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A Simple Guide to the Uses of Investment Casting

Investment casting is one of the most prevalent metal parts used by most industrial companies. These cast components embrace countless benefits that make them an alluring alternative to a wide range of businesses and industries. Investment casting provides the ultimate design flexibility for highly complex parts made from a large choice of alloys. Furthermore, the investment casting process is relatively simple, allowing high production rates and consistent dimensional accuracy to be achieved.

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Simple Facts Should Know About Investment Casting

What is Investment Casting?

Investment casting, otherwise known as lost-wax casting, is an industrial process based on one of the oldest known metal-forming techniques. It was developed over 5500 years ago and continues to be an integral part of metalworking to this day. This casting takes a wax outline of a part and coats it with a ceramic material. It is then heated until the wax is melted out of its center. Molten metal is then poured into the hollow ceramic mold. The metal hardens, gets broken out, and the part is made.

What are its Common Uses?

The uses of investment castings are immeasurable. Nonetheless, companies or industries engage in aerospace, power generation, firearm, automotive, military, commercial, food service, gas and oil, and energy industries use these metal components a lot. For instance, the firearms industry turns to cast parts for firearm receivers, triggers, hammers, and other precision parts. Investment castings are even used by beverage industry equipment manufacturers and international pressure relief valve manufacturers in the oil and gas industry. As a consequence, it’s safe to say that regardless of your industry, if your business can benefit from the advantages of investment cast parts and components, they might be the perfect metal option for any of your projects.

Why Use Investment Casting?

There are several explanations for why individuals choose to use this casting. Among the reasons why companies and industries use castings are the following:

  • It produces very smooth surfaces with no parting line, requiring only minor machining.
  • It can create exceptionally complex parts that would otherwise be extremely difficult or impossible.

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Get Highly Investment Casting Today!

At Ferralloy, Inc., we supply machined investment castings to quality-controlled companies and industries. Contact us today!

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!

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!

Rolled Ring Forgings | All About the Ring Rolling Process

Have you ever wondered how those doughnut-shaped rolled rings are formed? In the production of rolled ring forgings, manufacturers usually use metals or alloys that include aluminum or aluminum alloys, copper or copper alloys, titanium or titanium alloys, tool steel, carbon steel, stainless steel, alloy steel, cobalt alloy or nickel alloys.

What are Rolled Ring Forgings?

Rolled ring forgings also referred to as seamless forged rings are starting blank products that go through additional forming, machining and grinding in order to produce finished components. In most cases, its production involves a process called ring rolling on rolling mills that vary in size. Through this process, parts can be manufactured to tight tolerances and specific geometries that come with outstanding surface smoothness and concentricity. Forged ring products can have an outside diameter of a few inches like the smallest washer-ring to much larger parts that are over 9 feet in diameter.

How Rolled Ring Forgings are Produced

The first step involves the starting stock being cut to size by weight before it is upset in order to attain directional grain flow and the desired structural integrity. Next, the doughnut shape that’s needed for the ring rolling process is achieved by punching then piercing the workpiece. Once done, a completed preform will be ready for rolling. An idler roll is used to apply pressure to the preform.

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Looking for Rolled Ring Forgings?

If you need more information about rolled ring forgings and how they’re made, contact Ferralloy today. We have all the answers you need.

Forgings | The Different Types of Forgings

Forgings are an important part of any job site and will continue to be well into the future. Forged parts are durable, resistant to heat, and can be made from many different materials that also have a lot of wonderful qualities.

Closed Die

Closed die forging is another popular technique for creating the metal components you need. The process starts when two dies are put together and the material is put through the deformation process until it touches the sides of the die walls. Following that, a small amount of material will begin to flow out of the die impression gradually. When these cool, it provides increased resistance to the deformation process.

Rolled Ring

Rolled ring forging is used to create rings that are very strong, extremely versatile, and cost-effective. These parts are used in everything from jet engines, jet turbines, paper mills, windmills, helicopter gearboxes, and much more. Given how heat resistant the products of this process are, they are used in environments that see not only extreme temperatures but also a wide variety of temperatures. A lot of parts cannot stand up to quick and extreme temperature changes, but things made from rolled ring forging can withstand it.

