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What Is an Alloy Steel Forging?

Alloy steel forgings are common. They are a group of technical alloys that may be heat treated to achieve various mechanical properties. Below are the basic pieces of information you need to know. 

Automotive part production by hot steel forgings process

Everything There Is to Know About Forgings Made of Alloy Steel

Chemical Make-Up

The 0.20 to 0.55 percent carbon alloy steels account for most alloy steel tonnage. These steels are primarily utilized in automobiles and other machinery, and they are usually quenched and tempered to increase the strength and hardness. 

These steels frequently contain manganese, nickel, chromium, molybdenum, vanadium, aluminum, and boron to improve the characteristics obtained after quenching and tempering. Certain alloy steels include up to 9% chromium, making them appropriate for usage at elevated temperatures, though not to the extent that stainless steels or high nickel alloys are required.  

The components made from alloy steels promote hardenability and quality of steel that portrays its ability to harden in depth, ensuring strength and toughness over the entire section of a forged object after heat treatment.   

What Are the Benefits of Forging Alloy Steel?

After forging, the elements added to alloy steel provide distinct properties, such as greater hardness, increased corrosion resistance, enhanced strength, improved formability (ductility), and weldability. As a result, alloy steel forging is widely used to manufacture wear-resistant items. 

Because of their low cost, wide availability, ease of processing, and good mechanical qualities, alloy steels are preferred in steel forging. However, carbon steels are more resistant to heat and mechanical treatment than alloy steels. 

Small amounts of one or more alloying elements other than carbon, such as manganese, silicon, nickel, titanium, copper, chromium, and aluminum have been added to alloy steel. This gives forgings unique qualities that aren’t found in conventional carbon steel forging. 

Tank pours liquid metal at the steel mill for steel forgings

Where to Get Steel Forgings?

At Ferralloy Inc., we have a variety of steel forgings. Contact us today and we’re glad to be of help you. 

Steel Forgings for Container Systems

Steel forgings are produced through a manufacturing process that is different from casting. The unique properties of forgings result in components that are often more reliable and have improved tolerance capabilities.

manual forgings production

Why Use Steel Forgings for Container Systems

Easy to Machine

Steel forgings are easier to machine, making them a more efficient choice for automated production methods. Container lashing systems often use forged steel components because of their superior performance and reliability. Their superior reliability and tolerance capabilities make them a top choice for securing cargo during transport.

Improve Reliability

There are many advantages to using forgings for container systems. The most obvious benefit is the improved reliability that forgings offer. They also have a higher tolerance capability than cast components, meaning they can withstand more stress and wear. Additionally, forgings are much easier to machine, which leads to increased efficiency in automated production methods.

All of these advantages make forgings a natural choice for container systems. The superior performance and reliability of forgings can help ensure that your cargo is secure during transport.

Other Benefits

  • Improves dependability and tolerance capabilities of container system components.
  • Known for their consistency in composition and structure. Their machinability and mechanical characteristics are quite consistent.
  • Parts made of forged steel are more durable and dependable than those made of machined or cast steel.
  • Allows for the creation of designs that can withstand severe loads and strains.
  • When high quality is required, steel forgings are used in container systems.
  • There are no gas cavities, pockets, or cooling faults in steel forging parts, which might cause load failure.

manual forgings production

Get Quality Forgings at Ferralloy!

If you’re looking for a dependable way to lash your containers, steel forgings may be the solution you need. Contact us today to learn more about this versatile and reliable manufacturing process.

Different Types of Welding

Regardless of what the movies showcase, welding is, in essence, a serious job. It’s a highly-skilled trade that is employed to weld metal components such as seamless rings together. So, what are the various forms of welding and how are they applied in industries?

Cropped image of manufacture worker welding seamless rings

Common Types of Welding

Flux-Cored Arc Welding

Flux-cored arc welding is analogous to MIG welding since both use power supply and continuous wire materials. An uninterrupted electrode will be combined with a base metal. The electrode used is a flux-filled hollow tube that is introduced into the weld pool using a weld cannon. More so, this welding technique is applied in the machining industry to join thicker metals together.

