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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!

Castings Investment | The Value of Castings Investment

Is your current metalworking process hampered by component variance and additional cost? Perhaps you should consider switching to castings investment so that you can add more value to your project. Its manufacturing process is nothing short of versatile because it allows you to create a wide range of metal parts with various applications in many industries.

What are the Disadvantages of Secondary Operations?

Technically functioning parts can be produced by casting pieces and machining from solid. However, such secondary operations can be very inefficient when they’re being compared to investment casting. Factors such as production timeline, cost, and the required performance of the specific component need to be considered. For this reason, most manufacturers choose to steer clear of secondary operations that can negatively affect the speed-to-market, as well as part performance.

What are the Advantages of Investment Casting?

On the other hand, the investment casting process can offer near-net-shape or net-shape components without taking a lot of time. With the help of the latest software technology, manufacturers can make sure that the intricately detailed parts will come out mechanically sound even before the molten metal is poured into the mold. Furthermore, this metalworking method gives engineers and designers free rein while eliminating material waste that usually results from secondary machining.

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A Closer Look at the Value of Castings Investment

The process involved in creating castings investment allows manufacturers to achieve repeatability and reduction or elimination of various downstream operations. Furthermore, this will further reduce loops for reworking the parts and streamlines the process of delivery from the manufacturers to the various industries they serve. While you satisfy your customers’ requirements, you’ll also get to experience the benefits of one of the most optimized and repeatable precision metal processes in all of history. If you want to know more about castings investment, call Ferralloy, Inc. today. We’re the leading global supplier of engineered products and services and we offer total supply chain management to a diverse metalworking customer base.

Investment Casting | How the Investment Casting Process Works

Did you know that investment casting technique dates back over 5,000 years ago? This makes it one of the oldest ways to form metal. Furthermore, this is used in a wide variety of items including dental fixtures, jewelry, airplanes, cars, and other parts of complex geometry. However, if you’re curious to find out how to create a mold for investment casting, take a closer look at the entire process.

Investment Casting 101: The Process

In order to begin the process, hot molten wax is injected into an aluminum die to create wax patterns. Doing so will set the pattern to the size and shape of the required component. The wax pattern is then assembled onto a wax feeder system with each wax assembly resembling a ‘tree-like’ structure.

Next is the investment stage where a large robot dips the wax assembly into a bath of high-grade ceramic slurry. To build up a thicker coating, larger ceramic particles are dropped onto the surface of the wax assembly while it is still wet. After everything has dried, the coating or ‘investment’ process is repeated for a number of times in order to build a 10mm-thick shell mold.

Once the final mold is dried, the ‘lost wax process’ ensues where a steam autoclave is used to melt out the wax. During this stage, the mold is fired at approximately 1,000˚C with the goal of strengthening the mold by removing all traces of any remaining wax.

While they are still hot, molten metal is poured into these molds. The heat enables the metal to run even into its thin wall sections of the hollow shell. After leaving them to cool off, the ceramic shell is broken up and the casting is cut away from the feeder system. Lastly, the castings are then submitted to careful fettling, blasting, and heat treatment.

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Looking for More Information About an Investment Casting?

When it comes to investment casting, Ferralloy, Inc. is an expert with over a decade of providing the global metalworking industry with castings and other related products and services. Contact us today to learn more!

Closed Die Forging | All About the Closed Die Forging Process

In case you’re not familiar, forging refers to the manufacturing process that involves the shaping of a piece of metal with the use of compressive forces. A power hammer or a die delivers the blows. Today, it has become a major worldwide industry and its traditional products include hardware, kitchenware, cymbals, edged weapons, hand tools, and jewelry.

What is Closed Die Forging?

Sometimes referred to as impression-die forging, this type of forging process uses dies that have the precut profile of the desired part. These dies move towards each other and partially or wholly covers the metal piece. The raw material that’s been heated is positioned in the bottom die. The shape of the forging as a negative image is incorporated in the top or bottom die. When the top die presses against the bottom die, the raw material forms into the desired shape. In case you’re wondering, this process can be used to produce parts from a few ounces to 60,000 lbs. You may also be surprised to find out that some of these smaller parts are forged cold.

 

What Are its Capabilities?

