Metal Forms | Ferralloy

A metal alloy combines two or more elements, including metals and non-metals, to create a new material with enhanced properties compared to the individual elements. Alloys are typically created to enhance qualities like strength, corrosion resistance, hardness, ductility, and more.

At Ferralloy, we offer superior-quality metal alloys in various forms, including forged round bars, blocks, plates, sheets, wire, and more. Learn more about the materials we work with and the various forms we can provide below.

Forged Metal Round Bars

Forged metal round bars are produced using an open die forging technique. Heated metal is placed between a top and bottom die that presses the metal into a round shape. With this technique, the metal is not completely enclosed during the forging process. The starting stock must be constantly moved to create a precise product.

Open-die forging can improve the metal’s strength and fatigue resistance. Our forged metal round bars are used throughout many demanding applications, including:

LEARN MORE

Gears

Infrastructure

Shipbuilding

Oil & Gas

Machining

Forged Block & Steel Plates

Forged block and steel plates begin as ingots that are cut into the desired weight and then pressed between two flat-faced dies. For most applications, forged steel blocks are preferred over unforged blocks because they provide higher tensile strength, superior durability, and greater elasticity. However, these characteristics depend on the quality of raw resources and the grade of steel used.

Some of the most common applications for our forged block and steel plates include:

LEARN MORE

Chemical

Electric Engine Production

Food Manufacturing

Steel Plants

Machining

Forged Sheet Metal

Ferralloy can provide high-quality forged metal sheets that can be formed into various components using processes such as laser cutting, bending, hydroforming, deep drawing, punching, shearing, and more. We offer metal sheets in numerous alloys to meet the needs of the following applications:

Aerospace

Automotive

Household Appliances

HVAC Systems

Medical Equipment and Devices

Metal Wire Forms

The metal wire forming process involves a variety of bending and forming techniques to change the metal’s shape. Many popular metals are suitable for this process, including aluminum, brass, copper, stainless steel, and steel alloys. Depending on the application, techniques such as extrusion, drawing, or straightening might be used.

The most common applications for our metal wire forms include:

Aerospace

Automotive

Interior Design

Electrical

Medical

Metal Pipe & Tube Forgings

Forged metal pipes or tubes are created using a centrifugal casting technique. This method is ideal for creating thin-walled cylindrical shapes. It involves pouring molten metal into a mold and spinning it rapidly, creating a centrifugal force that presses the metal against the walls of the mold.

Forged pipe and tube shapes are strong and reliable. Since they have not been bored from a solid bar, there is little need for further machining and reduced waste.

Applications for metal pipe and tube forgings include:

Chemical

Hydraulic Machinery

Oil & Gas

Fertilization

Forged Metal Flanges

Forged metal flanges are produced using seamless rolled ring and closed die techniques. Both methods begin by cutting a billet of the required material and heating it in an oven until it can be shaped. In seamless rolled ring forgings, circular dies rotate in opposing directions, compressing the billet into a ring shape. Closed die forgings involve compressing heated metal through a closed die.

Forged metal flanges are durable, temperature-resistant, and easy to install. The forging process also helps enhance the component’s pressure resistance. Our forged flanges are used throughout many industries, such as:

Chemical

Petrochemical

Power Generation

Oil & Gas

Water Treatment

Forged Gear Blanks & Discs

Forged discs and blanks are versatile and long-lasting products. As with other forgings, they feature a more robust microstructure than that of alternative metal-forming processes. Our forged gear blanks and discs offer advantages like:

LEARN MORE

Cost Efficiency

Design Flexibility

Enhanced Fatigue Resistance

Increased Strength

Improved Wear Resistance

These products are used throughout diverse applications, such as:

Gear Manufacturing

High-Wear Applications

Heavy Machinery

Heat Exchangers

Mills

Mining Equipment

Metal Forged Rings

Forged metal rings offer greater strength and durability than those made using other manufacturing techniques. We use a cost-effective rolled ring forging process that eliminates the costs associated with plate burnouts and similar production options. Our forged metal rings are available in alloy, carbon, and stainless steel. They can be produced in as-forged condition, rough machined, or completely machined.

LEARN MORE

Common applications for our forged rings include:

Aerospace

Automotive

Oil & Gas

High-Pressure Valves, Gears, Bearings

Forged Metal Rolls

Forged metal rolls are produced using a continuous metal shaping technique that involves feeding a strip of metal through a series of contoured rolls. This process is not only highly efficient and cost-effective but is also compatible with an extensive range of materials. The resulting product offers many advantages, including:

High Precision

Surface Uniformity

Fatigue Resistance

Toughness

Highly Customizable

Our forged metal rolls are used in industries such as:

Automotive

Aerospace

Construction

Consumer Goods & Appliances

Forged Valve Bonnets

Forged valve bonnets are one of the most essential pressure valve components. They cover the valve body and are connected to it by a threaded, bolted, or welded joint. Forged valve bonnets offer design flexibility and high-strength characteristics. They are also durable and resistant to rust and corrosion.

The most common applications for our forged valve bonnets include:

Petroleum

Power generation

Natural gas

Low-Temperature Applications (cryogenic bonnets)

High-temperature Applications (extended bonnet ball valves and bonnet globe valves)

Water Treatment

ABOUT OUR METAL FORMS

Ferralloy offers many types of metal alloys, including superalloys, refractory metals, stainless steel, and titanium. Other alloys we offer include:

ALUMINIUM

NICKEL

NIOBIUM

STEEL

TANTALUM

TUNGSTEN

These materials are created through multiple processes. One method involves heating the alloying elements until they melt and then mixing them together. After the mixture has homogenized, it is allowed to cool and solidify, creating an alloy.

Another common method is sintering, in which powdered materials are heated to just below their melting point before they are pressed together under high pressure. No matter which method is used, it is essential to add precise amounts of each element to obtain the desired physical characteristics in the finished alloy.

QUALITY METAL FORMS BY FERRALLOY, INC.

Metal forms by Ferralloy are used throughout an extensive range of applications. We create industry-leading products at competitive prices, delivered when you need them. In addition to our range of quality metal forms, we also offer convenient value-added services, like machining, expert logistics management, and alloy scrap buyback and recycling programs. For more information about our quality metal alloys and forms, contact us today.

GET IN TOUCH