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Seamless Rolled Rings Process for Bearings

The seamless rolled rings process is normally used to create a shape for metals. In this process, the metal is formed into a hollow doughnut, providing the shape of the ring after the process as per the requirement and design of the product owner. Although the process may seem easy, in reality, it involves a difficult and intricate process. Below are the reasons why the process is used for manufacturing bearings.

bearings seamless rolled rings

Why Use Seamless Rolled Rings Process?

Strong and Versatile

Seamless rolled rings can be designed and created using any forgeable material. This includes alloys, stainless steel, carbon, aerospace metals, and more. Its strength and versatility make any metal component an approachable and flexible solution for parts used in chemical, refinery, and power generation industries. Likewise, they are stronger compared to other metal components. Seamless rolled rings are also able to maintain their strength during high-temperature fluctuations. 

Cost-Effective

Gears, slewing bearings, and large-diameter bearings are commonly used in enormous industrial equipment such as those used in nuclear power, hydropower, barge cranes, and harbor machinery. In contrast with casting, seamless rolled rings can efficiently eliminate slag inclusions, shrinkage cavities, pores, and other defects.

Aside from better mechanical and quality performance, one of the biggest advantages of utilizing seamless rolled rings is that it costs less than similar components to manufacture them. This is possible because the rings closely match the contour of the finished shape. As a result, the product requires fewer machining operations, reduced weight, and lower costs for raw materials.

forging seamless rolled rings

Get Quality Seamless Rolled Rings at Ferralloy Inc.

Being one of the prominent forging companies, you can have exceptional products at the best affordable price. Furthermore, we also aim to provide you customized options to cater to your needs and requirements. For more information related to seamless rolled rings, contact us through this link!

The History of Forging

Ever wondered how open die and closed die forging began? The art of forging emerged around 4,000 B.C. – some even say that it began way before this time. Metals like iron and bronze were forged to produce hand tools and other weapons for defense. However, the earliest recorded metal forged by early generations was made out of gold. If you want to know more about the history of forging, please read on.

closed die forging

Centuries of Forging Developments

Before the 19th Century

Limited amounts of natural gold were found in Spanish caves and were said to be used as tools and weapons in the late Paleolithic period. The forging of steel and iron continued in the 19th century and its improvements became the pillars of what has become of today’s forging processes.

19th Century

Forgers and other experts on the forging process were specifically skilled at hand, especially when it comes to open die and closed die forgings. Since bent and twisted iron can only be produced in high heat, the forgers became dexterous in hammer welding and several large shaft forgings.

In 1856, the emergence of the Bessemer steel-making process became a breakthrough in the history of the forging process. People now have an abundant supply of low-cost steel for creating and designing large quantities of forgings.

Historians say that the first cavity steel forging began with the help of the closed die process. It commenced in the United Stated in 1862.

20th Century

The Industrial Revolution and World War II both lead to the development of better forging equipment and processes. Eventually, electrical motors and induction heaters enabled forged rolled rings to be produced quicker, easier, and more effectively than ever before.

closed die forging

Know More About Closed Die Forging

Clearly, forgings have come a long way since 4,000 B.C. Start using the modern power of forged rolled rings for your next project by contacting our accommodating staff at Ferralloy Inc.

Achieving Excellence in Global Sourcing

Skillful labors and low-priced raw materials are primarily why companies opt for global sourcing. With these factors achieved, it becomes more cost-effective and favorable for the company. Nevertheless, global sourcing can also provide you with several challenges. Here are some tips to achieve excellence in global sourcing.

What is global sourcing?

Factors to Consider in Global Sourcing

Competitive Advantages

When choosing global sourcing, you must balance the impact on the company’s competitive advantages. For instance, one of the most essential aspects of this factor is the protection of product quality and intellectual property. If you think your company believes that its intellectual property is entirely important, then you should be very selective about your global suppliers. The more you depend on your proprietary information on other companies, especially when it comes to the specifications of your products, the greater the risk of losing it.

