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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!

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!

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.

Heat Treating Baskets | The 3 Different Heat Treatment Processes

For hundreds of years, people have been heat-treating metals for the purpose of improving their physical and chemical properties to fit a given application. However, we’ve come a long way since the blacksmiths of the middle ages forged and tempered metals to produce tools for everyday life. Today, material engineers and metallurgists use more specialized techniques and tools such as Heat-Treating Baskets to customize materials for definite applications.

 

The 3 Major Heat Treatment Processes

 

  1. Hardening

 

This process involves the heating of steel at a specific temperature until its pearlite is transformed into austenite before it is rapidly quenched in water or oil. The appropriate temperature at which the transformation quickly takes place is highly dependent upon the steel’s carbon content. For the core to be fully transformed into austenite, the heating time must be increased. In case you’re wondering, the hardened steel part’s microstructure us martensite, ferrite, or cementite.

 

  1. Tempering

 

When steel that has both been quenched and hardened for a period of time prior to being heated, the process involved would be tempering. The temperature at which this process is carried out is a critical factor that dictates the hardness and strength that is obtained. For example, high temperatures will produce high ductility, but low in hardness and strength. Conversely, low temperatures will result in low ductility, but high in hardness and strength. It’s extremely important to select the appropriate tempering temperature to achieve the desired level of hardness and strength. Tempering is performed on carbon steels that have been hardened to reduce their brittleness.

 

  1. Annealing

 

When steel is treated up to high temperature then cooled very slowly to room temperature to produce its high ductility and strength, but low in hardness, the process of annealing is being applied. In other words, annealing is performed by heating a component to the appropriate temperature before it soaks it at room temperature. The furnace is then shut off while the piece of steel is inside it.

 What are forgings

Are You Looking to Find Heat-Treating Baskets?

 Heat-Treating Baskets are crucial pieces of any kind of heat-treating process. Only Ferralloy offers high-quality baskets that are second to none. 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.

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.

Open Die Forging | What You Need to Know About Open Die Forging

When it comes to the forging process, there are many different types. One of the more popular types used to create parts that are used in your everyday life is through open die forging.

The Process

The open die forging process is a popular and effective way to produce the parts that you need and use on a daily basis. The process itself consists of deforming metal parts by heating them between a top die attached to a ram and bottom die. Depending on what type of metal is used, it will be exposed to temperatures that range between 500 °F to 2400 °F while slowly shaping the metal into the desired shape. This is done through pressing and/or hammering the metal into place. The process usually requires a secondary machine or refining in order to reach the desired specifications.

The Benefits and Applications

Even though parts created through open die forging usually require secondary machining, it is still a popular process that sees results. Parts created by open die forging are:

  • Discs
  • Rings
  • Sleeves
  • Shafts
  • Cylinders
  • And more

The biggest benefit of this type of forging is that the repeated working of the metal increases its strength and grain structure of the finished product. Parts made by this type of forging are tough and last long. They are resistant to fatigue and typically have a lower number of voids compared to other processes.

Where can I find the best open die forgings?

Looking for More Information About Open Die Forging?

Have you been looking for more information about open die forging, the process, or it’s practical applications? If so, contact us today. Ferralloy is here to help you find what you need 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.

Furnace Rolls – Different Types of Furnace Rollers

Furnace rolls are specialty rolls that are found in furnaces and used to allow furnaces to operate efficiently. When it comes to these, and furnace rollers, there are several different types, each with different specific functions. Let’s take a look at the different types of furnace rolls and furnace rollers.

Vertical Annealing Furnace Roller

A vertical annealing furnace roller is used to connect the galvanizing line of the vertical annealing furnace and the nitrogen-hydrogen. This type of roller is then ideal for furnace temperatures between 750 degrees and 950 degrees Celsius.

Heavy Plate Heat Treatment Furnace Roller

A heavy plate heat treatment furnace roller is used for normalizing hardening furnaces. This type of roller is wide and heavy and, as a result, the heat treatment process is carried out uniformly and rapidly. It is ideal for temperatures ranging from 550 ℃ to 950 ℃.

Horizontal Annealing Furnace Roller

A horizontal annealing furnace roller is similar to its vertical counterpart. As a result, it is used for continuous annealing. Just like the vertical one, it’s ideal for furnace temperatures between 750 degrees and 950 degrees Celsius.

Where Can I Get Furnace Rolls?

When you are in need of metal components, like furnace rolls, Ferralloy takes the time to learn and understand what your needs are in order to provide you with the highest quality product that you need. Only the highest quality metal components leave our factories, and to your specifications. After all, there’s a reason why we celebrated our 40th anniversary this year. Contact us today to learn more or to place an order.

 

What are furnace rolls?