Stick Welding

Otherwise known as shielded metal art welding, this type teaches you to utilize a disposable and well-protected electrode, such as a stick. The stick mixes and softens metals by creating an arc between the base metal workpiece and covered metal electrode. Further, the stick’s protective layer melts as it heats up, shielding the weld region from oxygen and other volatiles.

TIG Welding

Like MIG welding, TIG welding also uses an electric arc. The latter requires the use of a tungsten electrode. Tungsten is one of the most difficult metals to work with. It will not easily burn or disintegrate away. Welding can be done using a fusion method that may or may not use a filler metal.

An auxiliary gas supply, such as helium or argon, is also used. Additionally, TIG welding is also used in the automotive and aerospace industries, as well as other industrial areas.

MIG Welding

MIG welding is primarily utilized in the automotive industry to restore automobile exhaust systems and the construction of homes and other building structures. It is one of the most common welding techniques. This is a form of arc welding that employs the use of a continuous wire electrode.

Welder in the mask welding seamless rings

Learn More About Welding and Seamless Rings

Interested in learning more? The experts at Ferralloy are here to help with any of your questions. See us today for more information!

What Is Alloy Casting and Why Is It Important?

Have you ever wondered why your stainless-steel plates don’t corrode when exposed to water and air? It’s due to the fact that they’re made of alloy castings. They help metals perform better. As a result, you’re surrounded with it every day. Metals like copper, iron, silver, gold, and others are usually hard to come by in their purest form. Bronze, brass, steel, and other alloys are common. A homogeneous blend of two or more metals, or a metal and a nonmetal, is referred to as an alloy. We’ll learn everything there is to know about alloys and their uses. 

stainless-steel-pipe

Getting a Better Understanding of Alloy Casting

Alloy Casting Definition

The procedure is pouring molten metal – metal that has been reprocessed from scrap into a raw material – into a mold with a hollow chamber of the required shape and allowing it to harden. To complete the process, the solidified portion, also known as a casting, is ejected or broken out of the mold. They are used in their natural state, without any mechanical or heat treatment. Casting allows a complex object to be created in one piece, obviating the need for assembly, machining, and fabrication. 

 Alloys in Everyday Life

They come in a variety of shapes and sizes. Alloys can be found everywhere here are examples of lengthy goods utilized in the building sector: 

  • Train tracks  
  • Rails 
  • Girders 
  • Structural sections 
  • Rods 
  • Bars 
  • Wires 

They are also used in a variety of industries, including: 

solar-panel-construction

What Is the Best Way to Obtain Alloy Castings?

Ferralloy, Inc. can assist you if you’re interested in using alloy castings for your next project. We are a renowned global supplier of high-quality alloy castings to large corporations. For further information or a price, contact our metalworking experts today! 

How Wires Are Made

In our everyday lives, it’s inevitable for us to see wires. Because of global sourcing and technology advancements, we have them on telephones, chargers, and other devices. In case you ever wondered how these wires were made; then, you’ve opened the right article.

cut wires and global sourcing

Step-By-Step Guide to How a Wire Is Constructed

Metal Extraction from an Ore

We’ll start by looking at how copper is extracted from an ore. This process can be carried out in a variety of ways. The first phase is for miners to harvest ore from the ground. Copper ore can be found in mines worldwide, mainly in Asia and South America. With operational mines in eight states, the United States is considered the fourth largest copper manufacturer.

Extrusion of Copper

Copper wire is made using an extrusion machine, which forces metal through an extrusion die sequence to form a specific shape. When making wires, copper starts as an “ingot,” which is essentially a large brick of pure copper. After that, the ingots are flexed and straightened into long strands. The copper will then be heated until it becomes bendable before it is inserted into the machine. Once flexible, the machine will begin pulling and forming the copper into long strands upon reaching a particular temperature. Because copper strands can be stretched into fragile wires, usually a fraction of an inch, the thickness of the wire is set programmed in this step.

