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How Are Steel Forgings Made?

Steel forging involves the heating, deforming, and polishing of steel to create a durable and precise material. These materials are created by forcing materials into customized shapes, either by the die press surrounding a piece of metal or forcing such metal into custom-built patterns. Steel forgings have a broad range of properties and can use different types of materials.

steel forgings made

Properties of Steel Forgings

Limit on Size

Throughout the forging process, shaping a certain type of metal can be very difficult. The reason for this is that forging transpires while the metal is still solid. Because the metallurgists engaged in this project will have a bit of a challenge in altering the shape of the metal, there is a limit on the thickness and size. Hence, the larger the steel section being worked on, the more difficult it is to forge.

Consistency

The great thing about steel forgings is that there is consistency. Because the procedures are deliberate and controlled, each forging goes through the same processes. With steel forgings, it is ordinarily possible to guarantee a consistent material.

Anisotropic

As for the strength of steel forgings, it is not consistent throughout the process; instead, it is anisotropic. In physics, anisotropic is defined as a difference in a material’s physical or mechanical properties. This means that when the steel is worked on, deformation typically occurs.

Durable and Strong

This type of forging produces results that have exceptional strength and are generally tougher than steel produced through other means. Since steel is less likely to break and get altered in contact with other materials, it is often used by industries that require tools and components with increased durability and strength.

steel forgings made

Where Can You Get Steel Forgings?

Steel forgings are widely used by many companies, such as those in the mining, electronics, and aerospace industry. If you’re looking for quality steel forgings, you can give Ferralloy Inc. a call!

Forgeability of a Metal

The ability of a metal to undergo deformation without cracking by means of forging is what experts call the forgeability of a metal. With this characteristic, metals can easily be formed with low force and resistance. For instance, closed die forging involves a process wherein the dies move toward each other by covering the metal. The heated raw material is placed at the bottom die to produce a design or shape according to specifications. To know more about the forgeability of the metal, please continue reading.

 

What is Closed Die Forging?

All about Forgeability

Tests to Determine Forgeability

According to experts, there are two primary tests to determine forgeability of a metal – Upsetting test and Hot-twist test. Upsetting test involves cracking while upsetting a cylindrical specimen.  Although this test only provides basic guidelines, it uses different strain and temperature rates to ensure that forgeability can be determined.

On the other hand, the hot-twist test requires the twisting of a metal rod at different temperature rates. Using this method, forgeability can be determined for various materials, including steel.

Extrusion Process

Extrusion is conducted by deforming metal and transporting it into a chamber before the compression process starts. In standard extrusion procedures, a round billet is placed in a chamber and forced through a die opening by a ram. Additionally, this process requires extreme temperature for the material to be completely formed.

The methods of extrusion involved in forgeability of a metal are direct extrusion, indirect extrusion, hydrostatic extrusion, and impact extrusion.

Metal Flow

Metal flow is an important factor to consider when deforming a metal. It must have a substantial reduction in the cross-sectional part of the process to make sure that the flow is undisturbed. Also, extrusion defects may occur if there are impurities and oxides caused due to the inhomogeneous flow of metal. When this happens, surface defects will thrust or be expelled into the center of the extruded parts.

 

What is Closed Die Forging?

More Information about Closed Die Forging and Extrusion

At Ferralloy Inc., we strive to provide answers for every inquiry! Contact us today if you have any questions and our friendly staff will be glad to answer them!

Advantages of Using Steel Castings

The word “casting” is used to define or refer to the part made by the machine casting process, which dates back more than 5,000 years ago. When it comes to history, this process is performed to make significant and complex metal components that would have been difficult when using the traditional manufacturing method. Because of this development, steel casting emerged.

what are the advantages of steel castings?

Why Use Castings?

Strength and Durability

Most manufacturers choose to use stainless steel castings for valve bonnets because of their incredible durability and strength. You can expect these types of valve bonnets to function well and remain in excellent condition for a long period of time, even when you use them in extreme temperatures.