Moreso, if your competitive advantages are focused on achieving lower costs, it is critical to guarantee there are no hidden charges. Thus, you need to make sure there is no hidden cost so you can dispose of any realized cost advantage.

Monetary Risks

While the use of global sourcing can lower the cost because of the proximity of raw materials and lower labor costs, there are still monetary risks that can affect it. These risks include the expenses related to time zone differences, costs of transactions, and unanticipated increase in shipping costs. However, there are several financing tools available to global sourcing companies to offset these monetary risks such as forfeiting, factoring, and hedging against currency fluctuations.

Characteristics of the Raw Materials

Several aspects of the premeditated procurement process are distressed and overwhelmed by the characteristics of raw materials and other components. You will have to consider whether the modifications be made before or after the materials are sold, limitations of the supply of raw materials, and if goods are imported as components for manufacturing or simply in raw materials.

What is global sourcing?

Learn More about Global Sourcing

Ferroalloy Inc. is a global sourcing company that understands what its competitive advantages are and all other factors. If you want to enhance, protect, and utilize your company’s best interest, contact us today!

Forgeability of a Metal

The ability of a metal to undergo deformation without cracking by means of forging is what experts call the forgeability of a metal. With this characteristic, metals can easily be formed with low force and resistance. For instance, closed die forging involves a process wherein the dies move toward each other by covering the metal. The heated raw material is placed at the bottom die to produce a design or shape according to specifications. To know more about the forgeability of the metal, please continue reading.

 

What is Closed Die Forging?

All about Forgeability

Tests to Determine Forgeability

According to experts, there are two primary tests to determine forgeability of a metal – Upsetting test and Hot-twist test. Upsetting test involves cracking while upsetting a cylindrical specimen.  Although this test only provides basic guidelines, it uses different strain and temperature rates to ensure that forgeability can be determined.

On the other hand, the hot-twist test requires the twisting of a metal rod at different temperature rates. Using this method, forgeability can be determined for various materials, including steel.

Extrusion Process

Extrusion is conducted by deforming metal and transporting it into a chamber before the compression process starts. In standard extrusion procedures, a round billet is placed in a chamber and forced through a die opening by a ram. Additionally, this process requires extreme temperature for the material to be completely formed.

The methods of extrusion involved in forgeability of a metal are direct extrusion, indirect extrusion, hydrostatic extrusion, and impact extrusion.

Metal Flow

Metal flow is an important factor to consider when deforming a metal. It must have a substantial reduction in the cross-sectional part of the process to make sure that the flow is undisturbed. Also, extrusion defects may occur if there are impurities and oxides caused due to the inhomogeneous flow of metal. When this happens, surface defects will thrust or be expelled into the center of the extruded parts.

 

What is Closed Die Forging?

More Information about Closed Die Forging and Extrusion

At Ferralloy Inc., we strive to provide answers for every inquiry! Contact us today if you have any questions and our friendly staff will be glad to answer them!

Difference Between Hot Rolled Plate and Forged Ring

Plates are designed by continuous rolling and casting or, in most instances, steel is processed into a bullet then hot rolled to be shaped in its final plate thickness. Akin to steel plates, rolled ring forgings are forged in the same process – it differs only in terms of rolling directions. Continue reading to know the difference between the two.

What are rolled ring forgings?

Process, Cost, and Strength of Forged Ring and Hot Rolled Plate

Manufacturing Process

In case you’re wondering, it takes continuous rolling and casting to produce plates. It’s also possible to forge steel into a billet before it is hot rolled until it attains the desired thickness of its final plate. Forged rings are a lot similar to steel plates because the rings go through a forging process from a billet of steel before these are rolled into their required shape. The key difference between both is that forged rings need to be rolled in two directions while rolling the plates only requires a single direction.

Cost

Hot rolled plate is a bit expensive than rolled ring forgings as the former results in more material scraps. Since rolled ring forgings are milled to a precise donut shape, there are no middle holes to be thrown out or corners to be clipped during the manufacturing process. It is not acquired as a square, solid plate but is already ready to use.

