Contact Us: 1-440-250-1900

Near Net Shapes of Seamless Rolled Rings

Seamless rolled rings offer numerous advantages, such as using less material to be machined to achieve the final machined part. However, one of the most notable factors why industries opt for these rolled rings is the near net shape factor. Aside from the cost reduction, companies or manufacturers who use the seamless rolled rings process can maintain constant durability and strength in the product. 

where is the best seamless rolled rings?

Benefits of Near Net Shapes

Cost Reduction

By using seamless rolled rings, your company can reduce costs in several ways. For instance, the process involves less wear factor in the machining equipment and requires lesser machinery hours. Additionally, there is less input component needed to design and create the ring.

Since near-net designs of seamless rolled rings substantially reduce costs, it became popular in aerospace industries. Because of the high cost of several aerospace supplies and resources, enterprises engaged in this sector often look for cost-effective substitutes.

Reduced Waste Material

Seamless rolled rings allow you to save on waste and recycle disposal costs. Hence, most manufacturing industries always guarantee that the process should produce near net shapes to reduce waste materials costs.

Why Choose Near Net Shape Manufacturing

Near net shape, manufacturing is the perfect solution for those looking to cut back on manufacturing costs. This is because near-net-shape manufacturing does not require finishing steps. So, when you do not need any machining time, you can save on production costs. It also takes less time to produce near net shapes.

where are the best seamless rolled rings?

Get Seamless Rolled Rings Today!

Ferralloy Inc. is composed of engineers who are highly skilled in designing and create forged materials. They are used to dedicating their time to create durable and reliable metal works. Among the several developing industries and companies, Ferralloy Inc. is a leader in producing and near net-shaped metal workings with ring geometry. 

To know more about what we can offer, contact our team today through this link. We assure you that only quality and lifelong metal works will be provided. 

How Accurate is Investment Casting?

Investment casting is one of the first and most common types of metal components. The procedure to create these components involves pouring molten metal into a ceramic mold. The metal solidifies within the mold, and then the metal casting is broken out. Industries that focus on food equipment, railroad, heat treating, steel production and processing, coal mining, road construction, oil, aerospace, aircraft, and other countless industries discovered the benefits of this type of casting.

where is the best investment casting?

Accuracy of Investment Casting

Near Net Shape

Investment casting is extremely accurate and near net shape. Since metal components are created by using the same wax pattern, this accuracy can be maintained from casting to casting. Additionally, this process uses stainless steel, aluminum alloy, titanium alloy, or superalloy to create and yield precise metal components that can withstand high and low temperatures.

Additionally, near net shape manufacturing is an ideal solution for those wanting to save money as much as possible. This is because near-net-shape manufacturing does not require finishing steps. So, when you do not need any time for machining done, you can save on production costs.

Intricate Design

When using investment casting, engineers can design and create a lot to customize your product. Logos, product ID’s or numbers, letters, thru-holes, slots, blind holes, external and internal splines, gears, and thread profiles are just some of the intricacies that can be done.

Guarantees Product Quality

To ensure product quality, investment casting uses different methods such as coordinate measuring, ultrasonic, and dye penetrant. These methods will be used according to where the metal components will be used. Dye penetrant testing is a nondestructive method, and it includes cleaning the surface of a product, then applying a colored penetrant, or dye.

Ultrasonic testing is also nondestructive testing that works by sending high-frequency wavelengths through an object to detect cracks and other possible flaws. Lastly, coordinate measuring uses a probing system in the machine, and data collection allows for precision, which results in durability.

where can I get the best investment casting?

Where to Look for Investment Casting

It is important to ensure that any exact measurements are achieved in machined investment casting. At Ferralloy Inc., we have the experience and authority to provide this service and product to you. Contact us today!

Comparing Die Casting and Investment Casting Methods

Die casting, and investment casting are 2 of the foremost important types of casting. Die casting is a method wherein molten metal is created and formed into a mold cavity by way of enforcing high pressure. On the other side, investment casting is a process that involves the injection of wax into the aluminum cavity. Both die casting and investment castings have different advantages and disadvantages. Read on to know more.

where are the best investment castings?

How Does Die Casting Differ from Investment Casting?

Die Casting

As stated earlier, die casting differ from investment castings in such a way that the former involves a metal casting procedure. It is categorized by the use of a mold cavity to apply high pressure to the molten metal. These molds are then machined, designed, and created from higher strength alloys. Additionally, the majority of die castings are iron-free.

