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Castings | What Are Sand Castings?

A casting is a type of metal component that is vital to countless industries. They are created through the casting process, which consists of pouring molten metal into a mold and then allowing it to cool and solidify. The casting process is extremely versatile and offers the freedom to form intricate metal parts. Due to the versatility of cast parts, there are a wide-range of casting types. Some popular casting types include investment castings, heat resistant castings, and sand castings. Today we will explain sand castings so you can decide whether or not these metal components can benefit your next project.

Sand Castings: Explained

A sand casting is different from other cast parts because it uses sand as the mold material. The sand is typically mixed with a bonding agent, such as clay, and is then moistening with water or another liquid in order to create the appropriate mold strength and plasticity. The surface of a sand casting might not be as smooth as other casting types. However, its rough surface and minor imperfections can be easily fixed with machining. Sand castings are one of the most common cast parts and can be utilized for both short-run and long-run productions. Some of the appealing advantages of this type of casting include its cost effectiveness, easy to change design, and manufacturing speed, just to name a few.

If you’re interested in using sand castings, or any other type of cast parts, for your next project, contact us. At Ferralloy, Inc. we can provide you with the highest quality metal components at a competitive price and delivered on time. If you are interested in learning more about our sand casting capabilities, or are interested in getting a quote for your next project, contact our international company today! We can answer your questions and help you get the best parts.

Cobalt Alloys | Should I Use Cobalt Alloys?

Cobalt alloys are a non-magnetic alloy that contains a variety of different metal components. It’s two main elements, however, are cobalt and chromium. Cobalt alloys are one of the most well-known alloys in metalworking. While it was originally created to replace traditional metal cutlery that was prone to staining and general wear and tear, cobalt alloys now offer so much more. It can be found in a wide range of application for countless industries. Some examples of applications that use this alloy include: car engines, valve seats, poppet valves, saw teeth, machine gun barrels, artificial hip joints, turning tools, and various other acid-resistant machine parts. Why are these alloys used for so many different parts? And, more importantly, should you be using them for yours? Keep reading to learn all about the benefits of using cobalt alloys!

Benefits of Using Cobalt Alloys

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 in order to meet your exact specifications.

Now that you understand all of the benefits of using cobalt alloys, it’s time to decide if this alloy is right for your next project. If you are interested in ordering this alloy or any other metal, contact us. Ferralloy, Inc. has both the infrastructure and facilities to supply metals in numerous different grades and forms. Get the raw materials that you need at a competitive price and delivered just-in-time by contacting our international company today!

Alloy Castings | What Are the Benefits Aluminum Castings?

There are numerous different types of castings methods. There are investment castings, sand castings, centrifugal castings, and heat resistant castings. In addition to a wide-variety of processes, there are also numerous casting materials. While castings can be created using just one metal, alloy castings are often seen as the most advantageous with each specific alloy casting possessing its own set of benefits. One alloy casting that is particularly popular throughout many industries are aluminum alloy castings. Keep reading to learn about all of the advantages of using this metal component!

5 Advantages of Aluminum Alloy Castings

Aluminum alloy castings hold numerous benefits thanks to its chemical and physical properties. We outlined the 5 most important advantages of this type of casting below.

  1. Aluminum castings are extremely versatile and are able to possess a wide-range of characteristics.
  2. They can produce near-net-shape parts with a controlled surface finish, dimensional accuracy, and complex geometries.
  3. They create lightweight parts that are still extremely strong and hard.
  4. Aluminum alloy castings can withstand the highest operating temperatures when compared to any other cast alloy.
  5. These castings possess outstanding corrosion resistance, thermal and electrical conductivity, EMI and RFI shielding properties, and are fully recyclable.

Due to their wide-range of benefits, many industries rely on aluminum alloy castings. Specifically, the automotive industry has been the largest market for aluminum castings ever since the early 1900s. However, they can be found in any industry that requires strong, light, and detailed parts.

If you’re interested in utilizing all of the advantages of aluminum alloy castings for your next project, contact us. Ferralloy, Inc. is a leading supplier of quality castings to major companies throughout the world. We can provide you with as-cast or fully machined parts in many different ferrous and non-ferrous alloys. Visit our foundry online today to learn more!

Machined Castings | What Is Machining?

