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Alloy Casting for Pressure Valves

Aside from the fact that alloy castings are more cost-effective than other methods, casting also allows you to create certain parts that are designed according to your requirements. To give you a better idea about how beneficial it is for your business to choose alloy castings for pressure valves, read on.

alloy castings

Advantages of Using Alloy Castings

Flexibility

Alloy castings are shaped as liquid and possess features like low melting point, high fluidity, and good as-solidified strength. They are widely used in the form of die castings and general-purpose sand castings. Additionally, this type of castings is used where fluidity, good corrosion resistance, and rigidity are of greater importance than strength.

Unquestionably, the most widely used alloys are those containing between 9.0% to 13.0% silicon, which occasionally have small amounts of copper. Silicon increases fluidity and decreases shrinkage of molten aluminum alloy so that castability is high and intricate shapes and complex geometry can be cast. Hence, it becomes easier for alloy castings to be used in creating pressure valves.

Lightweight Yet Powerful

Although alloy steel castings are extremely lightweight, their sturdiness allows them to be effectively applied for companies that are involved in the manufacturing of vehicles. Furthermore, when it comes to the production of high-performance wheels, this type of casting can be your best option.

Durable

The calcium, zirconium, nickel, and cerium components in alloy castings make them highly durable compared to other options. You can expect your alloy castings to exhibit better resistance to wear and tear, as well as high heat.

alloy castings

 

Applications of Alloy Castings

Most alloy castings are applied in components that require intricate castings. This type of casting is widely used in water jackets, valve bodies, pressure-tight components, heavy-duty pistons for diesel engines, cylinder-heads for liquid and air-cooled engines, and automobile pistons.

If you want to know more about the applications of alloy castings, contact Ferralloy Inc. through this link!

How Are Steel Forgings Made?

Steel forging involves the heating, deforming, and polishing of steel to create a durable and precise material. These materials are created by forcing materials into customized shapes, either by the die press surrounding a piece of metal or forcing such metal into custom-built patterns. Steel forgings have a broad range of properties and can use different types of materials.

steel forgings made

Properties of Steel Forgings

Limit on Size

Throughout the forging process, shaping a certain type of metal can be very difficult. The reason for this is that forging transpires while the metal is still solid. Because the metallurgists engaged in this project will have a bit of a challenge in altering the shape of the metal, there is a limit on the thickness and size. Hence, the larger the steel section being worked on, the more difficult it is to forge.

Consistency

The great thing about steel forgings is that there is consistency. Because the procedures are deliberate and controlled, each forging goes through the same processes. With steel forgings, it is ordinarily possible to guarantee a consistent material.

Anisotropic

As for the strength of steel forgings, it is not consistent throughout the process; instead, it is anisotropic. In physics, anisotropic is defined as a difference in a material’s physical or mechanical properties. This means that when the steel is worked on, deformation typically occurs.

Durable and Strong

This type of forging produces results that have exceptional strength and are generally tougher than steel produced through other means. Since steel is less likely to break and get altered in contact with other materials, it is often used by industries that require tools and components with increased durability and strength.

steel forgings made

Where Can You Get Steel Forgings?

Steel forgings are widely used by many companies, such as those in the mining, electronics, and aerospace industry. If you’re looking for quality steel forgings, you can give Ferralloy Inc. a call!

Properties and Categories of Steel Forgings

There are various materials that can be used to create forged parts and components. Inconel, cobalt alloys, titanium, nickel, and steel are just a few of the innumerable forging materials. Which one you choose all depends on the specific application of your desired part. Below are the properties and categories of steel forgings you may want to consider for your next project.

steel forgings

What Are Its Properties?

Discussing the properties of steel forgings will give you an idea as to why it’s so commonly used. Because of the properties forged steel possesses, everything is made easier and more precise. Its properties are a bit unique when compared to steel casting.

Range and Uniformity

Although there are some limitations as to the thickness and size of the forgeable steel, it can still precisely follow the design’s consistency. Every forged steel that is manufactured undergoes an accurate and meticulous process that guarantees optimal results.

Persona and Solidity

Most experts say that when a metal is anisotropic, its strength tends to be unpredictable throughout the forging process. Such a persona of steel makes it easier to produce a good resulting grain flow during the fabrication method.

As for its solidity feature, steel forgings are known for their first-rate durability, greater toughness, and superb strength. When it comes in contact with other metals or substances, it is very unlikely to shatter.