Closed Die Forging of steel, titanium, aluminum, and other alloys can create a virtually limitless variety of 3-dimensional shapes that weigh from a few ounces up to over 25 tons. While closed die forges that are routinely produced on hydraulic presses have capacities up to 50,000 tons, those that were produced on mechanical presses have capacities up to 20,000 tons. Lastly, those that were regularly produced via hammers have capacities up to 50,000 lbs.

 

Since this type of forging process restricts metal flow due to the presence of the die contours, you won’t be surprised to know that Closed Die Forging can yield more complex shapes as well as closer tolerances compared to the open-die forging process. However, it’s important to note that if additional flexibility is required in forming symmetrical and non-symmetrical shapes, pre-forming operations that involve bending will have to be implemented on the piece of metal before it is forged in finisher dies.

Where are the best forgings?

Closed Die Forging 

Since Ferralloy is a trusted supplier of engineered products and services to a wide range of industries across the globe, we can give you straight answers about Closed Die Forging or anything that’s related to metal production. Contact us today!

 

 

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.

Heat Treating Baskets | The Benefits of Using the Right Heat-Treating Basket

The heat-treating process is one of the most important steps in preparing components to be used on job sites. One crucial piece of the process is the heat treating baskets. These baskets are often overlooked but play arguably the most important part of the process.

What is a Heat-Treating Basket?

A heat-treating basket is used in the heat-treating process. It is what the components that are about to be heat treated get put onto before being exposed to the extreme heat. Depending on what kind of treatment they are getting, it will vary for how long these baskets need to be exposed to the heat. Normally, these baskets break down quickly and can only be used a couple of times before they are completely broken down.

Benefits of a Better Basket

Typically, the average treating basket is designed to break down. Due to the extreme environments that they are constantly exposed to in the heat-treating process, manufacturers usually do not try to create something that lasts. But by doing that, you are already tacking a lot onto the final cost of the project because of all the baskets you will have to buy. Our heat-treating baskets are designed to last longer so you can get the most out of them without re-buying them constantly or having them break down mid-project.

What are heat treating baskets?

Looking for the Best Heat Treating Baskets on the Market?

If you’ve been looking for the best heat treating baskets that are second to none, then you need to contact us today. Ferralloy only carries the highest-quality baskets that are made to last longer than the average piece of equipment. Save yourself from constantly re-buying heat treating baskets by picking up the phone and getting in contact with one of our sales representatives today.

Forged Rolled Rings | How Are They Made & Where Are They Used

One of the most valuable components you can use in a project is forged rolled rings. These parts are easy to make, low cost, and can be applied to a countless number of industries. Check out all you need to know about the process, and it’s benefits before deciding if it is right for you.

The Forging Process

These rings are forged in a way similar to other heat-resistant components. First, the stock is placed on the die and upset. The molten metal is pierced, shaped, and once it reaches the proper specifications it is cooled. This yields a product that is extremely versatile and one that can be used in a wide range of industries.

What Are the Benefits?

When it comes to rolled ring forgings, there two big benefits. It can be made from a wide range of materials and is extremely versatile. Rolled ring forging can use materials such as:

  • Carbon
  • Stainless steel
  • Alloy steels
  • Inconel
  • Super Alloys
  • Aluminum
  • Nickel Aluminide
  • And much more

The forging process not only allows for a lot of different materials but also creates a product that can withstand a lot. These products can properly function in high-heat environments, dangerous cold, and withstand extreme changes in temperature too. You don’t have to worry about constantly re-buying the same components because these last long.

Real-World Applications

Because these components are made from a wide range of materials and have a long list of benefits, they have a ton of real-world applications. You can see ring rolled components in industries like aircraft and aerospace because of the extreme temperatures it can withstand. The oil and gas business use it for the same reason but with the added benefits of being durable. Road construction, coal mining, and steel production all are big users of these parts too.

Where are the best forged rolled rings?

Looking for Information About Forged Rolled Rings?

Have you been looking for more information about forged rolled rings? If so, contact us today. Ferralloy is here to help you find exactly what you need. With over 40 years of experience providing for a global customer base, we are ready to help you find the industrial components for your next project.

Ring Rolled Forgings | How Are Rolled Ring Forgings Made?

When it comes to ring rolled forgings, there is a lot you need to know. How are they made? What are they made from? Where can I find them in the real world? Can they help me with my next project? All of these questions and more can be answered below.

