Forged Gear Blanks & Discs

Ferralloy, Inc. specializes in high-quality forged gear blanks and discs to meet the needs of various industries. With decades of experience, we deliver precision gear blank forgings that combine strength, durability, and superior metallurgical properties. 

About Metal Gear Forging

Gear forging shapes metal alloys into precision gear blanks and discs by applying compressive force. The alloy is heated to a malleable state, then formed using a hammer, press, or die. Compared to other manufacturing techniques, such as machining or casting, forging produces gears with exceptional mechanical properties, such as increased toughness, wear resistance, and strength.

Forging improves material flow and grain structure for enhanced durability and performance. It also enables the production of complex gear geometries with tight tolerances, making it suitable for challenging applications in the automotive, heavy machinery, and construction industries.

Benefits of Quality Forged Gear Blanks and Discs

Forged gear blanks and discs from Ferralloy, Inc., offer a vast range of benefits, including:

Strength and Durability

The forging process involves applying compressive force to shape the metal, leading to a refined grain structure and increased strength. This results in gear blanks that can withstand high loads, fatigue, and shock, making them ideal for demanding gear applications.

Enhanced Metallurgical Properties

The forging process subjects alloys to extreme heat and pressure, which improves the metal’s grain structure while removing any defects or inconsistencies. This helps to enhance mechanical properties such as hardness, toughness, and wear resistance, leading to more reliable performance in critical applications.

Precision and Consistency

Forging enables precision control over gear blank shaping, ensuring accurate tooth profiles and consistent dimensions. Through the use of quality molds and dies, we can produce forged gear blanks with tight tolerances, which is crucial for efficient power transmission and smooth gear operation. The controlled forging process also reduces material inconsistencies for more predictable and reliable gear performance. 

Cost Efficiency

While initial setup and tooling costs for gear forging can be slightly higher than other manufacturing methods, the long-term cost-effectiveness of forged gear blanks can be significant. The inherent durability and strength of forged components offer the following advantages:

Types of Forged Metal Gear Blanks and Discs

Ferralloy, Inc. offers a comprehensive selection of forged metal gear blanks and discs in various sizes and shapes to meet the specific demands of different applications.

• Bevel Gears: Transmit power between shafts at an angle.
• Helical Gears: Feature angled teeth for smoother, quieter operation than spur gears.
• Rack and Pinion: Used in applications such as steering mechanisms to translate rotary motion into linear motion.
• Spur Gears: Straight-toothed gears that transmit power between parallel shafts.
• Worm Gears: Offer high torque reduction and are suitable for applications requiring high mechanical advantage.

Common Metal Gear Blank and Disc Applications

Ferralloy, Inc. can produce forged gear blanks and discs to meet the needs of various industries and applications, including:

Automotive and Truck

The strength, cost-effectiveness, and reliability of forged gears make them ideal for critical truck and automotive applications. Forged components are typically found in areas frequently exposed to shock and stress, such as:

Powertrain components like connecting rods, transmission shafts, differential gears, clutch hubs, and universal joints are also forged — typically from alloy or carbon steels, aluminum, or micro-alloyed steel. 

Agricultural Machinery and Equipment

Toughness, strength, and cost-effectiveness are important within the agricultural industry. Common forged components for agricultural machinery include:

Valves, Fittings, and Oil Field Applications

Forged components are ideal for valves, fittings, and oil field applications because they are free from porosity and possess excellent mechanical properties. Corrosion and heat-resistant materials are often used to forge components for:

Oil field applications include drilling hardware, high-pressure valves and fittings, and rock cutter bits. 

Hand Tools and Hardware

Forged components are commonly incorporated into various types of hand tools and hardware, including:

Other Applications

Forged parts are also common in dental and surgical instruments, as well as electrical distribution hardware, including brackets, sockets, suspension clamps, and pedestal caps.

Quality Gear Forgings and Forged Metal Discs by Ferralloy, Inc.

Since 1984, Ferralloy, Inc. has delivered high-quality forged gear blanks and discs to customers across North America and Asia. We are ISO 9001 certified, and our quality-driven organization strives to meet or exceed our customers’ expectations for quality, process improvement, and total satisfaction.

We provide a diverse range of value-added services to meet the evolving demands of our customers, including:

For more information about our quality gear forgings and forged metal discs, contact us today.