What Are Its Categories?

Steel forging can be categorized into two main types:

Open die forging is a type of drop forging technique of deforming a metal according to the desired shape. Without any limitation, it can utilize the inflicted pressure and power.

In contrast, closed die forging relates to a process in which a metal is placed between shapes customized to fit the metal. Such metal is then pressed and hammered, causing it to fill and flow in the cavities of the custom-shaped dies.

steel forgings

Learn More About Steel Forgings

At Ferralloy Inc., our commitment to high-quality engineered products and services is evident from our diverse metalworking customer base. For more inquiries, contact our experts through this link!

Forging Efficient Carbon Rolled Rings

Seamless rolled ring forging is generally a cost-efficient option, especially when the forging process uses carbon steel. It allows you to create a product that can be hardened through tempering and quenching. However, this may depend on the grade of the material used. Below are the characteristics of carbon-rolled rings you may want to know.

seamless-rolled-ring-forging

Common Characteristics and Downstream Processing

What Are the Characteristics of Carbon Steel?

Its characteristics may depend on the material the manufacturer uses. For instance, A Grade carbon steel such as A360LF2 is ideal for oil field application because of its corrosion-resistant feature. Most A Grade carbon steel includes alloying elements like nickel and manganese for enhanced toughness and hardenability. Some types are also great in medium strength applications.

Next to A Grade carbon steel materials are high carbon steel. Just like the former, it also contains manganese to improve the steel’s hardenability characteristic. Akin to 1040/1045, the most common high-grade carbon steels used are 15B22 and 1541V. They are also cost-effective and can be heat treated and welded for higher quality.

As for low carbon steel, it usually contains sulfur to increase and enhance its machinability aspect. Commonly known as resulfurized carbon steel, its common grades include 1146, 1141, and 1117.

Aside from low, high, and A Grade carbon steel, manufacturers also use plain carbon steel. It is the most cost-effective material used and is great for welding. Just like any other material, this one can provide decent surface hardness and toughness.

Downstream Processing

Carbon steel materials are generally used if the application doesn’t have to undergo a high-temperature environment and high strength processes. Also, when it comes to the downstream processing of this material, it involves the following:

  • Positive material identification
  • Chemical analysis
  • Mechanical analysis
  • Magnetic particle inspection
  • Ultrasonic inspection
  • Hardness testing
  • Shot blasting

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Get Efficient Seamless Rolled Ring Forging

At Ferralloy, we make sure that our products undergo a thorough inspection to better quality control. If you want high-quality and worth-the-investment carbon steel rings, our experts can guide you in finding the perfect one. Contact us today to learn more!

Cobalt Alloys Versus Inconel Alloys

Is your recent metalworking process hindered by component variance and additional costs? Perhaps you should consider switching to alloy castings so you can add more value to your project. Its manufacturing process is nothing short of versatile since it allows you to create a wide range of metal parts with several applications in a lot of industries.

where can i get the best alloy castings?

Which is Best: Cobalt Alloy or Inconel Alloy?

Applications of Cobalt Alloy

Cobalt alloy is used to cope with extreme wear and tear. By introducing a variety of other components, it can be specifically molded for a particular use. The primary advantages cobalt alloys can offer are exceptional wear resistance and exemplary material or component strength. It also has the ability to work under extreme temperatures. Because of its durability, though, it is a little more expensive.

The major applications of cobalt alloy casting include saw teeth, acid-resistant machine parts, poppet valves, valve seats, and exhaust valves of the internal combustion engine. Cobalt alloys are also applied in the following:

  • Turning tools for lathes
  • Medical applications including the manufacturing of artificial hip joints, other bone replacements, and cast structure of the dental prosthesis
  • M2HB machine gun and machine gun barrels

Applications of Inconel Alloy

Inconel is an alloy of nickel that also contains chromium and iron. It is resistant to both corrosion and high temperatures, making it a valuable material. It is worth the cost because the material is extremely tough and does not break down or falter often.

Given the properties of the material, it has several practical applications. It can withstand extreme temperatures and retain adequate tensile strength to hold substantial loads while being exposed to temperatures over 2,000 degrees Fahrenheit. In addition to that, Inconel is great when it comes to dealing with rapid temperature changes too. It can withstand the cold just as well as it withstands high temperatures.

where can i get the best alloy castings?

In Search of a Quality Alloy Castings Company?