Strength and Difficulty

Despite being less expensive than hot rolled plates, rolled ring forgings possess the same strength and quality as that of the former. According to forge experts, these rings similar tensile strengths and yield as hot rolled plates.

In terms of difficulty to wield, rolled ring forgings show no brittle or hard layer on its rings. For as long as the manufacturing complies with the standard and stringent consumer qualification processes, the rings are guaranteed to meet the mandatory specifications.

What are rolled ring forgings?

Get Rolled Ring Forgings at Ferralloy Inc.

Are you looking for hot rolled plates or rolled ring forgings? To inquire, get in touch with our friendly staff through this link.

How were Investment Castings Used in the Past?

Investment casting, otherwise known as a lost wax casting, is one of the oldest metal-forming processes that is still used as of this date. Approximately 5,000 years ago, investment castings started with a basic beeswax-formed pattern. Today, it involves highly complicated processes and technologies using refractory materials and specialized alloys.

what should i know about investment castings?

The History of Investment Castings

Original Use

The use of investment castings in ancient civilization was a bit different from the current method applied today. In the olden times, the craftsman designed the casting from beeswax by using basic tools such as shaving tools, melted wax, and other hot tools. To create the desired form, the craftsman will forge a pattern on the wax shape.

They will then fill the mold with a thin layer of melted wax. As soon as the wax mold is coated in ceramic, a perfect mold of the wax shape can be created. It will then be left to dry out before the craftsman can use it to forge a metal object. Such a process is generally used to create jewelry, decorative objects, and religious objects.

Modern Use

Investment casting is a complex metal-forming development that allows metal workers to create products with intricate and remarkable surfaces. The process starts by creating a mold and producing accurate patterns through the latest technological advancements. The good thing about the modern application of investment castings is that when the workers use wax to make patterns, it can still be reused.

The flexible patterns allow for easy reproduction and stress-free production of wax materials that underwent a series of coating and hardening. Once the materials are invested – jargon for poured – into the mold decorated with unique patterns, it will go through a lot of processes such as dewaxing, heating, pouring, removal, and cleaning.

what should i know about investment castings?

What Makes Investment Castings a Popular Metal-Forming Process?

If you want to know why investment casting survived throughout these decades and remains a widely used process, contact our staff at Ferralloy Inc. We can walk you through its history and help you realize why it’s an important metal-forming process.

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!

Tapping Better Resources with Global Sourcing

It’s undeniable that the figures for manufactured products in a low-cost country are significantly lower than those manufactured in developed countries. Many companies in the US enjoy the perks of lower production costs by sourcing the products globally. Besides lower production costs, global sourcing also makes it easier for companies to look for better resources.

What is global sourcing?

How Global Sourcing Makes Everything Better

Reach More Resources

Global reach provides companies with the convenience to reach more unavailable resources within the domestic market but is available overseas. Utilizing such potential already available beyond domestic areas can be great leverage to producing quality materials and components.

Long-running and experienced global companies like Ferralloy Inc. can help you with international procurement services. These companies are oftentimes powered by their active network of global suppliers licensed and certified by the authority.

The procedure of sourcing components from other countries can be simplified with the aid of other industries. Sourcing companies can get materials and other components at the lowest possible price without compromising quality.

No Language Barrier Problems

With the help of global sourcing companies, there remains no language barrier. There will be no miscommunication or lack of contracting differences. The sourcing needs can easily be met while allowing other organizations to benefit from the purchases.

What is global sourcing?

Other Benefits of Global Sourcing

Apart from better resources and no language barrier problems, global sourcing also offers good quality control and greater production capacity. A company can partner with a trusted overseas industry to guarantee that its products are in line with company standards. The global sourcing company can ensure that the entire testing process is carried out.

When it comes to a greater production capacity, there is no question that the selected overseas company has an abundant supply of materials. Aside from the available materials, most outsourced companies have highly-developed manufacturing infrastructures. Once these two factors are present, the large volume production can be achieved quickly.

If you’re looking for an exceptional company that takes on global sourcing, contact Ferralloy Inc. today!