The casting process is an essential part of metalworking. This process holds the ability to create a variety of 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 in order for the part to be further perfected. Keep reading to learn more about machining and to find out if you should use machined castings for your next project!

What is Machining?

Machining is a broad term used to describe the processes used to cut away materials in order to alter the appearance and shape of a casting or another metal product. Some specific machining processes include:

  • Cutting, generally using single-point or multipoint cutting tools with a clearly defined geometry
  • Abrasive processes, including grinding
  • Nontraditional machining processes that use electrical, chemical, and other sources of energy

No matter the specific process used, machining generally consists of the work piece, the tool, and the machine.

Why is Machining Used?

 Machining is used because it helps create very fine and detailed objects that would have been impossible to manufacture through casting techniques alone. Furthermore, machining has the ability to seal surfaces and threaded holes.

How Do I Get Machined Castings?

Machined castings can present some challenges. As a result, it’s important to get your parts from a company that understands both the casting and machining process. If you need machined castings for your next project, we are here to help! Established in 1978, Ferralloy Inc. can provide you with quality as-cast or fully machined parts at a competitive price and delivered on time. We are a driven organization that is committed to process improvement and customer satisfaction. Contact our metalworking experts for more information or a quote for your machined castings today!

Machined Investment Castings

The company is supplying a beverage industry equipment manufacturer with two versions of these investment cast components.  The 3 pound and 4 pound versions of the 316L investment castings were originally produced as  fabrications  from plate and bar stock.  The components were welded together and then machined.  By utilizing the investment casting process, the subassembly was able to be produced in one-piece and then finished machined.  This process change resulted in a cost reduction to the customer as well as becoming a more aesthetically pleasing component.

investment castings from ferralloy

Alloy Castings | What You Need to Know

Countless industries would not be able to function without castings. Formed by pouring a liquid metal into a mold and then allowing it to cool and solidify, these metal components create complex shapes that would be close to impossible to emulate using other methods. While you can create castings using just one metal, such as iron, alloys are an extremely popular casting material as well. Keep reading to find out what you need to know about alloy castings!

What Are Alloys?

Most metals used in castings and other metalworking processes are not metals at all. Rather, they are alloys. Alloys are metals combined with other substances to make them stronger, lighter, or better in some other way. The substances that are paired with the main metal are called alloying agents. The alloying agents can be another type of metal or a completely different chemical element. They are present in much smaller quantities (sometimes less than 1 percent of the total) than the main metal, but have a significant impact on the quality of the castings. 

What Should I Consider When Choosing a Casting Alloy? 

There are numerous different types of alloys that are used to create castings, each with their own advantages and disadvantages. As a result, there are a variety of factors to consider when choosing a casting alloy. Some specific considerations include strength, durability, production volume, corrosion resistance, cost, stability, and so on. For example, if your project requires components that are corrosion resistant with high strength, an aluminum or copper-based alloy could be an effective choice. Which alloy you utilize for your castings depends on which factors are required for your project.

How Can I Get Alloy Castings?

If you’re interested in using alloy castings for your next project, Ferralloy, Inc. can help! We are a leading supplier of quality alloy castings to major companies throughout the world. Contact our metalworking experts for more information or a quote today!

Forgings | Types of Forging Processes

Forgings are one of the most sought after metal components. At its most basic level, forgings are created by forming and shaping metals by hammering, pressing, or rolling. As a result, forgings come in a myriad of sizes and shapes with enhanced properties. Depending on your specific project and desired application, different forging processes are used to create the metal part. Keep reading to learn about the most popular forging methods!

3 Different Methods for Forgings

1. Rolled Ring Forging

Rolled ring forging is a process that uses two curved dies to deform the metal. Normally, the dies are two opposing rollers. This method produces forged products with a final shape that is similar to the dies. The rolled ring process is largely used due to its many benefits. Some of these benefits include a long lifespan, high productivity, low cost, and quality finishes.

2. Closed Die Forging

Closed die forging is a process that shapes a metal part by forcing it into the contours of a die. This process gets the name “closed die” because the material is confined between an upper and lower die. The closed die process requires a significant amount of force. It is often used to produce near net shapes.

3. Open Die Forging

Open die forging is a process that plastically deforms the metal with a series of compressive forces. It is carried out between two flat dies or simple shapes. Usually, the dies do not completely enclose the material, which is why this process is called “open die.” The open die forging method is used mostly for large objects and smaller quantities.

