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Seamless Rolled Rings Process for Bearings

The seamless rolled rings process is normally used to create a shape for metals. In this process, the metal is formed into a hollow doughnut, providing the shape of the ring after the process as per the requirement and design of the product owner. Although the process may seem easy, in reality, it involves a difficult and intricate process. Below are the reasons why the process is used for manufacturing bearings.

bearings seamless rolled rings

Why Use Seamless Rolled Rings Process?

Strong and Versatile

Seamless rolled rings can be designed and created using any forgeable material. This includes alloys, stainless steel, carbon, aerospace metals, and more. Its strength and versatility make any metal component an approachable and flexible solution for parts used in chemical, refinery, and power generation industries. Likewise, they are stronger compared to other metal components. Seamless rolled rings are also able to maintain their strength during high-temperature fluctuations. 

Cost-Effective

Gears, slewing bearings, and large-diameter bearings are commonly used in enormous industrial equipment such as those used in nuclear power, hydropower, barge cranes, and harbor machinery. In contrast with casting, seamless rolled rings can efficiently eliminate slag inclusions, shrinkage cavities, pores, and other defects.

Aside from better mechanical and quality performance, one of the biggest advantages of utilizing seamless rolled rings is that it costs less than similar components to manufacture them. This is possible because the rings closely match the contour of the finished shape. As a result, the product requires fewer machining operations, reduced weight, and lower costs for raw materials.

forging seamless rolled rings

Get Quality Seamless Rolled Rings at Ferralloy Inc.

Being one of the prominent forging companies, you can have exceptional products at the best affordable price. Furthermore, we also aim to provide you customized options to cater to your needs and requirements. For more information related to seamless rolled rings, contact us through this link!

Steel Castings vs. Cast Irons: Which is Better?

Among the most ideal ways to make lasting and quality components are through castings. It allows for a high level of detail, which results in not needing additional fabrication or assembly. When it comes to rolled ring forgings, steel and iron are the two most popular due to their exceptional mechanical properties for a vast range of applications.

Keep reading to find out which is best suited for your specific application!

rolled ring forgings

How Do Steel Castings and Cast Irons Differ?

Steel Castings

Steel castings are components that are formed by pouring molten steel into a mold cavity. The liquefied steels then cool and solidify within the mold. You can create the shape and the casting to perfectly fit your specifications. Although the casting process of steel can be difficult, the results are well worth it.

Moreso, steel castings are mainly used when other types of cast irons do not have enough strength or shock resistance. Its physical properties allow the castings to be both strong and ductile, making it extremely tough. Also, it limits the chances of fracturing under pressure.

Industries that use steel castings range from food processing and electronics to oil and gas. Some specific industries that use this type of casting include the railroad, construction, drilling, transportation, and mining industries

Cast Irons

When it comes to corrosion, iron has better corrosion resistance than steel. It is also often cheaper because of the lower material costs, energy, and labor required to produce a final product. Additionally, cast iron is relatively easy to cast–it pours easily and doesn’t shrink as much as steel.

rolled ring forgings

Other Substances Used in Rolled Ring Forgings

If you don’t know what to use for your next project, allow our team at Ferralloy Inc. to help you decide. Schedule an appointment today for more information about cast irons, steel castings, and other metals used in rolled ring forgings.

Benefits of Aluminum Rolled Rings

Due to being strong, versatile, and cost-effective, rolled rings are used for a variety of applications. These rings are commonly used as key components in jet engines, jet turbines, windmills, paper mills, helicopter gearboxes, and other tools or machines exposed in extreme environments. The rolled ring process uses different types of materials. One of the most commonly used is aluminum.

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Why is Aluminum Used in Rolled Rings?

Lightweight

Aluminum is famous for its soft and lightweight characteristics. This type of metal is frequently used by rolled ring manufacturers because it is non-sparking, non-magnetic, and non-toxic. More so, it works best alone or with other metals.

Quick trivia: if you’re wondering why aluminum has this dull silvery appearance, it’s because of the thin layer of oxidation that is abruptly created when the metal is exposed to air. Nonetheless, the low atomic weight of aluminum is the reason why it is low in density.

