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Tips When Looking for a Forging Manufacturer

Over the years, the forging industry has massively evolved. The use of different techniques and processes in forgings gave rise to various applications in construction, agriculture, automotive, machinery, and so much more. Below are the tips you may want to consider in looking for a forging supplier or manufacturer.

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Guide in Choosing a Forging Manufacturer or Supplier

Know Which Type You Want

Forgings have two most popular forms. These are open die forging and closed die forging. Although both originated in the fundamental forging process that involves beating a piece of metal until the desired shape, strength, and granular level is achieved, these two processes have differences.

Choosing a Company That Delivers On-Time

Did you know that your success as a company depends on the complex relationships that make up your supply chain? Be sure that your supplier supports your success and delivers on-time, all the time. A delay in the delivery will make things complicated and may even compromise your production.

Fact Check of the Company’s History and Reputation

Sellers and manufacturers aren’t hard to find. Some companies focus on low-cost and low-quality solutions. Hence, you can immediately spot them as their products fail to stand the test of time. 

Thus, it’s essential to look for a reputable supplier with a proven history of producing forgings that offer high quality and durability. Your reputation in the industry is at stake if you fail to choose companies that provide quality forgings.

Look for Any Certification

The supplier or manufacturer you chose to provide you with forgings must adhere to industry standards and specifications. In this way, produce durable and resilient forgings that can withstand extreme temperature, pressure, or adverse weather conditions.  

Certified suppliers and manufacturers maintain data-driven systems that are continuously audited. Aside from the fact that they quickly address quality issues by creating quality improvement plans, they also conduct subsequent reviews to monitor and evaluate these plans’ effectiveness.

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Get Quality Forgings at Ferralloy!

Having achieved ISO 9001 certification in both locations, we are a quality-driven organization committed to process improvement and customer satisfaction. Contact us 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.

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.

 

What is open die forging?

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.

 

Where can I find inconel?