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What is Shock Resistance?

In product condition processes, shock resistance testing is used to assess the impact of sudden acceleration due to the collision, drop, and explosion. Companies focused on castings investment and forging perform this test to develop products that can withstand harsh military, transportation, and industrial environments.

Castings Investment

What You Need to Know About Shock Resistance Testing

Simulate Real-World Use

Although shock resistance testing is sometimes compared to vibration testing, the former involves a more complicated and extreme process. The procedures are designed to use a specific type of force to recreate real-world use. Producers and manufacturers use an accelerometer to gauge the force and speed. Through this, the materials will be exposed to loads of pressure and impact.

After which, they assess and classify the material for stress and damage. Because of these rigid procedures, manufacturers and producers are able to guarantee that the product can meet the demands of its work setting.

Accurate Results

A team of experts conducts shock resistance testing that complies with several military and industrial standards such as EN 60068, DEF STAN 00-35, MIL-STD-810, and RTCA DO-160. These engineer experts aim to support custom and complicated projects through the assistance of specification selection and protocol development processes. Since manufacturers and producers possess a global platform of experts and laboratories, getting accurate results on time is never an issue.

Other Tests

Aside from the shock resistance test, there are also other tests that manufacturers routinely perform to guarantee quality results. Some of the tests employed are impact testing, drop testing, shock and impulse testing, bump/shock testing, decaying sine wave testing, shock pulse testing, and operational crash safety.

Castings Investment

Tests Employed in Castings Investment

Are you interested in learning about the other tests used in castings investment and how they can benefit the material cast? Contact Ferralloy Inc., today so our experts can address your questions!

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!

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!

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.

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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.

Forged Rolled Rings for Quality Products

Forged rolled rings offer several advantages, such as using less material to be machined to achieve the final product. However, one of the most notable factors why industries opt for this type of process is the intricate process involved in producing the final product.

What are forged rolled rings?

Process and Advantages of Forged Rolled Rings

Process

In the forged rolled rings’ manufacturing process, the waste of the metal that is punched out is prevented, and the metal piece is forged to become stronger and more durable. A donut shape is formed from metal and then forged into the metal ring that is desired.

The size and diameter are shaped from this donut-shaped metal as it reaches extremely high temperatures to the point that it becomes malleable. This process saves metal waste due to the ring being punched out, making it more cost-effective. Aside from being cost-effective, forged rolled rings can provide strong and durable metal components.

Advantages

  • Material Costs – Rolled ring forging can significantly reduce material costs! Typically, it uses fewer starting metal components to create the desired shapes. For instance, if the process requires a torch cut part, the complete center slug and entire corner stock are lost. With other forging processes, other parts are produced to a size that results in minimal waste.
  • Reduced Reduction Rates – This type of forging eliminates or reduces rejections by yielding enhanced structural integrity and using forging-quality materials. Additionally, the rolled ring forging process provides weld-free parts created with cleaner and quality material.
  • Efficiency in Production – Using a rolled ring forging process, the same material can be created from several and various sizes of starting billets or ingots. It allows for a wider variety of inventoried material grades. The production process’s flexibility implies that forges materials of almost any grade can be designed and produced rapidly and more economically.

What are forged rolled rings?

Looking for Forged Rolled Rings

Companies or manufacturers who use the forged rolled rings process can maintain constant durability and strength. Hence, clients who purchase these items are more likely to have worth-the-investment purchases. Contact Ferralloy Inc. to get forged rolled rings!

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.

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.

Advantages of Carbon Rolled Rings

Are you interested in utilizing the advantages of carbon rolled rings for your next project? If yes, contact Ferralloy, Inc., because our team can supply you with rolled ring forgings in diameters up to 110” and in various materials ranging from carbon to stainless steel.

where can i find rolled rings?

What Benefits Can Carbon Rolled Rings Offer?

Economical

When using carbon in the rolled ring process, the forged components made from this material tend to be cheaper than other rolled ring materials. Additionally, there are excellent forging tools to enhance the manufacturing process’s efficiency. Aside from being economical, it may considerably reduce the waste produced during the process.

Production of Various Shapes

To produce various shapes of forged components, it is required that the forging process also involves different methods. Since carbon steel forgings are incredibly flexible, it is easier to create them in different shapes. The most common shapes produced by this rolled ring process are hubs, discs, blocks, seamless rolled rings, and flanges.

Challenging Applications

Forged materials are enforced to play a critical role in various challenging applications such as pressure vessels, power generators, aircraft components, and oil rigs. The capacity of carbon rolled ring products to tolerate resistance makes them an excellent option for such applications. Additionally, the forged components produced are available in different sizes and grades.

Metal Grades

Aside from different sizes and shapes, carbon rolled rings have four distinct grades. These metal grades significantly differ from one another on the basis of their hardness, endurance, wear, and strength. This allows companies, using forged components, to choose a category that ideally suits their standards. While there are several alloys that can provide industries with various metal grades, no other alloy can provide the versatility of carbon rolled rings.

where can i find rolled rings?

Where to Find Carbon Rolled Rings?

If you’re one of those industries that want to purchase and secure quality carbon rolled rings, you can contact Ferralloy Inc. today!

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.