Open Die

Open die forging involves deforming metal components by heating them between a top die attached to a ram and a bottom die. The metals are then worked at temperatures between 500- and 2400-degrees Fahrenheit. The metal is formed by pressing or hammering the metal into the desired shape. This process usually requires some additional refining, which might drive the cost up a little.

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Looking for More Information About Forgings?

When it comes to looking for the best forgings on the market, you’ll need a seller that is informed. If you’re looking for more information about forgings, contact us today. Ferralloy is here to help you get the proper components for your next job.

Open Die Forging | The Differences Between Open and Closed Die Forging

When it comes to forging, there are primarily two types that come to mind. Open die forging and closed die forging are two great ways to produce the products you need for your next project.

Open-Die Forgings

Open-die forgings also are known as free forging, given that the die is not closed like in closed die forging. In this type of forging, the billet is placed between multiple dies that do not entirely cover the metal entirely. The dimensions will be changed by hammering and stamping the metal through a series of movements until the desired dimensions are reached. The biggest benefits of this kind of forging are:

  • Better fatigue resistance
  • Continuous grain flow and finer grain size
  • Increased strength and longer part life
  • Less material waste
  • Reduced chance of voices
  • Valuable cost savings

In open die forging, huge compressive forces are applied by the continuous striking of the forger’s hammer to deform the metal. Unlike closed die forging, the dies of open die forgings are very simple but always require secondary machining.

Closed-Die Forgings

Closed-die forging, otherwise known as impression die forging, is a metal forming process that compresses a piece of metal under high pressure to fill a closed die impression. Some of the biggest benefits of using closed die forging are:

  • The process is economical for large production runs
  • No material limitation
  • Better surface finish
  • Little to no machinating required afterward
  • More intricate designs can be achieved
  • And more

You can use pretty much any material and get a component that is heat resistant and filled with other tolerances that make them extremely useful.

What is open die forging?

Where Can I Get Information About Open Die Forging?

Have you been looking for more information about what goes into an open die forging? If so, contact us today. Ferralloy Inc is here to help you find exactly what you need ahead of your next project.

Open Die Forging | What You Need to Know About Open Die Forging

When it comes to the forging process, there are many different types. One of the more popular types used to create parts that are used in your everyday life is through open die forging.

The Process

The open die forging process is a popular and effective way to produce the parts that you need and use on a daily basis. The process itself consists of deforming metal parts by heating them between a top die attached to a ram and bottom die. Depending on what type of metal is used, it will be exposed to temperatures that range between 500 °F to 2400 °F while slowly shaping the metal into the desired shape. This is done through pressing and/or hammering the metal into place. The process usually requires a secondary machine or refining in order to reach the desired specifications.

The Benefits and Applications

Even though parts created through open die forging usually require secondary machining, it is still a popular process that sees results. Parts created by open die forging are:

  • Discs
  • Rings
  • Sleeves
  • Shafts
  • Cylinders
  • And more

The biggest benefit of this type of forging is that the repeated working of the metal increases its strength and grain structure of the finished product. Parts made by this type of forging are tough and last long. They are resistant to fatigue and typically have a lower number of voids compared to other processes.

Where can I find the best open die forgings?

Looking for More Information About Open Die Forging?

Have you been looking for more information about open die forging, the process, or it’s practical applications? If so, contact us today. Ferralloy is here to help you find what you need for your next project.

Inconel Alloys | Benefits of Inconel

Inconel is a family of austenitic nickel-chromium-based superalloys. These alloys are oxidation- and corrosion-resistant materials well suited for service in extreme environments subjected to pressure and heat. When heated, it forms a thick, stable, passivating oxide layer protecting the surface from further attack. This material retains strength over a wide temperature range, attractive for high temperature applications where aluminum and steel would succumb to creep as a result of thermally induced crystal vacancies. Its high temperature strength is developed by solid solution strengthening or precipitation hardening, depending on the alloy.