No matter if you need rolled ring, closed die, or open die forgings, we can help! Ferralloy Inc. is a leading global provider of forgings to major companies in countless different industries. We have the resources to provide you with forgings machined to your exact specifications. Visit our metal foundry online today for the highest quality metal components!

What is Zirconium? | Properties and Uses

There are a wide range of zirconium components in the metalworking industry. There are ingots, forgings, plates, sheets, rods, tubing, and so many other parts that are all made out of this metal. But what exactly is Zirconium? Keep reading to find out everything you need to know about this popular metalworking material!

Properties

Zirconium was first discovered in 1789 by Martin Heinrich Klaproth and took the world by storm thanks to its unique properties. It is a transition metal with a grayish-white luster. This solid metal is difficult to ignite and its compounds have a low inherent toxicity. One property that makes it particularly appealing is that it is exceptionally resistant to corrosion by many common acids and alkalis, seawater, and numerous other agents. It is also known to become magnetic at low temperatures when alloyed with Zinc. You can find Zirconium on the atomic table as the number 40 with the symbol Zr.

Uses of Zirconium

Zirconium’s intriguing properties make is a popular choice for parts and components in numerous different industries. For example, since it does not absorb neutrons, it is an ideal material for tubes and other parts in nuclear power stations. In fact, 90% of this metal is used in this way. Some other industries that use this metal for a variety of applications include solar power, chemical process, petrochemical, oil and gas, pharmaceutical, geothermal, mining, utilities, and many more.

If you are interested in using zirconium in one of its many forms, we can help. Providing different industries with metal parts that meet their specific requirements is what we do. Whether you need blanks cut to size, cold drawn shapes, or custom castings or forgings, we can fulfill your order accurately, competitively priced, and on a timely basis. Contact us today or visit our foundry online for a quote or to learn more about our services!

What are the Benefits of Titanium Tubing?

In the metalworking world, every metal part possesses its own unique set of benefits. No matter what industry you’re in, it’s important to know the benefits of different metal components so that you can choose the part that will be the most valuable for your specific project. One metal part that is used in various industries for it’s advantages is titanium tubing! What are the benefits of titanium tubing? Keep reading to find out!

4 Benefits of Titanium Tubing

1. Lower Density

The density of titanium tubes is significantly lower than steel, copper, or nickel products. Despite their low density, they are very strong and rigid when compared to other alloy components.

2. Resistant to Corrosion

Another benefit of utilizing titanium tubing is that titanium alloys are resistant to corrosion. This makes these tubes an appealing option if you need a part to work efficiently in a highly corrosive environment.

 3. Resistant to Chemicals

 Corrosion is not the only thing that titanium tubes are resistant to. They are also resistant to chemicals. These titanium parts can withstand different chemical compounds while still preforming effectively.

 4. Great Heat Transfer Properties

Titanium tubes have great heat transfer properties thanks to its thermal conductivity and resistance. The same can’t be said for copper and carbon steel tubes. Their resistance to heat also allows them to work successfully at temperatures up to 600 degrees or higher.

These are just a few of the many benefits that come from utilizing titanium tubes. Because of these benefits, you can find titanium tubing in countless important industries such as power generation, sporting goods, marine, nuclear, and paper industries.

If you’re interested in using titanium tubes for your next project, Ferralloy, Inc. can help! We also have the infrastructure and facilities to supply raw materials in numerous grades and forms! Visit our metalworking foundry online today!

Forged Furnace Roll Trunnions

Ferralloy, Inc. began shipping an order for 120  furnace roll trunnions, or bell ends as they are sometimes referred to, for a new heat treating furnace ordered by a large international steel producer.

The requirement for forgings in this application is somewhat unusual as this component is typically supplied as a sand cast component. For reasons related to the inherent mechanical properties of a forging, we were asked if we could source the billet material in the desired chemistry, forge the trunnions, and rough  machine them to the drawing dimensions. We produced the open die forgings, which were then normalized and machined.  The forgings will be welded to centrifugally cast tubes and then the entire assembly will be finish machined before field installation in the new furnace.

The forgings weigh 70 pounds in the rough machined condition and were produced from a grade of heat resistant alloy steel.

forget furnace roll trunnions