Among the notable advantages that clients opt to choose to die castings over investment castings are the following: it has an exceptional economic effect, high productivity, and creates good product quality.

Investment Castings

Investment castings involve an exact and strict casting process through the use of the lost-wax process to create components in the metal cast alloys. This process is known to be very accurate, creating components with accurate dimensions and smooth surface finishes. With this process, the machining and finishing processes are reduced. Thus, it will be more cost-effective without even compromising the quality. The only downside when choosing investment casting is that it is more expensive than sand casting.

Other Differences

Casting predominantly includes special casting and sand casting. Investment casting is included under special casting while die casting is considered pressure casting, which is another major type with the same level as investment castings. As for the cost, die casting costs are higher than investment casting since the former involves post-processing operations and high-processing costs. However, when large production is needed, die casting is recommended because investment casting is a manual process that requires more time and cost.

who sells the best investment castings?

Where to Get Die Casting or Investment Castings?

If you’re planning to get components or materials that underwent die casting or investment casting process, contact Ferralloy today for more inquiries!

Investment Casting | A Closer Look at Carbon Steel Investment Castings

Have you ever wondered why manufacturers choose carbon steel for producing quality investment casting products? To help you make an informed manufacturing decision, take a closer look at the metalworking process involved in making carbon steel investment castings.

What is Investment Casting?

Investment, in this case, means being “clothed” or “surrounded.” During the process, a plastic shell or a ceramic plaster forms around the wax pattern where the metal is poured into. The investment casting process involves the production of precision-engineered parts. These parts enable you to minimize subsequent machining, material waste, as well as energy.

In fact, you might be surprised to find out that other than die casting, no other casting method can produce very intricate components. For this reason, countless design engineers find the investment casting process extremely useful.

Uses of Carbon Steel Investment Castings

Carbon steel is a popular material for the process of investment casting. Manufacturers choose several grades of carbon and low alloy steel. This is because, aside from being easily machinable, the material offers significant benefits that include practicality, availability, and wear resistance. Furthermore, carbon steel has applications in multiple industries such as oil and gas, automotive, mining, military, and commercial.

Examples of Carbon Steel Investment Castings

Some examples of carbon steel castings include firearm components, handles, cranks, brackets, valves, nozzles, gears, housings, bi-pods, and hinges.

What is Investment Casting?

Are You Looking to Find a Partner Who Can Help You with Your Next Project?

If you’re looking to find a partner who can provide you with high-quality investment casting parts, get in touch with our team at Feralloy, your leading comprehensive engineered product resource. We are a trusted global supplier of engineered products and services. Feralloy offers total supply chain management to a diverse metalworking customer base.

Open Die Forging | Closed Die Forging vs. Open Die Forging

The forging industry has come a long way from using inefficient processes and antiquated applications. Today, we see forging engineering in various industries including machinery, construction, automotive, agricultural, oilfield equipment, and so much more. Although there are numerous options for metal deformation using the forging concept, the most widely-applied processes are closed and Open Die Forging.

 

The Difference Between Closed and Open Die Forging

 

  • Closed die forging is also called impression die forging. It’s a process that involves the compression of a piece of metal under high pressure in order to fill an enclosed die impression for the required shapes. Sometimes, a second forging operation is needed to achieve the shapes’ proper dimensions. Among the factors that determine the cost of a closed die forged part are the type of material, the need for heat treatment, and the tightness of tolerances.

 

In terms of application, closed die forging is commonly used for small critical parts such as forged fittings, forged automotive parts, forged lifting and rigging hardware, etc. because of its high precision. Its benefits include better surface finish, it requires little or no machining, no material limitation, cost-effective for large production runs, and the dimensions of net shapes and tighter tolerances are highly achievable.

 

  • Open die forging is also known as free forging or smith forging. It refers to the process of deforming a workpiece by placing it in between dies that are usually flat and don’t completely enclose the material. Through a series of continuous movements, the dies hammer the metal until the required shape is formed. This process is used for simple products in small quantities such as cylinders, rings, discs, and shafts.

 

This forging technique is found to be more appropriate for large parts in a number of tons. Examples of these parts include forged rollers, forged long shafts, and forged cylinders. The benefits of Open Die Forging include cost savings, minimal material waste, reduced chances of voids, reduced lead time, little or no tooling cost, finer grain size, continuous grain flow, longer part life, increased part strength, improved microstructure, and better fatigue resistance.

