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What are the Perks of Choosing Rolled Rings?

From pharmaceutical companies to machine shops to nuclear industries, it is safe to conclude that rolled rings are widely used in several industries. This type of forging is a procedure that starts with a circular form of metal. Such metal has already been pierced to make a hollow donut shape. The rolled ring is placed in a high temperature, then rotated to decrease its wall thickness while increasing the finished metal product’s diameter. Below are the perks of using a rolled ring forgings. 

Use of Various Materials

Rolled rings can be formed from numerous forgeable components such as aerospace metals, carbon, stainless steel, or alloy. Its versatility allows the rings to be more responsive and flexible. This is precisely why the industries engaged in refinery, chemical, and power generation choose this process. 

High Temperature Tolerant

Rolled rings forging is easier to manage and control when it comes to heat exposure. Unlike any metal components, rolled rings do not require extensive care when the heat is applied. The troubles of preventing such parts from deforming and melting rarely exist. With such procedure, manufacturers and other industries are guaranteed that it can withstand maximum heat.

Reliability and Cost-Effectiveness

Since rolled rings can withstand high temperatures, it can be inferred that the finished product is reliable with more resistance and strength capability. Aside from reliability, it is also known to be cost-effective. Rolled rings are formed and created at a lower cost than other components. It requires less machining as it closely matches the shape of the finished metal.

Strength

The strength factor of rolled rings forging is the most notable advantage of choosing such metalwork or process. Experts say that forgings have more strength than other components. It can maintain the power of the metal despite temperature fluctuations.

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Get Rolled Rings Forging at Ferralloy Inc.

At Ferralloy Inc., we are committed to providing you only the finest and efficient work. Also, our rolled rings are created by the best and dedicated manufacturers that offer precision machining. Contact our team today to learn more about us!

What Exactly is Inconel 600 and How is it Used?

Inconel is an alloy of nickel that also contains iron and chromium. It is resilient to both high temperatures and corrosion, making it a valuable material. The only disadvantage is that it is it’s not that affordable to produce. While it is reliable and durable, it is one of the more expensive materials you can use. However, it is worth the cost because the content is extremely tough. Likewise, it does not break down or falter often.

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Facts you Need to Know About Inconel 600

What is Inconel 600?

Inconel 600 a nickel-chromium alloy with stable high-temperature oxidation resistance. It is also resistant to chloride-ion stress-corrosion cracking, corrosion by high-purity, water, and caustic corrosion. Hence, this type of alloy is ideal for furnace components, chemical and food processing, nuclear engineering, and sparking electrodes.

What Makes it so Exceptional?

The chromium content allows the alloy to resist sulfur compounds and other oxidizing conditions. The chromium content found in Inconel 600 makes it ideal for a commercially pure nickel under an oxidizing environment. It is relatively un-hampered by the majority of alkaline and neutral salt solutions.

What are the Characteristics?

  • Below are the following characteristics which make Inconel 600 worth an investment.
  • Suffers from selective oxidation only due to reduction of conditions and alternating oxidations
  • Highly resistant to carburizing gases, nitrogen, and ammonia bearing atmospheres
  • High strength and scaling resistant because of the elevated temperatures
  • Exceptional resistance to high purity water 
  • Has the ability to resist organic acids such as stearic, formic, and acetic

Where is Inconel 600 Applied?

Inconel 600 is used and applied by several industries. It is involved in process equipment such as fluorinated and chlorinated hydrocarbon productions. Manufacturers of a heat exchanger and reactor vessels like using this type of alloy, especially in the construction of vinyl chloride and other substances.

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How is Inconel 600 Used?

Inconel is excellent when it comes to dealing with rapid temperature changes too. It can withstand the cold just as well as it faces the heat. Since the material does not corrode, it is very commonly used in various marine applications too. 

To know more about Inconel, contact Ferralloy today!

Lubricant Choices in Closed-Die Forging

Closed die forging includes a controlled plastic deformation process of alloys and heated metals to achieve the desired shape. Without an appropriate forging die lubricant, effective and economical closed die forging is unattainable.

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Factors Affecting Closed Die Forging Quality

Factors that Ensure Optimal Life of a Forging Die

The life of a closed die forging is affected by many factors. The most common of which is the proper method of application of die lubricant at appropriate intervals. Likewise, the forging result may also be affected by the reduction of friction during the forging process. Friction can sufficiently be reduced by using suitable die lubricants and polished dies.

Moreso, proper heat treatment, while the forging process is ongoing, is mandatory. The use of protective anti-scale coating will help reduce scaling on critical surface areas of the material. Lastly, using a correct die material and design can make a difference. 

Types of Forging Die Lubricants

There are numerous types of closed die forging lubricants. Manufacturers often used water with soluble oils, graphite, sawdust, or common salt. The use of these types of lubricants offers several benefits to produce quality forging materials. It is economical, eco-friendly, non-polluting, easy to use, and improve the forging die life and productivity. 

