Differences Between Forging and Casting Metal
Forging and casting are two very different manufacturing processes used to manipulate the shape of metal. In the casting process, metal is heated until molten. Then it is poured into a mold or vessel to create a desired shape. In the forging process, material is pressed or hammered into a certain shape while still maintaining a solid state. So why do we choose to forge?
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Forging is stronger than casting.
One of the main reason we choose to provide forging services is that it provides a stronger end product for our partners. According to a study performed by the Industrial & Manufacturing Engineering Department at the University of Toledo:
- Forged parts had a 26% higher tensile strength than the same cast parts.
- Forged parts had a 37% higher fatigue strength resulting in a much longer lifespan than cast parts.
- Cast iron only had 66% of the yield strength of forged steel, a measurement that indicates the load amount metal can hold before deforming.
- The forged parts had a 58% reduction in area when pulled to failure, compared to 6% reduction for cast parts. That means forge parts allow for much greater deformation before failure than cast parts.
Why is this?
When you melt metal, the grain size is free to expand. This creates a final product with a more random grain structure. A more random grain structure leads to deceased strength. The forging process keeps the grain structure tight and the product mechanically strong. There is also less need for expensive alloys to retain high strength.
Why use castings?
The main benefit of casting is to create components that are too large, complex, or otherwise unsuitable for the forging. We can forge part sizes up to 18” in length and weights up to 100 pounds. But if you are in need of an end product weighing 5000 pounds, casting would be a more suitable option. So use casting when:
- Your part is too large to forge.
- The part is complicated (contact us for advice on this)
- Part requires custom alloys added
Why use forging?
If your end piece is able to be forged, it should be forged. This will give your part better strength, more consistency, a tighter grain structure, and longer lifetime. Reach out to our engineers to see if forging is right for your project.
Forged Fittings Versus Casting
A cast fitting is made by pouring molten metal into a mold of the desired shape. Forged steel fittings are stronger and more reliable than castings because the grain flow of the solid steel piece is altered to conform to the shape of the part in the die. Because of this, forging provides uniformity of the structure and composition of the finished part. The refinement that occurs is due to the thermal cycle and deformation process which is what strengthens the final part in respect to internal working pressure, and external impact and shear strength.
Advantages of forging over casting:
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- Due to the tight grain structure, a forging is mechanically stronger than a casting.
- Unlike castings, forgings are not susceptible to cavities, cold pour problems, porosity or shrinkage.
- Castings typically require more expensive alloys to achieve the high strength required for most fittings.
- The tight grain structure of forgings provides more wear resistance and is not so hard as to be more likely to become brittle in comparison to castings, allowing the forged fitting to withstand higher pressures, more extreme conditions and experience a longer service life than a casted fitting.
Testing performed on a blank HRC 38-42 forged grinder insert wear/wash is about the same as on a high alloy HRC 46-50 cast grinder insert; however, a HRC 46-50 casting does not have the ductility to handle high impact grinding. This testing illustrates how forged steel fittings will withstand higher impacts, pressures and wear resistance than casted fittings.
In short, forged steel fittings have a longer and more reliable service life than castings, and are typically less expensive in identical applications.
This blog is an excerpt from our whitepaper, The Advantages of Forged Fittings. Click the link below to download your free whitepaper!
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