional. It provides efficient low thermal expansion, low elasticity module, non-toxic and non-magnetic, high melting point, exceptional oxidation capabilities, and exceptional bearing to cryogenics property. Other notable features are:

  • Excellent corrosion resistance
  • Outstanding strength-to-weight percentage
  • Low density
  • High-heat resistance

Main Properties

What makes titanium a special forging material is its properties. According to forging experts, the following are titanium’s main properties that make it an exceptional material for forging processes.

  • Hydrogen storage
  • Superconductivity
  • Shape memory
  • Low damping resistance, modulus of elasticity, thermal conductivity, non-magnetic, and density
  • High-temperature easy oxidation, strength, and heat resistance

Likewise, titanium rolled ring forging offers tensile strength close to yielding strength, good performance at low temperatures, and exceptional corrosion resistance.

what are seamless rolled ring forging?

Where to Look for Titanium Seamless Rolled Ring Forging

Are you interested in using these metal components for your next project? At Ferralloy Inc., we are a quality-driven organization that is committed to constant improvement and customer satisfaction.

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!

Plate Burnout versus Rolled Ring Forging

Rolled ring forgings are needed for several types of applications. The use of metal components may vary in size, thickness, and diameter. If you want to achieve a strong, durable, and cost-effective metal ring for your project, there are forging processes you need to be aware of. These processes include rolled ring forgings and plate burnout. Keep reading to learn the differences between the two to manufacture a metal ring.what are rolled ring forgings?

Difference between Plate Burnout and Rolled Ring Forging

Rolled Ring Forging

In the manufacturing process of seamless rolled ring forging, the waste of the metal that is punched out is prevented, and the metal piece is forged to become stronger and more durable. A donut shape is formed from metal and then forged into the metal ring that is desired.

The size and diameter are shaped from this donut-shaped metal as it reaches extremely high temperatures to the point that it becomes malleable. This process saves metal waste due to the process when the ring is punched out, making it a more cost-effective process. Aside from being cost-effective, rolled ring forging can provide strong and durable metal components.

Plate Burnout

As for the plate burnout process, it involves many processes in which a metal ring can be achieved. Just like rolled ring forgings, the process begins with a plate of metal. Once the component specifications are determined, the plate is punctured in the metal ring’s shape and size. This type of method makes the metal ring more susceptible to fatigue because the plates are exposed to extreme heat and pressure.

what are rolled ring forgings?

Determine Whether Plate Burnout or Rolled Ring Forging is the Best Process for your Project

For all of your metal manufacturing needs, Ferralloy Inc. has the authority and experience to help you. Our industry leaders in metalworking can suggest the best methods for manufacturing your metal parts and components at competitive rates. We are dedicated to producing and delivering the highest quality products to fulfill your project in the best manner. Contact Ferralloy Inc. today to inquire about your metalworking needs!