Metallurgical Versatility

Castings allow you to choose among different chemical compositions and organizational control that fit your project’s requirements. In other words, castings offer strong metallurgical variability and adaptability.

Furthermore, compared to any other cast metal, you can obtain a wide array of physical and mechanical properties by simply making variations in its carbon and alloy content or heat treatment.

Economic Benefits and Greater Reliability

You can depend on cast steel parts for day-to-day use because they are designed with an isotropic material that intensifies engineering reliability. When you factor in its design flexibility and shorter delivery time, castings can give you the economic efficiency you’re looking for.

Design Flexibility

With steel castings, you can select from a wide range of alloys that can provide your designers the flexibility to configure your cast according to their needs. Aside from the fact that maximum design freedom to produce complex shapes and hollow section parts is never impossible when using steel castings, these can also be configured in a sturdy and repeatable manner.

Since steel castings’ design flexibility allows you to make quick changes as needed, your delivery time is dramatically shortened.

what are the advantages of steel castings?

Are You Looking for Steel Castings?

If you want to explore your options and invest in steel castings, contact the team at Ferralloy, Inc. today!

Plate Burnout versus Rolled Ring Forging

Rolled ring forgings are needed for several types of applications. The use of metal components may vary in size, thickness, and diameter. If you want to achieve a strong, durable, and cost-effective metal ring for your project, there are forging processes you need to be aware of. These processes include rolled ring forgings and plate burnout. Keep reading to learn the differences between the two to manufacture a metal ring.what are rolled ring forgings?

Difference between Plate Burnout and Rolled Ring Forging

Rolled Ring Forging

In the manufacturing process of seamless rolled ring forging, the waste of the metal that is punched out is prevented, and the metal piece is forged to become stronger and more durable. A donut shape is formed from metal and then forged into the metal ring that is desired.

The size and diameter are shaped from this donut-shaped metal as it reaches extremely high temperatures to the point that it becomes malleable. This process saves metal waste due to the process when the ring is punched out, making it a more cost-effective process. Aside from being cost-effective, rolled ring forging can provide strong and durable metal components.

Plate Burnout

As for the plate burnout process, it involves many processes in which a metal ring can be achieved. Just like rolled ring forgings, the process begins with a plate of metal. Once the component specifications are determined, the plate is punctured in the metal ring’s shape and size. This type of method makes the metal ring more susceptible to fatigue because the plates are exposed to extreme heat and pressure.

what are rolled ring forgings?

Determine Whether Plate Burnout or Rolled Ring Forging is the Best Process for your Project

For all of your metal manufacturing needs, Ferralloy Inc. has the authority and experience to help you. Our industry leaders in metalworking can suggest the best methods for manufacturing your metal parts and components at competitive rates. We are dedicated to producing and delivering the highest quality products to fulfill your project in the best manner. Contact Ferralloy Inc. today to inquire about your metalworking needs!

What is Forged Steel?

Whether you’re going for a walk, heading to your office, or riding a bus on your way home, forged steel always makes its appearance. Steel forgings are made out of alloying carbon and iron. Forged steel is produced under extremely high, yet accurate, pressure. It has better ductility than other manufactured steel, possesses fatigue strength, more tensile, has an advanced grain structure, and has less surface porosity.

What are steel Forgings?

Properties and Types of Forged Steel

Properties

Forgings require unique properties to produce quality products. They are composed of specialized alloys like carbon and stainless steel. This offers incomparable strength for the manufacturer of mechanical and industrial parts.

Furthermore, when it comes to forged steel, it has exceptional properties that make it easier to differentiate from other materials. Therefore, it is mostly used in industrial and mechanical applications for its availability and strength.

The only notable disadvantage when using this metal is the size and thickness restrictions for the steel being forged. The reason for this is justifiable – metal forging is a rather tedious process. Despite the limitation, it is possible to retain the exact consistency in all manufactured forged steel. The steel forging process is accurately measured and quite thorough.

Types

Companies classify steel forgings into three types – cold forged steel, hot forged steel, and hardened forged steel. These types differ depending on the forming pressure and temperature during the making process.