The Process

First, the starting stock is cut by weight and then rounded into its beginning shape. It is then upset to achieve the proper directional flow. After that, the workpiece is punched and the starting stock then begins to resemble a donut. This donut of molten metal is then ready for placement and rolling. The idle roller applies pressure to the starting stock while the axial roller and drive roll continually work the molten metal into the desired shape. Once the desired shape is achieved, the ring is cooled and set aside.

Benefits of Ring Rolled Forging

There are many reasons why you would want components made from ring rolled forging. For starters, the rings are usually extremely durable and can stand up to extreme conditions. Whether it is extreme heat, cold, or severe temperature change — rolled ring forging components are perfect for these environments. You can use many different types of materials to make these rings too; everything from carbon to alloy steels. This makes the rings even more versatile.

Rolled Ring Forgings in the World

Given that you can make the rings from almost any material, it means that you will see them across almost every industry. Rolled ring forgings can be found in the following industries:

  • Aircraft
  • Aerospace
  • Oil & Gas
  • Construction
  • Coal Mining
  • Steel Processing
  • Heat Treating
  • Marine
  • Railroad
  • And more

You probably have something made from rolled ring forging around you right now but don’t know it. They can be made for to almost any size or width, meaning that it can be applied to the largest machines or humbled-sized pieces of technology.

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Looking for More Information About Ring Rolled Forgings?

Have you been looking for more information about ring rolled forgings? If so, contact us today. Ferralloy has been providing for a global customer base for over 40 years and looks forward to providing for your business too.

Castings | What is Gravity Fed Casting and are the Benefits?

When it comes to casting, there are primarily two popular methods. Pressure casting, which uses gas or air pressure to help facilitate the flow of material into the casting and gravity fed casting uses the natural force of gravity to help the material flow where it needs to. Castings are all around you and are not as hard to make as you would think.

The Process

The gravity fed casting method can be broken down into primarily three steps. First, the heated mold is coated with a releasing agent that will help the final product come out of the mold at the end. It also helps cool the mold after the previous part was added. After that, the molten metal is poured into the mold and nature takes its course. Once the molten metal has spread to where it needs to in the mold and the part has sufficiently cooled, it is removed from the mold and the process is repeated until the order is filled.

Benefits of Gravity Fed Casting

Gravity fed casting has a lot of benefits. For starters, this method has a much smoother cast surface finish compared to sand casting. Because of that, it requires less machining and thus should lower the cost of your project. Gravity fed casting also allows you to create thinner walls and has a much faster production time compared to other casting methods. The process is very repeatable and offers good dimensional accuracy too.

Where can I find castings?

Looking for More Information About Castings?

Have you been looking for more information about castings? If so, contact us today. Ferralloy Inc. is here to help you find the parts and components you need for your next job at the right price.

Seamless Rolled Rings | The Benefits of Rolled Ring Forging

When it comes to seamless rolled rings, there are not only many benefits but also even more practical applications for them in the real world. You might be surprised to find out what goes into the process and what this metal component is used for in the world.

Why Rolled Rings Forgings are Used

Rolled ring forgings are set apart from other types of forgings because of how many advantages it has. Some of these benefits are:

  • It is extremely versatile
  • Cost-effective compared to other methods
  • It is very strong

Parts made by rolled ring forging are typically used in extreme, high-temperature situations. Not only can these rings withstand the high temperatures that they were designed to, but also high fluctuations in temperature too. In addition to its strength, these rings are very versatile too. They can be made from numerous materials like alloys, stainless steel, carbon, aerospace metals, and more. What makes this method even more ideal is how cost effective it is. Because it doesn’t require extra machining, rolled ring forgings truly can be the best option for certain parts.

What is it Used For?

Given all of the benefits of using components made by rolled ring forgings, there is an even wider range of use for these products. These rings can be used in jet engines, jet turbines, paper mills, windmills, helicopter gearboxes, and many more places. If you are going to do a job that requires working in or around an extreme environment, chances are you are going to be using components made by rolled ring forging.

Where are good seamless rolled rings?

Looking for More Information About Seamless Rolled Rings?

Have you been looking for more information about seamless rolled rings? If so, contact us today. Ferralloy Inc is here to help you find exactly what you need for your next project. We have been a leader in the metalworking industry for decades and continues to use the latest and greatest technologies to manufacture the highest-quality components.