Extremely Durable

Another reason why forging companies use aluminum is that it’s durable. Aside from being famous for its lightweight characteristics, aluminum doesn’t disappoint manufacturers when it comes to durability. What makes aluminum durable is the long life span combined with the right amount of energy.

Low Maintenance and Corrosion-Resistant

Aluminum is also low maintenance because it requires little care and cleaning compared to other metals.

What makes aluminum corrosion-resistant is its tendency to create a solid oxide layer over the surface. The oxide created is responsible for the high rust resistance.

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Know More About Aluminum Rolled Rings

The factors mentioned above make aluminum rolled rings an ideal option for parts and components exposed to high-stress applications. Hence, it is often found in the aerospace and defense industry. Likewise, when applications call for high-quality, precision, and strength, aluminum rolled rings have no match.

At Ferralloy Inc., our experience means you get the best. Get in touch with us to learn more about the benefits aluminum rolled rings can offer!

Forging Efficient Carbon Rolled Rings

Seamless rolled ring forging is generally a cost-efficient option, especially when the forging process uses carbon steel. It allows you to create a product that can be hardened through tempering and quenching. However, this may depend on the grade of the material used. Below are the characteristics of carbon-rolled rings you may want to know.

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Common Characteristics and Downstream Processing

What Are the Characteristics of Carbon Steel?

Its characteristics may depend on the material the manufacturer uses. For instance, A Grade carbon steel such as A360LF2 is ideal for oil field application because of its corrosion-resistant feature. Most A Grade carbon steel includes alloying elements like nickel and manganese for enhanced toughness and hardenability. Some types are also great in medium strength applications.

Next to A Grade carbon steel materials are high carbon steel. Just like the former, it also contains manganese to improve the steel’s hardenability characteristic. Akin to 1040/1045, the most common high-grade carbon steels used are 15B22 and 1541V. They are also cost-effective and can be heat treated and welded for higher quality.

As for low carbon steel, it usually contains sulfur to increase and enhance its machinability aspect. Commonly known as resulfurized carbon steel, its common grades include 1146, 1141, and 1117.

Aside from low, high, and A Grade carbon steel, manufacturers also use plain carbon steel. It is the most cost-effective material used and is great for welding. Just like any other material, this one can provide decent surface hardness and toughness.

Downstream Processing

Carbon steel materials are generally used if the application doesn’t have to undergo a high-temperature environment and high strength processes. Also, when it comes to the downstream processing of this material, it involves the following:

  • Positive material identification
  • Chemical analysis
  • Mechanical analysis
  • Magnetic particle inspection
  • Ultrasonic inspection
  • Hardness testing
  • Shot blasting

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Get Efficient Seamless Rolled Ring Forging

At Ferralloy, we make sure that our products undergo a thorough inspection to better quality control. If you want high-quality and worth-the-investment carbon steel rings, our experts can guide you in finding the perfect one. Contact us today to learn more!

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!

Understanding Carbon Steel Rolled Rings

Creating carbon steel rolled rings is a process that uses carbon steel. It contains up to around 1.2% carbon while other present elements are in quantities too small to impact its properties. With this material, carbon rolled rings are commonly used for pressure and structural vessel applications. To understand more about carbon steel rolled rings, below are the facts you need to know.

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All About Carbon Steel Rolled Rings

Why Choose Carbon Steel

Manufacturers engaged in rolled ring production will tell you that carbon steel is among the most cost-effective option when it comes to steel. Since it is cost-effective, the rolled rings process can attain the high strength a stainless steel can offer. However, you can still achieve good quality products that can be hardened through tampering and quenching.

Carbon Steel Grades

High-grade carbon steel rolled rings is often used in applications that don’t require high temperature or high strength environments. Below are the carbon steel grades you need to familiarize yourself with.

  • A Grade – This type of carbon steel is ideal for oil field applications since it is corrosion resistant. It comprises alloy substance such as nickel or manganese. Thus, it can enhance the toughness and hardenability of the metal produced.
  • High Carbon Steel – Akin to A Grade carbon steel, this type also comprises manganese to improve hardenability and toughness. It can be heat treated or welded for higher durability.
  • Low Carbon Steel – This is commonly known as re-sulfurized carbon steel as it contains sulfur to provide exceptional machinability.
  • Plain Carbon Steel – The least expensive type but provide a good welding factor. It comprises high carbon content and low alloy content. Hence, plain carbon steel can offer excellent surface hardness and good toughness.