If you’re looking to find top-quality alloy casting, get in touch with the leading comprehensive engineered product resource – Ferralloy, Inc. Contact our knowledgeable staff to inquire about our services!

Continuous and Lost Foam Casting

There are several types of machined castings and the less discussed methods are continuous

and lost foam casting. Both have complicated technological processes and complex technical characteristics. Here are the facts on the two types of castings.

where can i get machined castings?

Why Choose These Types of Castings

Continuous Casting

It is a state-of-the-art casting method that involves the continuous pour of molten metal into a crystallizer. Once it solidifies, the casting is continuously pulled out from another end so the metal can obtain any specific length.

When it comes to technical characteristics, continuous casting can enhance production efficiency. Likewise, because of the simplified techniques, this process can dramatically reduce the desired production area and labor intensity. Another advantage why using continuous casting is recommendable is the fact that it offers good mechanical properties, uniform structure, and dense crystals.

Continuous castings are often applied in productions with cross-sectional shapes like pipes, rod billets, slabs, and ingots. This type of casting is also used in components made of magnesium alloys, aluminum alloys, copper alloys, iron, and cast steel.

Lost Foam Casting

Otherwise known as a solid casting, lost foam casting is a contemporary method that involves a combination of foam or paraffin models akin to the shape and size of the casting to produce a model cluster. After drying and brushing the refractory coating, it is buried in dry sand and poured under intense pressure to vaporize the model.

As for its technical characteristics, lost foam casting can reduce production costs and investment. It also offers a high degree of freedom during the production process, flexible design, and no parting surface.

As for application purposes, it works best in producing different sizes of precision castings with complicated structures. The best thing about this type of casting is that there are no restrictions on the kind of alloy used.

where can i get machined castings?

Learn More About the Other Types of Machined Castings

Apart from lost foam and continuous casting, there are also other types of casting processes such as squeezing die casting, vacuum die casting, and many more. Contact our experts at Ferralloy Inc. to know more!

Benefits of Alloy and Steel Castings

Depending on the purpose and ultimate use of the metal part, different procedures are employed to create the highest quality piece possible. As for the castings process, it is considered to be one of the best.

The process involves the heating of the metal until it turns molten before being poured into a die to form a specific shape. It is beneficial when the shape of the component is intricate or when the component needs to be a very large size. To know more, below are the benefits of using alloy and steel castings.

where can i get castings?

Why Use Castings?

Advantages of a Steel Casting

Design flexibility, metallurgical versatility, and large weight and size range are the notable advantages alloy castings can offer. Their flexibility grants the designers the freedom to choose whichever shape and size they desire. It is extremely simple to form and change the shape of components, and all in a timely manner.

More so, steel castings obtain a wider range of physical and mechanical properties than any other cast metal. All that this casting needs to do is simply vary the carbon and alloy content, fluctuate the heat treatment, and gain good weldability and workability.

Advantages of an Alloy Casting

Alloy castings are extremely versatile and are able to possess a wide range of characteristics. They can produce near-net-shape parts with a controlled surface finish, dimensional accuracy, and complex geometries.

Additionally, alloy castings can withstand the highest operating temperatures when compared to any other cast alloy. These castings possess outstanding corrosion resistance, thermal and electrical conductivity, EMI and RFI shielding properties, and are fully recyclable.

where can i get castings?

Where to Get Quality Castings?

If you’re interested in utilizing all of the advantages of steel and 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 quality and exceptional machined parts in a lot of different ferrous and non-ferrous alloys. Various types of steels are also available to cater to your project.

Advantages of Using Steel Castings

The word “casting” is used to define or refer to the part made by the machine casting process, which dates back more than 5,000 years ago. When it comes to history, this process is performed to make significant and complex metal components that would have been difficult when using the traditional manufacturing method. Because of this development, steel casting emerged.

what are the advantages of steel castings?

Why Use Castings?

Strength and Durability

Most manufacturers choose to use stainless steel castings for valve bonnets because of their incredible durability and strength. You can expect these types of valve bonnets to function well and remain in excellent condition for a long period of time, even when you use them in extreme temperatures.

Metallurgical Versatility

Castings allow you to choose among different chemical compositions and organizational control that fit your project’s requirements. In other words, castings offer strong metallurgical variability and adaptability.

Furthermore, compared to any other cast metal, you can obtain a wide array of physical and mechanical properties by simply making variations in its carbon and alloy content or heat treatment.

