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What are the Advancements in Open Die Forging?

A lot of industries know by now that open die forging can measurably decrease the costs of materials, as it needs less starting stock to create several part shapes. Hence, less machining is required to achieve a specific metal component with the added assistance of lesser lead time.

Likewise, it has the ability to reduce wear and tear on the apparatus, tool, or equipment. Fundamentally, most open die forgings are specifically made one at a time, giving every purchaser the option to buy one or hundreds of materials as needed.

where is the best open die forging?

What are the Developments in Open Die Forging?

Improved Structural Integrity

An open die forging often provides weld-free parts formed and manufactured with cleaner and forging-quality materials. One of the developments in this type of forging is that it can now eliminate rejections to achieve a fully improved structural integrity.

Using a slightly different forging process, the same material can be produced from several varieties and sizes of starting billets or ingots. Through this process, a vast range of inventoried grades are created. It only shows that because of this flexibility, any parts or geometry can be produced economically, reasonably, and quickly.

Near Net Shape or Size

Although open die forging is commonly known to produce near net shape or size, advancements in this aspect allow it to create even precise and durable parts. Because every part of the forging process employs forge tooling is numerous ways to decrease the machining process time and input material, a good quality component is produced.

Experts know that tooling is the foundation for a perfect impression forging. However, this application is ideal only when the process involves a high quantity of repeatable products. With open die forging, the tolerances achieved because of advancements in technologies provide less machining requirements to acquire finished sizes and shapes.

Ultimate Solution in Custom Designs

Open die forging is also famous for being the ultimate preference in custom designs. Because it is flexible enough to the point that it is easy to achieve near net shapes and sizes, it becomes even easier to produce custom-designed metal components.

where is the best place to get open die forging?

Where to Get Open Die Forgings?

Are you planning to purchase quality open die forgings? If so, contact Ferralloy Inc. today! Our team is highly trained to help you find your needs.

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!

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!

 

 

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.

Titanium Fasteners | Benefits of Titanium vs Other Materials

There are many different metals that can be used in an industrial setting, but the best is titanium. Titanium fasteners, tubing, and bolts are just a few things the material can be made in to. It can be used to make many different types of parts and has tons of benefits. As a result, there are many different parts that titanium can be used for.

Usually Maintenance Free

Given that titanium’s oxide layer protects the fasteners from corrosion, it makes it much more durable than the average material. Given that it doesn’t corrode, that means there is little to no maintenance needed on the piece. You will want something that is strong, durable, and sturdy like titanium for your next project.

Cost-Efficient

Because titanium parts are typically maintenance free and do not corrode in the first place, it is a very cost-efficient component. You will not need to keep replacing it or worry about it falling apart on you. Once you make the investment in titanium, you won’t need to worry about sinking more money into it.

Can Combine with Other Metals

One of the biggest advantages of titanium is that you can combine it with other metals to create an alloy. You can combine it with:

  • Steel
  • Aluminum
  • Manganese
  • And more

Having such a versatile material like titanium is not only very helpful but smart too. Using the best materials will lead to the best results.

Are you looking for Titanium Fasteners?

Looking for Titanium Fasteners?

If you are looking for the best titanium fasteners, contact us today. Ferralloy has been providing titanium parts to countless industries and companies throughout the world for almost four decades. We are here to help you and your business in any way possible.

Inconel | What You Need to Know About Inconel

In today’s manufacturing industry, the use of metal alloys is as prevalent as ever. The whole metals of old have been replaced with metal “blends”. An example of this is Inconel. Let’s take a look at what you need to know about this type of alloy and where you can find it for your next project.

What is It?

Inconel is a name for certain groups of nickel alloys, many of which also include chromium. It is one of the most popular types of alloys in modern manufacturing. This is due to its resistance to rust and corrosion, as well as its hardness and durability.

What Are Its Uses?

Inconel is commonly used in parts destined for high-pressure environments. Examples of this include turbine blades, exhaust pipes, and heat shields. It is also used in various types of automotive and aircraft parts that have to stand up to high pressure and/or high temperatures. The heat resistance is what makes it so popular. Where aluminum or even steel might wither and not handle heat well, Inconel reacts very well to high temperatures.

Is It Easy to Work with?

One of the few drawbacks to the durability is that it can be difficult to work with when it comes to production equipment. Since it handles high temperatures so well, things like machining and welding can be a challenge. As a result, a water-jet cutter, or specific kinds of ceramic cutter is needed when dealing with it.

Are You Looking for Inconel?

If you are in the market for Inconel, or any other type of metal part, we have you covered at Ferralloy. Contact us today to learn more.

 

Where can I find inconel?

Alloy Castings | Interesting Facts About Alloy

Casting can be used to make a wide variety of products. There are also numerous materials that can be cast. One of those materials is alloy. Let’s take a look at some facts as it pertains to alloy and alloy castings.