  • Cold Forged Steel – the process is done under temperatures up to 160 ºC.  Typically, the low temperature will account for a smoother surface finish.
  • Hot Forged Steel – the temperature for this technique ranges from 900 ºC to 1300 ºC. The temperature is often above recrystallization to produce materials with good formability.
  • Hardened Forged Steel – the temperature ranges from 750ºC to 950ºC. The materials produced are more versatile but have limited ductility.

What are steel Forgings?

Get Forgings with Outstanding Durability at Ferralloy Inc.

At Ferralloy Inc., our specialists see to it that your products are of first-class and exceptional quality. To know more about the products we offer, contact us today!

Understanding Forged Steel

Many people have never heard of foraged steel, but little do they know it’s used all around them. Most things made out of metal can be made stronger with forged steel! Forging was originally implemented to produce different kinds of steel ends with distinct properties. Currently, hydraulic hammers, and other forging machines and processes, make it possible for the development of steel forgings.

What are Steel Forgings?

Process and Categories of Steel Forgings

Process of Producing Forged Steel

The forging process begins by heating the steel to a high temperature, making the material more malleable and ductile. Next, it will be formed to the desired shape by applying the right amount of pressure to the steel. With the precise processing methods, steel forgings make it possible for a billet of steel to permanently be shaped without compromising its quality.

Additionally, steel forgings require a forge oven, forge furnace, or any forging heating system to sufficiently deliver the precise temperature needed. Furthermore, the deformation and thermal cycle process allow for rain refinement and metallurgical recrystallization to strengthen the finished product. This process is important to improve impact toughness and quality.

Categories

Steel forgings can be divided into 3 categories: the cold, warm, or hot forging of steel. Cold steel requires room temperature forging require a room temperature forging. The process often involves a self-heating method in which temperature may reach up to 150 degrees Celsius. This category requires high forming forces and low formability.

As for warm forgings, the temperature reaches between 750 and 900 degrees Celsius. However, just like cold steel forgings, this category needs higher forming forces but only has limited formability.

Lastly, hot forgings may reach up to 1250 degrees Celsius. Since the temperature is often above the recrystallization level, this forging category only requires low forming forces and still has good formability results.

What are Steel Forgings?

More Information about Steel Forgings

Aside from the forging process and categories involved, there is still a lot of information you need to know before purchasing forged steel. Additionally, you should know the advantages, disadvantages, properties used. At Ferralloy Inc., our friendly experts will lay down all the facts you need to know. Contact us today!

What Do You Know About Plaster Casting

Plaster mold castings are machined castings that combine gypsum and enhancing compounds to create a mold. A pure plaster is not very strong; therefore, a combination of plaster and additives are used to enhance castability, permeability, dry strength, and green strength. For instance, magnesium oxide or talc is sometimes added to reduce setting time and avoid cracking.

What are Machined Castings?

Everything You Need to Know About Plaster Casting

What is it Made of?

You’d think this was a simple answer – plaster, right? It gets a little more complicated. Machined castings are made in different ways. The plaster pattern is made of either metal or rubber. Next, it is often coated with an anti-adhesive material to avoid it sticking to the mold.

Molds are Inexpensive

Machined castings can get expensive and large. With plaster castings, it’s easy to change, reuse, and remold. They are also pretty affordable. If you want to get a machined castings quality product without gaps around the mold, and at an affordable price, plaster casting is the perfect option.

Plaster Casting Process

Machined castings require a lot of attention to detail to get the result you want. Once you have determined the parting line, or where the two halves of the cast meet, the plaster is combined and the pattern is covered with an anti-adhesive. The plaster is then poured into the pattern and shaken, allowing the plaster to fill the gap. Finally, it is left alone in the cast for about 15 minutes to set.

Once you feel comfortable with the mold, it is heated at high temperatures to remove all the excess water. As soon as the metal hardens, the plaster is removed from the cast and the finishing process begins.

What are Machined Castings?