Aside from using water and other mixes, closed die forging manufacturers also use oil without graphite, special oil with graphite, or furnace oil. These types require no purchase hassles, they are the least expensive, and they can improve your material’s die life.

Selection of the Right Type

Choosing the right type of closed die forging lubricant will depend on numerous parameters such as complexity of the forging, size, methods of dispensing the oil, pollution control, cost reduction, and depth of die cavity. 

The selection of the best type will require rigid guidelines and several field trials. Hence, the correct procedure of dispensing the lubricant and appropriate type of oil plays a decisive factor in achieving your desired metal shape. 

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Quality Closed Die Forging at Ferralloy

At Ferralloy Inc., we provide furnace components, extrusions, fabrications, fasteners, forgings, and the like with only the best quality. Contact us today!

Precision of the Lost Wax Casting Process

A casting investment is often resorted to because it can produce metal components with near-net shape, thin walls, precise shape into external or internal features, exceptional surface finish, and can produce fine details.

This normally results in highly satisfactory customer cost savings in machining, labor, and materials. One of the processes often used to get an accurate casting is the lost wax casting. Read on to know more.

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How Precise is the Lost Wax Casting Investment Process?

What is the Lost Wax Process?

In lost wax casting investment, a specific and general wax pattern of the preferred finished part is produced and mounted onto a wax tree. This first process involves the use of the metal delivery system. The wax tree is interchangeably plunged into a ceramic substance and topped with a stucco material. After this, it is left to dry out, and the process is repeated until a thick shell is achieved.

Once the shell is achieved, it is then melted out, creating a cavity in the form of the preferred pattern. The molten metal is then poured in such an area until it is filled. After the molten metal solidifies, the thick shell is fragmented, and the gating material is detached. The remaining parts are the finished product.

What are the Characteristics of the Lost Wax Process?

The distinctive characteristics of the lost wax casting investment are accurate tolerances and low roughness values. Moreover, considerable autonomy exists in both material choice and product design.

Accurate castings are usually applied in areas where high-quality metal components are demanded. For example, finished products brought by the lost wax process are often used in areas with substantial temperature differences and hostile or aggressive environments. Additionally, because of high and specific demands, unique and rare alloys are commonly used for these castings.

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Specializing in Lost Wax Casting Investment

To get the most out of your purchase or investment, you must use the services of companies that specialize in the lost wax process. On the other hand, you can simply seek companies that will do the job of looking for specialized companies that produce high-quality and high precision metal finishes. At Ferralloy Inc., we guarantee that only the best products are provided and offered for you to choose from. Contact us today!

Why Use Alloy in Seamless Rolled Ring Forging

The process of seamless rolled ring forging involves different types of materials used. The rings may be made of carbon, stainless steel, or alloy. Alloy steel is a steel that contains an additional alloying material aside from carbon to improve the heat treat response or mechanical and physical properties of the rolled rings.

This additional alloying material creates steel fatigue resistance, as well as, strength and stability of the rings. Moreso, there are three diverse types of exotic alloys. Below is a short yet in-depth discussion of these types.

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Types of Alloy Rolled Rings

Waspaloy 

It is a nickel-based superalloy with an age-hardening feature that gives this seamless rolled ring forging useful strength. This type of exotic alloy works best on provisions with solution-annealed conditions. Although it is a bit difficult to wield, it’s still known to be reasonably impermeable to oxidation and possess high-standard corrosion resistance.

Therefore, it is useful for functioning in extreme environments. Waspaloy alloy rings are often used in turbine disks, shafts, rings, seals, and gas turbine blades.

Inconel

This type of exotic alloy is a family of the non-magnetic stainless steels. They can sustain their structural integrity despite being exposed to excessive temperatures. Additionally, they are resistant to oxidation and are typically used in applications that need materials that yield corrosion caused by stress-corrosion cracking and high purity water.

Inconel is normally used in industries involved in commercial gas turbines, in making jet engine parts, chemical or food processing, and aerospace.

Hastelloy X 

Hastelloy X is an alloy composed of molybdenum, iron, chromium, or nickel, making it both resistant to extreme temperatures and oxidation. They provide good ductility and are definitely easy to fabricate.  These types of seamless rolled ring forging are found in the combustion zone parts of the gas-turbine engines like flame holders, combustor cans, spray bars, and transition ducts.

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Looking for the Finest Seamless Rolled Ring Forging?

Contact Ferralloy today for more information!

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!

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.

Rolled Ring Forgings | Processing Issues Rolled Ring Forgings Resolves

Did you know that compared to other traditional metalworking methods, using rolled ring forgings allows you to resolve the most common manufacturing problems? Rolled ring forgings are created from a circular piece of the metal preform that’s been punched at the center, rounded out and cut until the desired part weight is achieved. To prove this point, check this out:

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What are the Common Ring Processing Issues that Rolled Forgings Can Solve?

