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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.

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.

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.

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?

Rolled Ring Forgings | What Are the Advantages of Rolled Ring Forgings?

Rolled ring forging is a process where metal is formed into a ring shape. Rolled ring forging is used in a number of sectors, from the nuclear industry to machine shops to pharmaceutical companies. It is popular because of its many advantages. Let’s take a look at some of the advantages of using rolled ring forgings.

Reliability

Since the rings are forged at very high temperatures, the finished product has more strength and resistance compared to other components. This is very beneficial for rings that are being used in high-temperature situations.

Many Different Materials

Any material that is forgeable can be used to make rolled rings. That includes alloy, stainless steel, carbon, and aerospace metals. The ability to use several different materials makes them not only more cost-effective, but also allows them to be used in many different industries including power generation, chemical, and refinery industries.

Cost Effectiveness

As we touched on above, rolled rings are very cost effective. There’s less machining involved because the rings closely match the contour of the finished shape. As a result, the rings are manufactured at a lower cost than other similar products.

Are You Looking for Rolled Ring Forgings?

Rolled ring forgings are incredibly popular due to the fact that they can handle high temperatures are significantly cheaper than other options. If you are looking for rolled ring forgings for your next project, look no further than Ferralloy. We have the rolled rings that you need. Contact us today to learn more or to place an order.

 

what are rolled ring forgings?

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?