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Is All Inconel the Same?

It’s important to note that there are different types of Inconels and different Inconels have different compositions. Each type of Inconel possesses unique traits that make it effective in different circumstances. Inconel 600 has very different uses than Inconel 625. In the case of Inconel 600 for example, is used to create effective parts in the chemical and food processing industries thanks to holding a higher resistance to oxidation and various forms of corrosion.  Inconel 625 on the other hand possesses high levels of strength without ever having to go through heat treatment, making it an appealing option for aerospace and marine engineering industries.

This metal is often utilized in extreme environments. From gas turbine blades, seals, and combustors, to turbocharger rotors and seals. You will also find it being used in electric submersible well pump motor shafts, high temperature fasteners among other specialized machinery. While there are many variants of this alloy, each with its’ unique traits that make it effective in different circumstances, the majority of the alloys are used frequently in the chemical industry.

No matter what your application may be, if you’re interested in using metal components, we can help. Ferralloy, Inc. has the infrastructure and facilities to supply raw material in numerous grades and forms. Visit our metal foundry online today!

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Investment Castings | What is the Investment Casting Process

If you’re not already using investment castings, it might be time for you to start. These castings are extremely versatile. They can be big or small and made out of a large range of materials, all while maintaining exceptional accuracy. With benefits like these, it’s no surprise that investment castings are one of the oldest and most widely used types of metal parts. However, in order to get a better sense of whether or not investment castings are the right parts for your next project, it’s important to get a sense of how they are made. What is the investment casting process? Keep reading to find out.

What is the Process for Investment Castings?

The investment casting process dates back thousands of years. The process has since been modernized, but its importance remains the same. We broke down and explained the entire process below.

Step 1: A wax pattern of the desired part is created and mounted onto a central wax gating system to form a tree-like assembly.

Step 2: The tree is alternatively dipped in a slurry of refractory coating materials and is allowed to dry. This step is repeated until a thick shell is created over the wax pattern.

Step 3: The wax pattern is melted out so that a cavity in the shape of the pattern is all that is left. The cavity is then filled with molten metal.

Step 4: After the metal cools and solidifies, the shell is broken away, the gating material is removed, and the finished cast part remains.

Now that you understand its process, it’s time to ask an important question: are you interested in using investment castings? If you are, make sure that you get the highest quality castings by contacting Ferralloy, Inc. Our years of investment casting experience guarantees that we can supply you with superior products and meet the challenges of virtually any project. Visit us online today to learn more!

Seamless Rolled Rings | What You Need to Know

The metal components that you use can make or break your project. As a result, it’s essential to choose a part that isn’t just good for your project, but rather one that is perfect for your project. One of the most popular metal parts that play an essential role in countless projects are seamless rolled rings. These rings can be used in numerous products (i.e. valves, flanges, bearings, robotics, gears, couplings, machines, clutches, and drives) throughout countless industries. What are seamless rolled rings? Keep reading to find out everything that you need to know about this indispensable metal part!

What Are Seamless Rolled Rings?

Seamless rolled rings are metal parts that are produced through a process called ring rolling. This process takes a circular preform of metal that has been previously upset and pierced to form a hollow “doughnut” shape. The doughnut shape is then heated above the recrystallization temperature and places over the idler or mandrel roll. This idler roll then moves in a series of motions and rotations to reduce the wall thickness and increase the diameters until the rolled ring takes its desired shape. Rolled rings can be produced in configurations that range from flat, washer-like parts to tall, cylindrical shapes and heights ranging from less than an inch to more than 9 feet tall. As a result, seamless rolled rings are great metal parts that be made to your exact specifications.

Get the best seamless rolled rings for your next project by contacting Ferralloy, Inc. today. We can supply you with rolled ring forgings in diameters up to 110” and in a wide variety of materials such as carbon, alloy, stainless steel, titanium, nickel alloys and more. Not to mention, our distribution model ensures that you will receive your deliveries on time so that you can better manage the amount of product that you keep on hand. Learn more about our rolled ring forgings and all of our other metal products by visiting us online today!