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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!

Machined Forgings | What is Machining?

When working with foundries to order the manufactured metal components you need, there may be several options offered to you for your specific piece. To deliver a completely finished and high quality product, Ferralloy offers machined forgings to the customers who require this value added service. Our efficient and established processes can produce premium machined forgings. Find out more about machining below!

What is Machining?  

Machining is a manufacturing process in which a metal component is cleaned up to the specific measurements that companies require them to be. After the forging process the product that is produced is a rough shaped component. For some applications it is important for the forging to be exact measurements and exact shapes and this is where the machining process comes into play. With several different tools and techniques, the component is perfected through the machining process. There are several different tools available to use during this process, including boring, cutting, drilling, grinding milling and turning tools. There are also different types of cutting techniques like laser, plasma and oxy-fuel cutting.

What are Machined Forgings Applications?

There are several industries where machined forgings are required, including, in particular the aerospace industry. In order to manufacture vehicles in which will be utilizing the laws of physics to fly in the air, there is a specific science behind it. The pieces used in such aircrafts need to be manufactured to precise measurements in order for the product to function correctly. Machined forgings are just one of the components used in the aerospace industry.

Closed Die Formed Machined Forgings

At Ferralloy we supply high quality products and services to a large range and varied metalworking customer base. We are experts in the foundry industry and can manufacture machined forgings to your exact specifications. Contact our metalworking supply company today for more information about our product selection and manufacturing capabilities! We can help supply your company with the metal components you need!

Inconel Alloys | Uses and Characteristics

With all the different applications that metal is used, different characteristics are needed for each use. The wide array of metals available to be manufactured into the component or part needed for a project allows companies to get the metal that has all of their specifications in order to serve their purpose in the most effective way. One such metal that many industries use is Inconel alloys. What is it? Why is it used? Keep reading to find out!

Inconel alloys have many applications because of its unique properties

What are Inconel Alloys?

This is a metal from the nickel chromium family. Inconel is considered a super alloy and special metals with specific applications. It has several characteristics that make is a desirable metal. Inconel alloys are resistant to corrosion which makes it suitable for some extreme environments. It is also resistant to oxidation and can withstand high temperatures. When it is exposed to heat, Inconel forms a layer to protect the surface from heat and other damage. It is not only heat resistant, but maintains its strength when heated. Its high temperature strength is thanks to solid solution strengthening or precipitation strengthening, depending on the alloy variety. This material is also resistant to pressure which makes it perfect for extreme applications.

What are Inconel Alloy Applications?

Due to all of these characteristics, Inconel alloys can be used for a wide variety of applications, including sea-water applications. The properties of Inconel alloys make it perfect for propeller blades, submarine quick disconnect fittings, submarine auxiliary propulsion motors, steal-line bellows and more.  It is also widely used in the aerospace field for aircraft ducting systems, engine exhaust systems, hydraulic line tubing and heat-exchanger tubing in environmental control systems.

Whatever your application may be, Ferralloy Inc can supply you with the highest quality metal components! We are industry leaders, providing you with parts at competitive prices and in quick turnaround time. Inconel is just one of the many metals we supply and work with, so give us a call at 440-250-1900 or visit our foundry online today!

Furnace Rolls | What is Carburizing Furnace?

When you are in need of metal components, like furnace rolls, Ferralloy takes the time to learn and understand what your needs are in order to produce the highest quality and most effective product. Some clients are in the business of carburizing metals and for this industry we produce the highest quality heat resistant fabrications and castings available, including high quality furnace rolls.

Specialized furnace rolls are important for carburizing furnaces.

What is Carburizing?

For many, this action is unfamiliar, they just reap the benefits of “case hardened” metals. But what is it? Carburizing is a common heat treating process that hardens a surface to make it resistant to wear while maintaining strength of the core. This process is usually performed on carbon steel parts, high alloy steel bearings, gears and other components that require higher than usual resistance and strength.

Most times the process entails heating components in a pit furnace or sealed atmosphere furnace and then carburizing gases are then added at temperature. This is a very heated process, with temperatures usually hitting 1560°F to 1740°F. With these high temperatures, the components within the furnace operation need to be heat resistant and able to withstand the intense pressure of the process.

Specialized Furnace Rolls

A heat treating furnace requires heat resistant castings and specialized furnace rolls in order to operate efficiently. All of these parts make up a carburizing furnace and without the heat resistant characteristics, the process would not be able to take place.

Think of aerospace components, that need to definitely be resistant to wear and maintain a strong structural integrity. This process needs to occur in order to add a case hardness to many metal structures we use everyday. And in order for carburizing to occur the proper components need to be manufactured and produced at the highest quality. That’s why Ferralloy is your foundry of choice! Only the highest quality metal components leave our factories, and to your specifications. Give us a call for your heat resistant metal component needs!

Steel Forgings | What Is Forging?

When there is a need in the metal working industry for steel forgings or a product that will need to withstand a large amount of pressure and wear, or if a company is in need of a mechanical piece, the process of forging may be required. Most of the parts in a car and aerospace components are made with this process, and these industries require steel forgings often because the strength and durability requirement. Forging is a specialty of Ferralloy and we will discuss in detail the process, to help you better understand why our products are of the highest quality.

Steel forgings of the highest quality can be ordered from Ferralloy Inc.

What is the Forging Process?

The forging process is a manufacturing process that involves applying force to metal in order to deform and change the shape of the metal and form a specific piece. Usually the metal is deformed using a negative cavity, or a die, and then is hammered, pressed, rolled or squeezed to modify the metal into the desired geometric shape. Metal forging is used to create some of the strongest manufactured parts, like steel forgings, as mentioned previously, that are commonly used in cars and aerospace components.

The forging process can be done either with cold or hot forging, depending on the ultimate shape and purpose of the part being created. If the component required a lot of detail and sophistication in the design, hot forging will most likely be used. However, if the steel forgings are less sophisticated and need to be manufactured in large quantities, cold forging will be the best option.

No matter what your steel forgings specifications are, our professional metal working company can manufacture whatever component you need. We offer many value added services, like machining, for industries like the automotive, aerospace, off-road equipment, mining, food service and more across the board! If you find your business in need of steel forgings, know that Ferralloy will deliver a high quality metal component at a competitive price! Call or visit us online 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.