Alloy Facts

  • An alloy is a blend of two or more metals.
  • Many alloys with the word “silver” in their name are only silver in color. Examples of this include German silver and Tibetan silver.
  • Solder is an alloy that is used to bond metals to each other. As a result, it’s an alloy blend of lead and tin.
  • Stainless steel is an alloy of iron, low levels of carbon, and chromium.
  • Pewter is a tin alloy that consists of 85-99% tin mixed with copper, antimony, bismuth, lead, and/or silver.
  • Brass is an alloy consisting mostly of copper and zinc.
  • Bronze is an alloy of copper with another metal, usually tin.
  • Electrum is a naturally occurring alloy of gold and silver with small amounts of copper and other metals.
  • Electrum was used as far back as 3000 B.C. for coins, drinking vessels, and ornaments.
  • While gold can exist as a pure metal, most gold you encounter is actually an alloy.
  • An amalgam is an alloy made by combining mercury with another metal.
  • Almost all metals form amalgams. The exception to this is iron.

Are You Looking for Alloy Castings?

At Ferralloy we know that different projects call for different materials. That’s why we offer castings in a variety of different materials, including alloy. Contact us today to learn more or to place an order.

 

where can I get alloy castings?

Inconel | What Are the Types of Inconel?

Inconel is in the superalloy family. It is nickel-chromium-based and is corrosion resistant. As a result, it is ideal in extreme environments subjected to pressure and heat. When it comes to Inconel, there are a few different main types. Let’s take a look at some of the different types.

600

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

617

This type is a high-temperature nickel-chromium-cobalt-molybdenum alloy that is both corrosion and oxidation resistant. Its main uses include gas turbine engine ducting and combustion liners. It is also popular in the chemical processing industry due to its resistance to a wide range of aqueous corrosive media.

625

Like the 600, Inconel 625 is a corrosion and oxidation-resistant nickel-base alloy. It has outstanding strength and toughness in the temperature range cryogenic to 2000ºF. This is because of the solid solution effects of columbium and molybdenum. This type of alloy can be found in heat shields, furnace hardware, gas turbine engine ducting, combustion liners and spray bars, chemical plant hardware, and special seawater applications.

Are You Looking for Inconel?

At Ferralloy, no matter what the grade or the use we have the alloys that you need for your next project. Contact us today to learn more or to place an order for your next project.

 

Where can I find inconel?

Investment Castings | The Investment Casting Process

Investment casting is one of the oldest manufacturing processes. It dates back thousands of years and is used to make pipe fittings, turbine blades, armament parts, lock parts, hand tools, and even jewelry. They can be made using a wide variety of metals. Those include aluminum alloys, bronze alloys, magnesium alloys, cast iron, stainless steel, and tool steel. Let’s take a look at the process that goes into making investment castings.

Pattern Creation

When it comes to creating the pattern, the injection is inserted into the metal die and are formed as one piece. The cores are used to form any internal features on the pattern. These patterns are then attached to a central wax gating system. The gating system forms the channels through which the molten metal will flow to the mold cavity.

Mold Creation

These patterns are then dipped into fine ceramic particles, coated with coarse particles, and then dried to form a ceramic shell around the patterns and gating system. This process continues until the shell is thick enough to withstand the molten metal. The shell is then placed into an oven and the wax is melted out leaving. This leaves a hollow ceramic shell.

Pouring

During this step, the mold is preheated and the molten metal is poured. This fills out the mold cavity.

Cooling

After the mold has been filled, the metal then cools and solidifies into the final casting shape. Cooling time depends on the thickness of the part, thickness of the mold, and the material used.

Removal and Finishing

After the molten metal cools, the mold is then broken and the casting removed. Finishing takes place when the final product is grinded or sandblasted to make it completely smooth.

Are You Looking for Investment Castings?

Ferralloy is your home for all your investment casting needs. Contact us today to learn more or to place an order.

 

Who has investment castings?

Alloy Castings | Can Alloy Completely Replace Other Metals?

In the eyes of the average person, alloys and metals are one in the same. Many people think that an alloy is part of the metal family. That’s not the case. Not only are alloys and metals different, they have very specific uses. Let’s take a look at just a few of the reasons why alloy castings and other metals aren’t interchangeable.

Flexibility

While alloys are hard and durable, metals tend to have more of a flexibility or give to them. Metals can be compressed or reshaped without breaking them. They can even be reshaped with the use of a hammer. Alloys can’t be reshaped without breaking it.

Durability

You might think that since alloys cannot be broken easily that they are more durable than metals. Well, you would be wrong. At least strictly from a definition standpoint. Durability is not just measured by strength and hardness. It is also measured by how long it lasts in the same state. From strictly the long-lasting standpoint, many metals are considered more durable than alloy.

Recycling

While metals can be recycled, alloys can’t. Since alloys are made from two or more elements they can’t be recycled since those elements can’t be separated. The only way an alloy can be recycled is by restoring and reusing it.

Are You Looking for Alloy Castings?

Whether its alloy or another type of metal, at Ferralloy we have you covered. Contact us today to learn more about our products and find out how we can help you with your next project.

 

Who has alloy castings?