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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!

 

 

Open Die Forging | How Open Die and Closed Die Forging Differs

Forging is used in a variety of industries for things like construction machines, agricultural machinery, automotive, and oilfield equipment. When it comes to forgings, there are two main types. Those are open die and closed die forging. Let’s take a look at how open die forging and closed die forging differ.

Definition

Open die forging is also referred to as free forging. During the open die process, metal billets are compressed under external compressive force and deformed to the desired dimensions or shapes without forging dies. Closed die forging is also known as impression die forging. During the closed die process, the material is heated by a medium frequency induction heating furnace to high temperatures. It is then forged between upper and lower dies to get the expected shapes.

Process

For closed die forging, the molding dies are first precision machined. The metal bars are then placed on between upper and lower dies and forged to any shapes needed. As a result, closed die forging is a net shape or near net shape process. With open die forgings, enormous compressive forces are imposed by the continuous strike of a forging hammer to deform the metal billets. Unlike closed die forging, the open die process is significantly more simple.

Are You Looking for Open Die Forging?

At Ferralloy, we have the forgings you need for your next project. Whether it’s open die or closed die, we have the parts you need. Contact us today to learn more or to place an order.

 

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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?

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?

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.

 

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Rolled Rings | How Are Rings Rolled?

Rings are typically rolled by a process called ring rolling. Ring rolling is done on rolling mills. They can be produced in configurations ranging from flat, washer-like parts to tall, cylindrical shapes, with heights ranging from less than an inch to more than 9 feet. Let’s take a look at the process for rolled rings and how they are made.

Ring Rolling Process

Starting Stock – The first step is the rounding of the starting stock. It is then upset to achieve structural integrity and directional grain flow.

Punching and Piercing – After being rounded and upset, the stock is then punched and pierced to achieve the doughnut shape needed.

Idler Roll – After the stock has been given its doughnut shape, the rolling itself can begin. The process begins with the idler roll applying pressure to the preform against the drive roll.

Increasing Diameter – The next step is to increase the diameter. That happens as the continuous pressure reduces the wall thickness. The axial rolls then control the height of the ring as it is being rolled.

The Size is Achieved – This entire process is repeated until the desired size is achieved. At this point, the ring rolling process is complete and you have a rolled ring in your desired size and shape.

Are You Looking for Rolled Rings?

Rolled rings come in a variety of sizes and shapes depending on what they are being used for. At Ferralloy we know that, which is why we offer a wide variety of rolled rings in different sizes and shapes. Contact us today to learn more or to place an order.

 

what is the rolled rings process?

Steel Castings | What is the Difference Between Cast Iron and Cast Steel?

When it comes to casting, there is often little to no need for additional fabrication and assembly. That’s because it offers exceptional capacity for design detail. While many different materials can be cast, steel and iron are the two most popular due to their excellent mechanical properties for a wide range of applications. Let’s take a look at some of the differences between steel castings and iron castings.

Corrosion Resistance

When it comes to corrosion, iron has better corrosion resistance than steel. That doesn’t mean that either are impervious to corrosion though. When left unprotected, both metals will oxidize in the presence of moisture. Eventually, they will completely decompose. To prevent this, coating is recommended for both steel and iron castings.

Cost

Cast iron is often cheaper than cast steel because of the lower material costs, energy, and labor required to produce a final product. While raw steel is more expensive, there are, however, prefabricated forms of steel. Those include sheets, rods, bars, tubes, and beams.

Castability

Cast iron is relatively easy to cast, as it pours easily and doesn’t shrink as much as steel. This flowability makes cast iron an ideal metal for architectural or ornate ironwork structures such as fencing and street furniture.

Are You in the Market for Steel Castings?

Whether you are in the market for cast iron or cast steel, at Ferralloy we have you covered. No matter what the project, we have the product for you. Contact us today to learn more about our casting products and to place an order.

 

What are steel 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.

 

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Seamless Rolled Rings | What Do I Need to Know?

Seamless forged rings are created through a process called ring rolling. They are produced using a range of configurations and are used for a variety of parts. Some of those include bearings, valves, robotics, gears, and some machines. Let’s take a look at some other important things that you need to know about seamless rolled rings.

Process

The seamless ring process begins by taking a circle-shaped metal that has already been pierced to look like a doughnut, thus the ring name. The shape is then heated beyond the required temperature for recrystallization. It is then shaped into the desired shape.

Advantages

When it comes to seamless rolled ring forging, there are many advantages over other methods. A few of those include:

  • Durability
  • Can handle high temperatures
  • Cost-effective
  • Lesser restrictions
  • Ability to predict how the metal will react
  • Wide-ranging size

Most Popular Shapes

The most popular and simply shaped ring made is the rectangular-shaped cross-section model. While that one might be the most popular, one of the benefits of rolled rings is the ability to forge the metal into nearly any shape. That includes any number of more complicated, customized shapes characterized by contouring on the external and internal diameters.

Are You Looking for Seamless Rolled Rings?

Seamless rolled rings can be used in a variety of parts that are found in a variety of different industries because of the advantages listed above. Since it is so important, it is crucial to get a part that you can rely on. That’s why at Ferralloy, we offer high-quality seamless rings. Contact us today to learn more, or to place an order.

 

What are seamless rolled rings?

Castings Investment | What Materials Are Used?

When it comes to castings investment, many different materials can be used. The type of material used to make the casting largely depends on what the casting is being used for. Some materials work better under extreme temperatures, while some have more give to them. Let’s take a look at some of the different materials that are used to make castings.

Aluminum

Aluminum is a relatively adaptable substance to work with. As a result, it is popular when it comes to the casting process. Aluminum‘s corrosion resistance, high thermal/electrical conductivity, good mechanical properties and strength at high temperatures therefore make it a popular choice for many different casting methods. Those include:

  • Die casting
  • Investment Casting
  • Sand Casting
  • Mold Casting

Steel

Steel is a naturally tough material. Because of that, it is ideal for castings that need to be able to withstand exceptional wear, shock or heavy loads. It is also good when it comes to corrosion resistance. Steel is often mixed with chromium, iron, and nickel. This is done in order to further improve its corrosion or heat resistance.

Copper

Copper offers excellent electrical conductivity. As a result, copper castings are popular in the construction industry for electrical components. The one downside to copper is that it can be subject to surface cracking, porosity, and formation of internal cavities.

Are You Looking for Castings Investment?

At Ferralloy we are your home for castings. Whether it’s aluminum, steel, copper, or even another material, we offer the highest-quality castings on the market. Contact us today to learn more or to place an order.

 

what are castings investment?