Metal Casting Versus Forging 3 Factors to Ponder

Metals and Mining Review | Monday, December 19, 2022

The components in forging are made from billets manufactured at a steel mill. These mills usually produce a limited range of grades and alloys.

FREMONT, CA: Though metal casting may be the best method for producing a wide variety of parts, forging may be the best choice depending on one’s needs. Alternatively, vice versa. Here are three factors to consider when determining if casting or forging is the best option for the part, application, and overall requirements.

The Dimensions of the Finished Product

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The overall size of a finished product is one of the most noticeable distinctions between metal castings and forgings. Forging is a method of moving metal when it is still solid. To change the original shape of the metal, a huge amount of force is required, and the force required increases dramatically as the section size grows larger. Since castings begin as liquid molten metal, they can flow into nearly any shape or size if a mold is available. Another factor to consider is the weight of the components. When two identical parts are made, one by casting and the other by forging, the casting is typically lighter than the forging. As a result, weight savings are common when forgings are replaced with castings.

Alloy Selection

The availability of alloys to use is a significant difference between castings and forgings. The components in forging are made from billets manufactured at a steel mill. These mills usually produce a limited range of grades and alloys. On the other hand, castings are melted and poured at the foundry, lowering special alloy prices. The optimal ferrite content is a significant factor when choosing alloys and a manufacturing method. Ferrite has properties that make it more corrosion resistant than a comparable forging when used in regulated quantities.

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Internal Strength of The Component

Another trait to think about is the component's internal structure and power. The forging process changes the grain structure and can 'aim' or 'point' it in a specific direction, resulting in a directionally solid component. Castings are isotropic, while forged sections are anisotropic (have different property-measurement values in different directions) (contains similar property-measurement values in all directions). The choice between the two processes is based on the application; forgings are usually stronger in one direction, while castings are stronger uniformly throughout. A forging will maintain its shape longer if the application requires a uniformly strong component, whereas a casting will perform better if the application requires a uniformly strong component.

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