Machined Castings that are Worth the Investment

The final step is the most fun! It includes blasting, heat treating, grinding and cleaning. If you want to get quality castings or talk to an expert, contact Ferralloy Inc. now!

Steel Forgings | Steel Forging Facts

Forged steel is comprised of an alloy of carbon and iron. It is compressed under extreme pressure to make a very hard and strong substance. Forged steel is used to create all types of materials in many different industries. Let’s take a look at some facts about steel forgings, including where you can get them for your next project.

History

Early types of forged steel were developed in Persia and China. Traditionally they were made by a smith, who would wet the metal with water and then pound it with a hammer atop an anvil. Modern methods of forgings were developed throughout the 1800s.

Types

There are three types of forged steel: drawn out, upset, and squeezed-in. Drawn out steel increases the length of the alloy while decreasing the width. With upset steel, the length is decreased, while the width is increased. Squeezed-in steel uses closed dies that produce flow in all directions and compacts the steel into a solid shape.

Benefits

Anything that can be made of metal can generally be made stronger and more weight-conscious by forged steel. Because of this, it can be used in a wide variety of industries. Industries from manufacturing to pharmaceuticals benefit from using steel forgings.

Are You Looking for Steel Forgings?

At Ferralloy, we offer high-quality steel forgings for all industries. No matter what you are looking to use it for, we will work with you to make sure you get the products you need to be successful with your next project. Contact us today to learn more, or to place an order.

 

What are steel forgings?

Heat Treating Baskets | Benefits of Steel Fabrications

Heat treating baskets can be an efficient way to handle the parts finishing process. A well-designed basket is effective at keeping parts safe from damage and is often useful for a variety of processes. While the baskets can be made out of a variety of materials, steel fabrications are the best for a number of reasons. Let’s take a look at the benefits of using steel fabrications with your heat treating basket.

Heat Resistance

Obviously, when it comes to a heat treating basket, the biggest need is heat resistance. With steel, the heat resistance far exceeds that of plastic or other materials. The melting point of a basic stainless steel alloy is about 2,550 degrees Fahrenheit while even the strongest of plastics has a melting point of 750 degrees Fahrenheit.

High Load Capacity

On average, steel has a much higher tensile strength than plastic. The higher tensile strength of steel allows baskets made from this material to handle loads that would crush a frame made of plastic.

Lasts Longer

While there are many factors that can cause a plastic basket to fall apart, steel baskets, are able to resist those factors. They include being impervious to:

  • High temperatures damaging the polymer’s bonds
  • Chemicals soaking into the basket and contaminating it
  • Oxygenation of the basket decaying its molecular structure

Are You Looking for Heat Treating Baskets?

At Ferralloy we offer high-quality heat treating baskets in steel and other materials. Contact us to learn more about how we can get you the heat treating basket you need today.

 

What are heat treating baskets?

Closed Die Forging | What Materials Are Commonly Used?

While closed die forging is applied for almost all the metal materials, in actual production, only part of the materials are used for the different characteristics. The material used is one of the main factors that affect the cost of the forgings. Let’s take a look at some of the common materials used in closed die forgings.

Aluminum

Aluminum is popular due to its low density, high strength, and easy machining. It is widely used in the automotive and aerospace industries. While it is commonly used in the aerospace and automotive industries, it is a challenge for domestic forging due to the fact that it is easily deformed.

Steel

Steel is by far the most common material used when it comes to closed die forging. Alloy steel, carbon steel, and stainless steel are all used depending on what the forging is used for. Stainless steel material is often used for components that require corrosion resistance and rust resistance. Alloy steel and carbon steel are the most widely used in closed die forging process for its competitive price and easy deformation.

Brass

While brass is used in closed die forgings, it is the most expensive of the three materials that we have discussed. Brass forging is most commonly used for valve and pump fittings.

Are You Looking for Closed Die Forging?

At Ferralloy, we offer closed die forgings made of many different materials. Contact us today to learn more about how we can make closed die forgings for your next project.

 

Where can I find closed die forging?