Capabilities of Carbon Rolled Ring

Carbon rolled rings utilize a foolproof forging process that creates seamless rolled rings with outstanding circumferential grain flow and ample internal structure. Also, the precision rolling procedure offers exceptional surface smoothness and concentricity.

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Want High-Quality Carbon Rolled Rings?

Ferralloy Inc. is a solutions provider that offers high-quality carbon steel rolled rings. Products are delivered according to the preference and most demanding requirements of clients. Contact us today!

Materials and Processes in Seamless Rolled Ring Forging

Several industries have used carbon steel forgings, whether you are aware of it or not. Such material has a variety of uses and comes in 4 different grades with different purposes to achieve the desired product. Numerous industries use the method called seamless rolled ring forging to produce a material of high quality and durability.

who offers the best seamless rolled rings forging?

Material and Process of Seamless Rolled Ring Forging

The Process

To start the forging process, a circular metal component will be pierced to create a hollow ring that somewhat looks like a doughnut. Upon the creation of an empty piece, the ring is then handled and processed to recrystallization temperatures. After the recrystallization process, it is then placed onto the idler roll. Once it is under pressure, it will be positioned towards the drive roll.

Additionally, a seamless rolled ring forging may be manufactured using numerous variants of configurations. Whether it is a small washer-like part or tall cylindrical shape part, the rings are regularly in a rectangular cross-section shape. What’s more is that whether you want a customized or convoluted shape, these types of rings may be produced through the use of shaping tools.

The Material

The notable aspect of a seamless rolled ring forging is that it is dependent on the material used. In every tool or metal component manufacturing industry, hardness, strength, and the ability to resist wear and tear are the most vital factors that need focus.

Among the three elements, the most important is the ability to withstand wear and tear since several of these products are used in engines and machines. These tools and components must be able to sustain heat as these are exposed to high temperatures.

As for the two factors, both hardness and strength are critical in the material. Most of these products are used by industries engaged in heavy-duty methods and processes. Thus, the tools and components must be strong enough to withstand collision and impact.

where is the best seamless rolled ring forging?

Get Quality Seamless Rolled Ring Forging Materials

At Ferralloy Inc., we offer competitively priced and engineered metal products to companies throughout the world. Contact us now for more inquiries!

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.

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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!

Simple Guide to Forged Rolled Rings

Forged rolled rings are used in a wide range of industries. These forgings are an appealing metalworking option thanks to their strength, versatility, and cost-effectiveness. But how do they get that way? Rolled rings can hold so many advantages thanks to their forging process. Keep reading to find out everything you need to know about this metalworking method!

where can I get forged rolled rings?

Basic Facts About Forged Rolled Rings

Why Are They Used?

Cost-effectiveness, versatility, and strength are among the many reasons why rolled rings are used. One of the most significant advantages of utilizing this type of rings is that it costs less than similar components to manufacture them. The reason for this is that the rings closely match the contour of the finished shape. As a consequence, the product needs fewer machining operations, has a reduced weight, and lower costs when it comes to raw materials.

As for versatility, these rings can be made using any forgeable material, including alloys, stainless steel, carbon, etc. Its versatility makes this metal component responsive and flexible. Lastly, forged rolled rings are more durable compared to other metal components, and they are likewise able to sustain their strength during temperature fluctuations.

Types of Rolled Rings

There are three main types of forged rolled rings, namely carbon, alloy, and stainless rolled rings. Carbon rolled rings are commonly used for pressure and structural vessel applications. In contrast, alloy rolled rings are used for gear and bearing applications in addition to a variety of industrial equipment applications. As for stainless rolled rings, they are used for food and chemical processing applications.

what are forged rolled rings?

Where Can you Get Forged Rolled Rings?

Rolled ring forgings are metal parts that are created through a process referred to as ring rolling. Rolled ring forgings are a prevalent metal part. They are used for bearings, clutches, couplings, drives, flanges, gears, glass-lined reactors, machines, robotics, valves, and more.

If you’re interested in using forged rolled rings, Ferralloy, Inc. can help you with every bit of concern. Schedule an appointment today so our professionals can give you a hand!