The components used in various industrial and commercial equipment are created using multiple methods. The most commonly employed techniques include casting and forging. The method employed is dependent on various factors, including raw material availability and end-user specifications, amongst others. In this article, we will determine the best method for you and the right materials to achieve optimal results.
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The key difference between casting and forging is how the finished metal components are formed.
Casts are formed when heated molten material is poured into a cast mold and left to solidify into desired shapes. Casts typically require very high temperatures to achieve the required material shapes.
On the other hand, forged materials may or may not involve the use of extremely elevated temperatures to craft material into the required shapes. Forging is done using compressive forces and may be done cold (forging conducted at room temperature) or warm (the target metal is heated above room temperature but below the recrystallization temperature.)
Further, there are differences in the tensile strength of metal components produced by casting and forging. Forged materials are typically stronger and less likely to shatter under stress compared to similar cast materials.
To forge a metal component, the target material has to be subjected to repeated die or hammer strikes which gradually craft it into the desired shape. Repeated deforming and shaping can be done either under elevated thermal conditions or at room temperature.
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The metals chosen for forging are largely dependent on the ease of accessibility and production capacities of the manufacturer. Potentially every metal can be forged, but the most commonly forged ones are listed below:
Metal casting is a process that requires molten material to be delivered into a pre-determined mold and allowed to cool into its final shape. Casting can be used to create intricate finished components but always requires markedly elevated temperatures to turn the metal into its liquid form.
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There are several metals suitable for casting with methods that date back to early times.
Some common metal raw materials still in use in modern casting methods include:
An interesting dilemma sometimes encountered with industrial parts is determining whether they were cast or forged. Casting materials and forging materials are often similar, so an accurate differentiation can&#;t be made solely based on the raw metal utilized.
The easiest way to differentiate products created from the two processes is by simply confirming the steps in the manufacturing cycle they underwent.
There are various factors contributing to the cost of producing cast metal parts or forged metal components. The major determinants of price include:
For moderate to large lot sizes, forging can be used to generate the desired materials. On the other hand, material casting is a more versatile method that can be used to create finished materials in small, medium, and large lot sizes.
Furthermore, the materials and equipment required for metal casting are typically cheaper than those needed in metal forging. Overall, both methods can be used to create satisfactory finished products, but the choice of method should warrant careful consideration of the factors outlined above.
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In a variety of industries, casting and forging are popular methods of creating components and parts. In spite of this, the processes are very different from one another, and the products produced by each have different characteristics. As a leading industrial manufacturing and engineering company specialising in metal forming and fabrication, we are here to clarify casting from forging and help you decide which is best for your project.
The process of casting involves pouring molten metal into a mould and then letting it cool and harden before removing it from the mould. This process is ideal for mass-producing parts and creating identical products using the same mould.
The casting comes in various forms. When liquid metal is forced into a die instead of a mould and kept there by pressure until it hardens, this is called die-casting. The process is known for its support for high-speed applications. Mould casting on permanent moulds is the process of pouring molten metal into a metal mould, either using gravity or a vacuum. Permanent mould castings can produce stronger castings than die casting, but they can be hard to remove from the final product. Thus, semi-permanent mould castings are also available. With these moulds, the cores can be expended, making the removal process less difficult and more affordable.
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Last but not least, sand casting is a method of casting that involves pressing a pattern into a fine mixture of sand. Moulds are formed for the molten metal to be poured into. Despite its slow speed, this process is more economical than other methods of casting. For large-scale metal fabrications and intricate designs, this is a good choice.
What is forging?
In forging, metal is shaped by compressive force. Hammers or dies are used to shape metal until the desired shape is achieved. Through the process of forging, the metal becomes deformed and shaped, which results in a continuous grain flow that allows it to remain strong. Furthermore, the removal of defects, inclusions and porosity from the product is an ancillary benefit of this unique grain flow.
In addition to its low cost, forging is also beneficial for medium and long production runs. By careful design of forging tools, it is possible to manufacture products at relatively high speeds with minimal downtime.
When forging takes place at room temperature, it is referred to as cold forging. The forging process can also be undertaken with the metal heated above room temperature to temperatures below that of recrystallization, which is called warm forging. In the hot forging process, metals are heated to their recrystallization temperature, which differs for each material. With blacksmiths using forging centuries ago, forging is amongst the oldest types of fabrication.
Castings produce metal products with relatively low strength, while forgings create metal products with higher strength and hardness. Forged metals have a lower likelihood of shattering when they come into contact with different objects.
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During forging, a change of shape is forced into the metal, either by pressing or hammering. Consequently, the metal gains strength. Contrary to other fabrication methods, the forging process stretches the metal grain, aligning it in one direction rather than causing it to be randomly oriented. However, forging can only be done within size limitations.
Forging entails a greater degree of difficulty because the metal is kept in a solid state, unlike casting. Metal sizes and thickness are restricted by forging because it is more difficult to change the shape of the metal. The larger the metal section, the more difficult it is to forge.
On the other hand, casting allows more complex shapes to be produced because molten metal flows into a mould or die cavity. It is possible to cast products of up to 200 tons of weight out of almost any material. Casting is usually much cheaper than forging. Each casting method has its own advantages and disadvantages, so the most suitable method will depend on the application.
1. Size & weight of the Finished Product
2. Design of the Component
When it comes to designing a part for either casting or forging, some characteristics to evaluate include:
3. Alloy Selection
A key consideration when it comes to castings vs forgings is the availability of alloys to use. In forging, the components are made from billets produced at a steel mill. These mills generally only manufacture a specific number of grades and alloys.
In comparison, castings are melted and poured at the foundry making special alloy costs more manageable.
4. Internal Strength of the Component
Deciding between the two processes depends upon the; forgings will typically be stronger in a particular direction, but castings are stronger uniformly throughout.
When the application involves frequent impacts, a forging will retain its shape longer. If a uniformly strong component is needed for the application, a casting will perform better.
5. Cost of Castings vs. Forgings
The price of castings vs. forgings is dependent upon multiple variables. Each of the processes is less expensive in some cases and more expensive in others. Various factors that play into the price of a part are:
In this guide, we focus on the fundamental differences between casting and forging.
When it comes to metal components, there is no such thing as a size fits all approach. The best choice for you may depend on the specific metal component, its purpose, and its overall needs. If you need particular metals, either casting or forging may be the best. Consultation with manufacturers is the best way to determine which process is right for you.
Get in touch with us or send a quote request if you think metal casting may be the right solution for your application.
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