Covering and Cutting

As soon as the copper wires have reached the maximum length and width, they will be covered with low-density polyethylene material. However, this will depend on the material used for the wire. So, if producers used a different wire component, then the type of cover will also be different.

bundle of wires and global sourcing

Learn How Global Sourcing Makes the Manufacturer’s Life Easier

With all the technology, in-depth processes, and growing global sourcing, companies can save tons of costs for manufacturing or producing products. Schedule an appointment with us today to know more about global sourcing!

 

Where Does Zirconium Come From?  

You’ve might have heard and seen zirconium from various TV shows and documentaries, but what and where does this precious metal come from? To start, zirconium comes from the mineral zircon that belongs to the group of nesosilicates that are rock-forming minerals. This metal is usually used as a refractory and opacifier by industrial forgers and forging smiths.    

Zirconium Porcelain Tooth Plate

History of Zirconium

Source of Zirconium

This silver-gray transition metal is often found and produced by mining and processing the titanium minerals ilmenite as well as rutile. Some of the major mining sites of zirconium can be found in Australia, South Africa, the USA, Russia, and Brazil. It can also be collected from coastal waters that have zircon-bearing sand which is then processed to separate the lighter materials. 

Raw Materials

Zirconium is derived from its raw material zircon which can be commonly found in the crust of the earth. This precious mineral can be seen in different colors, including reddish-brown, yellow, and colorless. Because of its solid composition, zircon is highly resistant to weathering and internal radiation damage.    

Processing the Mineral

There are different processes involved in processing this mineral, the most common of which includes three processes which are extracting and refining the zircon, and finally refining the baddeleyite. After passing quality control, the processed and refined zirconium is then exported to different plants and machine refineries across the globe.    

Uses of Zirconium

Zirconium alloys can be found in different metals such as pipes, heat exchangers, and even nuclear power plants. It is also used in steel alloys, colored glazes, and bricks, as well as in the making of artificial gemstones. Because of its malleable and ductile compounds, it can be highly resistant to corrosion and can be used in superconducting magnets.   

What is a Zirconium Porcelain Tooth Plate

Importance and Other Uses of Zirconium

Zirconium is undeniably an important metal that has many uses in both forgings and in medical applications. This compound has its uses even in biomedical applications, such as dental implants, crowns, and knee and hip replacements. Get to know more about this metal when you contact us today! 

Common Defects of Steel Forgings

Defects in steel forgings are often left out because they’re either hard to spot or because manufacturers rely too much on machined forgings. A lot of these defects usually come from the raw materials used in making the forgings.  Imperfections in steel forgings are considered to be defects, ranging from unfilled sections to surface cracking.    

blacksmith starts machined forgings

Different Imperfections in Steel Forgings

Surface Cracking

Surface cracking is one of the most common defects in steel forgings, this imperfection occurs when metals are forged on surfaces at have low temperature. This defect is characterized by having cracks and flakes appear on the metal. To avoid surface cracking, there must be proper control of the temperature when working on steel forgings.  

Die Shift

This defect often occurs when the upper die and lower die misalign during forging. Die shift becomes a problem when forging because the forged product does not have the right dimensions. This defect can be corrected by adjusting and aligning the upper and lower die properly.  

Unfilled Section

One common defect in steel forgings that can be easily spotted is the unfilled sections. This type of imperfection happens when some of the forging sections remain unfilled due to inexperience or poor steel forging designs. This mistake can be avoided by carefully planning and exercising proper forging techniques.  

