Rolled ring forgings begin by cutting and forming a circular metal piece into a shape resembling a doughnut. This doughnut-shaped metal piece is heated to a temperature above its recrystallization point and then placed onto an idler or mandrel. The idler moves the rolled metal ring toward a drive roller that continuously, evenly, and uniformly rotates to press the ring into the desired thickness and size.
This metalworking technique results in seamless rolled rings that can be used in the following applications:
At Ferralloy, Inc., our expertise in the rolled ring forgings process allows us to produce seamless metal rings of varying sizes, preserving the metal’s grain structure while significantly enhancing its mechanical properties.
Benefits of Quality Rolled Ring Forging
Rolled ring forging offers a diverse range of benefits for various industries and applications, such as:
High Strength
Rolled ring forging creates forged metal parts exhibiting exceptional strength. Rolled ring forged parts can maintain their performance and durability in extreme temperatures and other harsh conditions where standard components might fail. This unsurpassed resilience makes these parts an ideal solution for use in heavy-duty applications like:
- Mining & Road Construction
- Paper mills
- Oil refineries
- Trucks & Off-Road Vehicles
Cost-Effectiveness
Despite being a complex process, rolled ring forging creates cost-effective final products and can be more economical than alternative fabrication and forging methods, thanks in part to its minimal machining requirements and low tooling costs.
Versatility
Aluminum, nickel, stainless steel, carbon steel alloys, and many other metals can be used to manufacture seamless rolled rings. Our rolled manufacturing capabilities allow us to produce top-quality components with a diameter of up to 110″. This versatility enables producers and customers to select the material that offers optimal performance in the given application.
High-Temperature Endurance
Manufacturing rolled ring forgings involves processing metals at high temperatures (at or near their recrystallization point). Careful handling and treatment throughout this process ensures that final products are capable of withstanding high-temperature environments.
Other Benefits
Additional advantages of seamless rolled ring forging include:
- Superior structural integrity
- Controlled directional grain flow
- Elimination of porosity and inclusions
- Elimination of welding (reducing risk of breakage and part fatigue)
- Increased tensile and yield strength
- Minimized waste
TYPES OF ROLLED RINGS
Ferralloy works with several types of rolled rings to create the necessary hardness, tensile strength, and workability for the given application. Common types of rolled rings include:
Carbon Steel Rolled Ring Forging
Carbon steel rolled ring forging is best suited for applications that do not require the strength or cost of stainless steel. The rolled ring forging process enhances the steel’s strength for better durability and forces porosity out of the metal to achieve a consistent grain flow.
Alloy Steel in Rolled Ring Forging
Blending specific combinations of various metals creates a durable alloy steel that exhibits properties such as strength, quality, and resilience. When higher tensile strength is necessary for a specific application, adding carbon can enhance the material’s capabilities. Higher levels of carbon can also result in increased hardness and reduced workability.
Stainless Steel in Rolled Ring Forging
Stainless steel is a popular choice for use in the rolled ring forging process. This metal is widely used due to the following characteristics:
- Corrosion resistance
- Exceptional strength
- Lasting longevity
- Recyclability
Super Alloys in Rolled Ring Forging
Exotic alloys such as Inconel, Waspaloy, and Hastelloy offer many advantages that make them ideal for seamless rolled ring forging, including:
- Fatigue resistance
- Temperature resistance
- Corrosion resistance
These properties help exotic alloys withstand harsh environments while maintaining high tensile strength.
ROLLED RING INDUSTRIAL APPLICATIONS
Rolled ring forging services from Ferralloy offer distinct advantages for the following industries:
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Electric Power Generation Industry
Electric Power Generation Industry
The electric power generation industry relies on rolled rings and other forged components to withstand lengthy exposure to the following:
- Various chemicals
- Environmental fluctuations
- Extreme temperatures
Ferralloy has the capabilities to produce rolled ring parts with exceptional strength, chemical resistance, and temperature resistance for use in variable conditions.
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Marine and Shipbuilding Industry
Marine and Shipbuilding Industry
Marine systems can experience different loading conditions during operation, such as:
- Axle drive
- Bending
- Transversal loading
This stress and changing sea/weather conditions can lead to considerable wear and tear and corrosion throughout, decreasing the lifespan of the propulsion shaft. In turn, Ferralloy only provides the highest quality rolled rings to support the requirements of marine and shipbuilding applications.
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Mining Industry
Mining Industry
Our rolled ring forgings are ideal for demanding mining applications. Forged rolled rings like ours can be used in components such as rollers, rotor rings, and ring gears. Large mining trucks can also use our rolled rings in their braking systems.
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Road Construction Industry
Road Construction Industry
This industry benefits from seamless rolled rings and forgings that can maintain reliable performance in harsh operating conditions. Our rolled ring forgings can be used in axles and shafts, flanges, roller bearings, and more.
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Oil and Gas Industry
Oil and Gas Industry
Rolled rings are widely utilized in the oil and gas sector for the following applications:
- Pipe connectors
- Pressure vessel ring connectors for pipelines
- Various flanges
Ferralloy can supply seamless rolled rings for these and other applications in the oil and gas industry.
Electric Power Generation Industry
The electric power generation industry relies on rolled rings and other forged components to withstand lengthy exposure to the following:
- Various chemicals
- Environmental fluctuations
- Extreme temperatures
Ferralloy has the capabilities to produce rolled ring parts with exceptional strength, chemical resistance, and temperature resistance for use in variable conditions.
Marine and Shipbuilding Industry
Marine systems can experience different loading conditions during operation, such as:
- Axle drive
- Bending
- Transversal loading
This stress and changing sea/weather conditions can lead to considerable wear and tear and corrosion throughout, decreasing the lifespan of the propulsion shaft. In turn, Ferralloy only provides the highest quality rolled rings to support the requirements of marine and shipbuilding applications.
Mining Industry
Our rolled ring forgings are ideal for demanding mining applications. Forged rolled rings like ours can be used in components such as rollers, rotor rings, and ring gears. Large mining trucks can also use our rolled rings in their braking systems.
Road Construction Industry
This industry benefits from seamless rolled rings and forgings that can maintain reliable performance in harsh operating conditions. Our rolled ring forgings can be used in axles and shafts, flanges, roller bearings, and more.
Oil and Gas Industry
Rolled rings are widely utilized in the oil and gas sector for the following applications:
- Pipe connectors
- Pressure vessel ring connectors for pipelines
- Various flanges
Ferralloy can supply seamless rolled rings for these and other applications in the oil and gas industry.
Why Us? Quality Rolled Ring Forging by Ferralloy, Inc.
When working with a forged ring manufacturer, it is essential to deal exclusively with a provider that has the necessary skills, supplies, and experience to get the job done right. At Ferralloy, Inc., our vast experience speaks for itself. Our forging capabilities allow us to provide the most dependable and durable seamless rolled rings available, ensuring exact requirements are met every time. As an international organization that serves a global marketplace, we offer competitively priced engineered products with manufacturing facilities in both Asia and North America.
We are ISO 9001 compliant and have manufacturing facilities in the U.S.A., China, and India. Our quality-driven company is committed to delivering unsurpassed quality, and we provide a full range of value-added services that meet or exceed our customers’ expectations.
Contact us today to learn how Ferralloy can meet the specific requirements of your rolled ring forgings application.
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