Custom Alloys

What Is Custom Melting?

Custom melting begins with controlled alloy chemistry based on ASTM, AMS, AISI, SAE, or proprietary specifications. We produce a dedicated melt to create an ingot or billet for further processing through open die forging or seamless rolled ring production.

Companies often request custom melt material when:

• A legacy alloy is no longer commercially available

• Standard mill lead times extend beyond project schedules

• Nickel or stainless markets experience supply constraints

• A project requires modified chemistry

Because we control chemistry at the melt stage, we ensure material consistency before forging begins.

Available Alloys and Melt Sizes

We provide custom melt material across multiple alloy families, including:

• Carbon steel

• Alloy steel

• Tool steel

• Stainless steel

• Aluminum

• Titanium

• Nickel alloys and superalloys

Minimum melt requirements vary by material and typically range from 300 pounds to 30,000 pounds. We verify ingot or billet chemistry through strict testing and issue a certified mill test report to document compliance.

In many cases, we complete custom melts in approximately 30 days. Therefore, projects that would otherwise face extended delays can move forward on schedule.

Forging Capabilities for Custom Melt Alloys

Custom alloy forged parts follow the same controlled forging procedures as standard materials. We produce:

• Forged blocks

• Round and square bars

• Discs and cylinders

• Flanges and shafts

• Step shafts

• Seamless rolled rings

• Complex forged geometries

Depending on alloy type, part complexity, and order quantity, lead times for forgings and rolled rings typically range from 10 to 14 weeks after receipt of order.

Because we integrate melt control with forging expertise, we maintain full traceability from chemistry through final machining.

Production Volumes and Delivery Flexibility

All Metals & Forge Group supports projects from a single prototype to several hundred production units. Whether the need involves one critical replacement part or an annual production program, we align melt volume and forging capacity accordingly.

This flexibility allows customers to secure material availability without overcommitting to unnecessary inventory.

Quality Control and Machining Advantages

All Metals & Forge Group operates under an ISO 9001:2015 and AS9100D registered quality system. We begin every project by reviewing end use, mechanical property requirements, surface condition, geometry, and delivery schedule.

Every custom alloy forged part undergoes ultrasonic testing to confirm internal integrity. In addition, we rough machine forgings to within 3 mm of finished dimensions. This practice reduces CNC machining time and lowers total manufacturing cost. Our standard rough-machined finish is 250 RMS to allow accurate inspection before final processing.

When required, we perform finish machining to tolerances as tight as ±0.001 inch with 64 or 32 RMS surface finishes. Many suppliers ship parts in the black or at 500 RMS; however, our machining standards significantly reduce downstream operations.

From inquiry through final shipment, we actively manage quality at every stage. Whether producing a single component or a long-term production run, we deliver custom alloy forged parts engineered for reliability and schedule performance.