Open Die Forging

Ferroalloy is a reliable comprehensive engineering resource that offers total supply chain management to a diverse customer base on a global scale. If you want to gain a deeper insight between closed and Open Die Forging, contact us today.

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.

Alloy Castings | What You Need to Know About Investment Castings

When it comes to investing in the proper components for your next project, one method you should consider is investment castings. This method can utilize alloy castings and more to make the best components possible.

The Process

There are primarily two ways that investment castings are made, gravity fed and vacuum casting. Gravity fed casting utilized the natural force of gravity to aid the molten materials in filling the castings. Vacuum casting uses gas or air pressure to help the materials reach all of the intricate parts of the casting. Both have their advantages and determining which is best for your next project will depend on the specifics.

The Benefits

The biggest benefit of using investment castings is that the process does not require secondary machining, which saves you a lot of money and time. Not having to further work the finished product allows you to cut costs and get working at the job site. Another big benefit is how durable these products are. Parts made by investment casting can be made from a wide variety of alloys that have a wider variety of applications.

Real World Applications of Investment Castings

Because so many different types of alloys can be used to craft these products, you see them in a wide variety of industries. The most common ones are:

  • Aircraft and aerospace
  • Oil and gas
  • Road construction
  • Coal mining
  • Steel production
  • Heat treating
  • Railroad
  • Food equipment
  • And much more

Investment castings are all around you at any point in your day. You should consult our office and see if investment castings are right for your next project.

What are alloy castings?

Looking for More Information About Alloy Castings?

Have you been looking for more information about alloy castings? If so, contact us today. Ferralloy is here to help you find what you need for your next project.

Alloy Castings | What You Need to Know About Alloys

When it comes to the modern industrial site, you need materials that can stand up to a lot of different environments. Alloy castings are going to be something you use often on projects. What are alloys? They are a highly-useful material that can change the way you do business.

Properties

Some metals have better electrical conductivity than others, some metals are more heat resistant than others, and some are resistant to corrosion. But what happens when you need something that has all of these properties? This is where alloy comes into play. Steel is a great example because it requires the right combination of carbon and iron. Alloys are not just a combination of materials but finding out what works on a chemical and elemental level.

Production

When it comes to alloys, some are naturally occurring while others require some processing to be used in an industrial setting. Ferro-alloys like Ferro-chromium or Ferro-silicon are produced by smelting mixed ores and are used in steel production. Producing alloys is not an easy process, it requires the right environment and temperature or else you could end up with two metals separating into layers like oil and water.

Composition of Metals

Some popular alloys that you probably interact with on a daily basis are:

  • Brass
  • Bronze
  • Pewter
  • Cast and wrought iron
  • Coin metals
  • Solder
  • And more

Not only are existing alloys produced every day, but thousands of new alloys are being developed as well. Meeting certain standard and purity is the most important part of creating a new alloy that can be used in the real world.

What are alloy castings?

Looking for Alloy Castings?

Have you been looking for more information about alloy castings? If so, contact us today! Ferralloy is your destination for everything to do with alloys.

Investment Castings | Types of Casting and What They Can Do for You

It takes many types of people to make the world go around and it takes many types of parts to make any machine work. One of the many ways to make these components is through investment castings.

What Is an Investment Casting?

Investment casting is a type of manufacturing process that involves creating castings from a wax pattern that is then repeatedly dipped in refractory ceramic material until a mold is formed. After the casting is made, the wax that helped give it shape is heated up and melted out of the cavity and replaced with molten metal. The metal solidifies inside the mold until it is fully cooled and then the casting is removed to reveal the finished product.

Vacuum Castings

One of the ways to make an investment casting is called vacuum casting. Vacuum castings follow the same process of investment casting but use an industrial vacuum to help the molten materials better set inside the casting. This is used for parts that need extra help settling into corners and other small areas.

Gravity Fed Castings

Much like vacuum castings, gravity fed castings are another way investment casting are made. This method involves using the natural force of gravity to aid the molten material in filling the casting. This is a favorite of manufacturers because it does not introduce gas or any pressure that might lead to air bubbles in the component that would weaken it. This is also a great way to mass produce components too.

What are investment castings?

Looking for More Information on Investment Castings?

Have you been looking to utilize investment castings on your next project? If so, contact us today. Ferralloy is here to help you find what you need.