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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?

Closed Die Forging | The Closed Die Forging Process

Forging is a manufacturing process involving the shaping of metal using localized compressive forces. When it comes to forging, there are two types: closed die and open die. In this blog, we will take a look at closed die forging and the process that goes into it.

Creating the Mold

The first step of the closed die forging process involves creating the mold. The mold allows for the forgings to be created to the exact specifications of the customer. The creating of the mold and the subsequent creating of the forging can take 2-3 weeks to complete.

Choosing the Steel

Depending on the type of forging and its use, there are several different types of steel that can be used in the closed die forging process. Stainless steel, carbon steel, and alloy steel are all common types of steel found in forgings. Stainless steel is used where both the properties of steel and corrosion resistance are required and is typically the most popular steel option.

Heating the Steel

Before the steel can be forged, it has to be heated. When the steel is heated to the desired temperature, it can be molded and formed into a new, desired shape. Once it is heated to the desired temperature, it can be placed in the mold to form the desired shape.

Forging the Steel

After the mold has been created and heated, the forging process can then begin. After the mold has been created, it is then placed within the closed-die forging dies.

Are You Looking for Closed Die Forging?

At Ferralloy, we have the closed die forgings you need no matter what the project. Contact us today to learn more or to place an order.

 

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Titanium Fasteners | Types of Materials Used to Make Fasteners

When it comes to fasteners, they can be made out of a variety of different materials. The material chosen depends on the use as the different materials react differently to different factors in the environment. While titanium is one of the popular materials used to make fasteners, let’s take a look at some of the other materials used in addition to titanium fasteners.

Steel

Steel might just be the most popular material used to make fasteners. They are offered in a wide range of grades for different types of uses. As a result, machine screws, carriage bolts, studs, nuts, and cap screws are all fasteners that are made from steel.

Aluminum

When it comes to aluminum, it is the least costly material that can be used to make fasteners. Aluminum fasteners are classified as hardenable and nonhardenable and weigh about one-third as much as steel. Some grades of aluminum are even stronger than that of mild steel. Cold-formed bolts, screws, rivets, and machine-screw nuts are just a few of the things that are made with aluminum.

Titanium

Titanium fasteners are largely found in the aircraft industry. Their excellent corrosion resistance and good high-temperature performance make it the ideal material for aircrafts and aircraft parts. As a result, joints are the most popular item that titanium is used to make, including joints loaded in shear and tension-loaded joints.

Are You Looking for Titanium Fasteners?

At Ferralloy, we offer fasteners made from a variety of different materials, including titanium. If you are looking for titanium fasteners for your next project, contact us today.

 

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Seamless Rings | What Materials Are Used?

Seamless rings are created through a process called ring rolling, which uses a machine called a rolling mill. When it comes to the making of the seamless rolled ring, many different materials can be used. Let’s take a look at some of the different materials used to make seamless rolled rings.

Aluminum

Aluminum is incredibly popular in the aerospace, defense, and transportation industries. That’s because it has a low density and is extremely corrosion resistant. The ductility of aluminum makes it easy to forge. It also makes it susceptible to residual stresses though during the heat treating process.

Stainless Steel

Stainless Steel is used in a variety of industrial applications where moderate strength and enhanced corrosion resistance is required. Standard grade stainless steels forge easily and are less susceptible to residual stresses than other alloys. However, the more complex stainless steels require far more sophisticated forging techniques to optimize corrosion resistance and mechanical properties.

Alloy Steel

The majority of steel products used today are made from iron alloyed with carbon and other elements such as chromium, nickel, and molybdenum. The addition of carbon and other alloying elements has increased the strength of the metal by up to 1000 times.

Are You Looking for Seamless Rings?

When it comes to seamless rings, the type of material used plays a large factor in the functionality of the rings. At Ferralloy we offer seamless rolled rings in a wide variety of shapes, sizes, and materials. Contact us today to learn more or to place an order.

 

What are seamless rings?

Steel Castings | Types of Cast Steel

Steel castings are solid metal objects produced by filling the void within a mold with liquid steel. While cast steel typically has lower mechanical properties than other metals with the same chemical composition, they are better because they can be made into complex shapes in few steps. Let’s take a look at a few of the different types of cast steel

Carbon Cast Steel

Like other types of steel, carbon cast steel is classified according to its carbon content. Low carbon cast steel is relatively soft and not readily heat-treatable, while medium carbon cast steel is somewhat harder and can be strengthened by heat treatment. As you can imagine, high carbon cast steel is used when maximum hardness and wear resistance are desired.

Alloyed Cast Steel

Alloyed cast steel is categorized as either low- or high-alloy. Low-alloy cast steel reacts similarly to that of normal carbon steel. However, low alloy carbon steel has higher hardenability. High-alloy cast steel is designed to produce a specific property, such as corrosion resistance, heat resistance, or wear resistance. Some common examples of high-alloy steel include stainless steel and Hadfield’s manganese steel.