Economic Benefits and Greater Reliability

You can depend on cast steel parts for day-to-day use because they are designed with an isotropic material that intensifies engineering reliability. When you factor in its design flexibility and shorter delivery time, castings can give you the economic efficiency you’re looking for.

Design Flexibility

With steel castings, you can select from a wide range of alloys that can provide your designers the flexibility to configure your cast according to their needs. Aside from the fact that maximum design freedom to produce complex shapes and hollow section parts is never impossible when using steel castings, these can also be configured in a sturdy and repeatable manner.

Since steel castings’ design flexibility allows you to make quick changes as needed, your delivery time is dramatically shortened.

what are the advantages of steel castings?

Are You Looking for Steel Castings?

If you want to explore your options and invest in steel castings, contact the team at Ferralloy, Inc. today!

How Much Do You Know About Inconel?

Do you know what type of alloy is known to have oxidation – and corrosion-resistant materials? Inconel, a brand name for specific nickel-chromium alloys, is well-suited for service in extreme environments subjected to pressure and heat.

It is often used by industries that use forged materials exposed to extreme heat because of this capability. However, did you know that it’s extremely hard to weld on its own?

where can i get iconel?

Weld Inconel with TIG Welding

What is Titanium Inert Gas (TIG) Welding?

Titanium belongs in the family of reactive metals; meaning, it possesses a resilient affinity for oxygen. At room temperature, this metal reacts with oxygen to produce titanium dioxide. The passive and impenetrable coating combats further interaction from the surrounding particles. With titanium inert gas welding, manufacturers can secure the weld area from water vapor and oxygen.

How Does TIG Welding Enhance Inconel Welding?

As stated earlier, Inconel is generally complex to weld since the welds tend to crack because of too much heat and pressure. Nonetheless, certain types of Inconel are specially designed to be weldable.

In welding Inconel, industries must use an Inconel 625 filler metal. This is usually the most common weldable type of Inconel. According to metal experts, this type is useful in welding two pieces of Inconel together. Another good part of using Inconel 625 is that it can also be welded with other metals. For instance, most welding industries use stainless steel and Inconel to produce durable and heat-resistance metal.

For welding Inconel, you have to expect an ill-defined weld pool that may seem dirty and substandard for welders used to steel; however, this is normal. The important thing is that it welds a resilient and highly corrosion-resistant product.

where can i get iconel?

More Information About Welding Inconel with TIG Technique

The TIG technique offers the welder to gain more control over the materials. Additionally, this technique uses a clear-cut welding arc and is well-fitted for automation. Contact Ferralloy Inc. to learn more!

What to Know About Custom Machined Forgings

Machined forgings involve various metalworking processes that manufacture parts with a strength greater than other metalworking techniques. Once the piece of the metal is shaped during the forging process, the internal grain structure of such metal becomes uninterrupted throughout the part, producing results with exceptional reliability at high-stress points and inconceivable strength.

what is machined forgings

Benefits of Opting for Custom Machined Forgings

“Cannot Fail” Applications

Materials used in custom machined forgings are aluminum, nickel, titanium, stainless steel, micro-alloy steel, re-sulfurized steel, alloy steel, and carbon steel. With these materials, the parts created through this process are mostly used in several “cannot fail” applications such as parts used by chemical industries, mining companies, automotive industries, and aerospace.

Apart from these companies, metal parts produced through custom machined forgings are also used in pharmaceutical, medical, marine, power and energy, food and beverage, petrochemical, military, heavy trucking, and agriculture.

Enhanced Metallurgical Properties

In most cases, custom machined castings use selective heating and non-uniform cooling to avoid failure or damage to a particular component. With this customized metalworking process, you are guaranteed that your finished shape will have superior grain flow without internal voids.

You’re probably aware that shrinkage and porosity are often seen in casted products. However, with machined forgings, the occurrence of unexpected failure under high-temperature differences or stress is greatly reduced.

Versatility and Cost-Effectiveness

When you learn about forging processes, you’ll be amazed at the wide array of metals that can be forged into a particular shape. Although each of these options comes with a unique set of characteristics, the forging process can be applied in the production of specific parts that your project requires.

Additionally, when it comes to precision metal manufacturing in high production runs, machined forgings offer a significant cost advantage due to the fact the materials used in the process are cheaper compared with the materials required in other metalworking processes.

what is machined forgings?

Where to Look for a Machined Forgings Product?

At Ferralloy Inc., our team makes sure that we only work with reliable and trusted forging partners. Contact us today for quality products.