Failed Structural Integrity

When manufacturers use the casting method in creating rings, the parts they produce often fail the acoustic requirements. This implies extra cost as the rings have to undergo further welding and machining to be able to satisfy the requirements in terms of connectivity. Moreover, welding and machining the rings increase their chances of producing substandard rings. Aside from this, their ability to resist corrosion is also significantly affected and their original shape will also be altered. On the other hand, the ring shape of ring forgings won’t be altered and their resistance to corrosion won’t be diminished because there would be no need for further welding or machining throughout the entire manufacturing process. Thanks to their directional grain flow, forged rolled rings exhibit superior strength.

Lack of Strength

Cast rings generally lack strength. This means that the cost of their upkeep will become potentially higher because weaker rings are prone to breaking and have a shorter lifespan. If you want more durable rings that are less likely to suffer breakage even under heavy strain and pressure, you’d be better off with forged rings.

Increased Wastage

In most cases, more materials are wasted when rings are cast, rolled, and welded from plates. Also, the shapes and sizes of the rings produced by such methods don’t usually meet the desired quality. On the other hand, forged rings can be customized in terms of size, thickness, and shape without wasting the material.

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Do You Need Rolled Ring Forgings?

If you don’t know where to find high-quality rolled ring forgings, contact Ferralloy, Inc. today.

Rolled Rings | What You May Not Know About Rolled Ring Forging Tolerances

A technological process called ring rolling is widely used in various industries that include energy and aerospace because it offers high efficiency, precision, and performance. Furthermore, the demand for rolled rings has been steadily increasing because these components are used in the production of aerospace engine parts, gear sprockets, flanges, bearing bushes, rope pulleys, pressure vessel shells, and nuclear reactor parts. In case you’re wondering, it’s possible for these rolled rings to have diameters that are up to 10 meters. Furthermore, they feature a unique circumferential grain flow that’s distinct to components that are produced via the ring rolling process.

What You Need to Know About Rolled Rings and Tolerance Standards

If there’s one thing that you need to know about the seamless forged ring process, it’s the fact that you can expect it to exhibit a higher rate of precision. This enables its finished components to meet the tolerance standards.

Rolled Ring Forging’s Ability to Create Higher Ratios

Thanks to the rolled ring forging process, it’s possible for identical and exact products to have a higher ratio. This is done through a fixed process that involves punching a hole into the central part of a piece of metal. This metal is at its malleable state after going through a heating process. Once the metal component has been pierced, the manufacturer places it between the inner and outer diameter rings. Both rings will be pressed against the donut-shaped metal in order to stretch the diameters until the required thickness is achieved. In most cases, the ratio of the wall thickness to its height could be anything from 1:16 to 16:1.

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Where to Find Top Quality Rolled Rings

Ferralloy, Inc. supplies forged rolled rings in diameters of up to 110” from alloy, carbon, as well as stainless steel. Whether you want them to be rough-machined or in its as-forged condition, you can count on us to give you the results you’ve been looking for. Call us now for inquiries.

Seamless Rolled Ring Forging | What are the Industries that Use Seamless Rolled Ring Forging?

Seamless rolled rings are popular among a number of sectors because of the advantages that they offer – cost-effectiveness, strength, reliability, its ability to withstand the maximum heat, and the fact that they can be made from practically any forgeable metal. Furthermore, these rings come in different sizes ranging anywhere from 2” to 300” inched in diameter that weigh as little as a pound or even as much as 300,000 pounds! If you’re curious to find out which industries use seamless rolled ring forging, read up.

Production of Oil and Gas

It would be impossible to produce oil and gas without using seamless rolled ring forgings in forge flanges and pressure vessel connections for the pipelines. Aside from this, hydraulic fracturing or fracking, surface gas, and oil exploration, as well as subsea connections, all require the use of the seamless rolled ring forging.

Automotive and Aviation

Thanks to seamless rolled ring forging, our cars are performing as they should. These parts are used for almost everything in the automotive industry – clutches, gears, bearings, couplings, and so much more. In the aviation industry, the seamless rolled ring forging happens to be a key component in the production of critical parts such as jet turbines and jet engines.

Heavy-Duty Manufacturing

Seamless rolled rings are present in every manufacturing industry because they are viewed as standard components in chemical processing, gear and bearing applications, and more. Since seamless rolled ring forging works well in extreme environments and temperatures as well as harsh weather conditions, they’re used in the production of reactors, wind turbines, paper mills, heating and cooling systems, rock crushing equipment, mining, robotics, and shipbuilding.

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Where to Get Top Quality Seamless Rolled Ring Forging

Ferralloy, Inc. has a team of forging experts who are able to provide you with the strongest and most reliable seamless rolled ring forging. Give us a call today.