Are You Interested in Steel Castings?

At Ferralloy, we are a leading supplier of quality castings to major companies throughout the world. We specialize in all principle casting methods, including steel. No matter what your next project is, we have the steel castings for you. Contact us today to learn more about the castings that we offer or to place an order for your next project.

 

what are steel castings?

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?

Titanium Tubing | What to Know About Titanium Tubes

One of the many products we offer at Ferralloy is titanium tubes. These tubes have many different uses and are found in a variety of different fields. Before purchasing titanium tubing, let’s take a look at a few things you should know about them.

It Has Many Desirable Attributes

When it comes to Titanium, it is significantly superior to stainless steel when it comes to chemical resistance. The high strength-to-weight ratio makes it ideal for a diverse range of applications. Those applications include the automotive industry, the medical field, and in analytical instruments. When it comes to the medical industry, the biggest benefit of titanium is that it’s biocompatible. That means that not only will the human body accept it, it’s also nonmagnetic.

There Are a Variety of Grades

Just as there are many different “grades” of stainless steel, there are many different grades when it comes to titanium tubes. Titanium can be mixed with other types of metals, including nickel, to produce a variety of different titanium-based products. These can be ideal in situations where you might need a more flexible or even more durable tube. One specific example of this is NiTi (or nickel titanium). NiTi is often used to produce medical tubing that requires a high degree of flexibility and kink resistance.

Are You Looking for Titanium Tubing?

Whether you are looking for titanium tubes for the medical field, the automotive industry, or something else entirely, at Ferralloy we have you covered. Contact us today to learn more about our titanium tubes or to place an order.

 

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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.

 

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Investment Castings | The Investment Casting Process

Investment casting is one of the oldest manufacturing processes. It dates back thousands of years and is used to make pipe fittings, turbine blades, armament parts, lock parts, hand tools, and even jewelry. They can be made using a wide variety of metals. Those include aluminum alloys, bronze alloys, magnesium alloys, cast iron, stainless steel, and tool steel. Let’s take a look at the process that goes into making investment castings.

Pattern Creation

When it comes to creating the pattern, the injection is inserted into the metal die and are formed as one piece. The cores are used to form any internal features on the pattern. These patterns are then attached to a central wax gating system. The gating system forms the channels through which the molten metal will flow to the mold cavity.

Mold Creation

These patterns are then dipped into fine ceramic particles, coated with coarse particles, and then dried to form a ceramic shell around the patterns and gating system. This process continues until the shell is thick enough to withstand the molten metal. The shell is then placed into an oven and the wax is melted out leaving. This leaves a hollow ceramic shell.

Pouring

During this step, the mold is preheated and the molten metal is poured. This fills out the mold cavity.

Cooling

After the mold has been filled, the metal then cools and solidifies into the final casting shape. Cooling time depends on the thickness of the part, thickness of the mold, and the material used.

Removal and Finishing

After the molten metal cools, the mold is then broken and the casting removed. Finishing takes place when the final product is grinded or sandblasted to make it completely smooth.

Are You Looking for Investment Castings?

Ferralloy is your home for all your investment casting needs. Contact us today to learn more or to place an order.

 

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Forgings | The Difference Between Hot and Cold Forging

Hot and cold forging are two different metal forming processes. While they are performed at significantly different temperatures, they deliver similar results. Several factors are taken into account when deciding between hot and cold forging. Let’s take a look at some of the differences between hot and cold forgings.

Hot Forging

When a piece of metal is hot forged, it is heated to extreme temperatures. The average temperatures necessary for hot forging are up to 1150 degrees Celsius for steel, 360 to 520 degrees Celsius for Al-Alloys, and 700 to 800 degrees Celsius for Cu-Alloys. This kind of extreme heat is necessary for avoiding strain hardening of the metal during deformation. Traditionally, manufacturers choose hot forging for the fabrication of parts that have a greater influence in the technical arena.

Cold Forging

While it is called cold forging, the process is not actually done at cold temperatures. It is called cold forging because the temperatures are significantly cooler than with hot forging. Cold forging is typically performed at room temperature and is generally preferred when the metal is already a soft metal, like aluminum. The most common metals in cold forging applications are usually standard or carbon alloy steels. Cold forging is chosen over hot forging because of its cost savings. Read this article here for a more detailed explanation of the cold forging process.

Are You Looking for Forgings?

Whether it’s hot or cold forging, Ferralloy has you covered. We offer high-quality forged parts for all types of projects. Contact us today to learn more about our forging process, or to place an order for forged parts for your next project.

 

what's the difference between hot and cold forgings?