Scale Pits

This imperfection often occurs when you don’t properly clean the forged surface when forging outdoors. When you’re forging without shade or protection, the forged surface is riddled with dust or dirt that irregularly forms on the surface of the forging material. This can easily be solved by cleaning the forged surface.    

what you need to know about machined forgings

Factors That Affect Machined Forgings and Steel Forgings

There are a lot of factors that can affect your machined forgings and steels forgings, that’s why it’s important to plan before you start. If you want to know more about forging, get in touch with our team today!  
 

Choosing the Right Alloy for Your Cast Products: Aluminum vs. Steel Casting

Casting has evolved into a significant stage in the production process. Many industries use casting products because casting delivers even the most challenging concepts. Casting has no restrictions on the types of layouts, patterns, or structures that can be made. Casting can be performed with a range of different components. Steel castings and aluminum castings are currently the two of the most common materials.

pouring melted steel castings

Aluminum Casting vs. Steel Casting

Corrosion Resistance Properties

The comparison between the two alloys might go either way, depending on their functions. Aluminum is naturally corrosion resistant and can tolerate long periods outside under moist conditions.

However, carbon steel can rust easily. Thus, it frequently needs to be coated or sealed to work effectively. On the other hand, stainless steel has the more excellent corrosion resistance of not only carbon steel but also aluminum.

Weight

The weight of aluminum is less than that of steel. Aluminum is an excellent choice if you want a material that is both tough and light.

When compared to steel-made products, aluminum products are lighter. The strength and solidity of an aluminum casting are improved by adding more elements to it. However, it must retain its weight-friendly characteristic.

Strength

Although steel is typically more robust than aluminum, certain aluminum alloys outperform certain steel types.

For weight-bearing structural elements or applications that require much strength, steel is frequently the first choice.

Aluminum has the benefit of being lighter, but it must be produced with care to meet strength requirements.

Heat Resistance

Aluminum is not as heat resistant as steel because of its lower melting temperature. Aluminum begins to degrade at roughly 900 degrees Fahrenheit, whereas steel does not melt until temperatures reach over 2,500 degrees Fahrenheit.

As a result, contrary to aluminum, steel may be the best alloy to use in applications that need a lot of heat.

drilling machining steel castings

Want to Know More About Steel Castings?

There are numerous factors to consider before selecting a casting material. If you’re unsure how to start, it’s better to get advice from a casting professional who can answer your questions immediately. Don’t hesitate to get in touch with us right away!

Why It’s Important to Know the Metals You’ll Be Working With

Choosing the right metal for your steel forgings will ensure that the forged product will meet design requirements and be of the highest quality. Furthermore, you want to choose a metal that will perform well in the application without causing any problems like corrosion, severe wear and tear, or mechanical failure. 

steel forgings press and quenching

What Are the Most Common Forging Metals?

When heated or forged using certain ways, each metal has different properties and reactions. Some manufacturers will specialize their techniques to deal with specific metals, such as aluminum, steel, or titanium, as a result of these distinctions.  

Though technically, any metals can be forged, which metals can be forged depends primarily on the supplier that you hire and their production capability. 

The following are some of the most commonly used metals in metal forging: 

Alloy Steel 

Alloy steel have had their qualities adjusted or enhanced by adding extra metals like silicon, manganese, or nickel to the steel. Forging metal parts with alloy steel provides high wear resistance and strength. 

Stainless Steel 

Stainless steel is a corrosion-resistant, heat-resistant, strong, and long-lasting metal. When the metal is forged, all of these characteristics are strengthened even more. 

Aluminum 

Aluminum has a high corrosion resistance, allowing it to be used in harsh situations like those found in aeronautical applications. 

Carbon Steel 

Carbon steel has a higher carbon content than ordinary steel, which gives it extra strength. The metal is also effective in high-temperature and high-pressure environments. 

steel forgings Forged product

Looking For More Information About Steel Forgings?

At Ferralloy Inc., we guarantee that the products you purchase are manufactured by industries that prioritize quality. Schedule an appointment today with our team if you are still unsure which manufacturing process is right for you. 

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!