Forging and casting are two different manufacturing methods. When something is cast the material is heated above its melting temperature and poured into a mold where it solidifies whilst when something is forged it is physically forced into shape while remaining in a solid state although it is frequently heated.
Forging is stronger than casting.
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.
Steel casting and forging are used to produce parts for various industries such as petrochemical plants, power generation and waste processing, rendering plants, railways, mining and mineral processing, agriculture and livestock handling and water treatment.
One of the main reasons we choose to provide forging services is that it provides a stronger end product for our partners.
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.
In this process, metal shapes are formed by pouring melted metal into a mold cavity, where it is then cooled and later extracted from the mold. Metal casting is used to make many of the metal objects used in our daily lives including automotive parts, steel plates, coils, pipes, poles and more.
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 mould or vessel to create the desired shape. In the forging process, the material is pressed or hammered into a certain shape while still maintaining a solid-state. So why do we choose to forge?
Arguably, metal casting is the earliest and most influential industrial process in history. Today, nearly every mechanical device we use, from automobiles to structural steel are manufactured using metal parts that were created using the casting process.
This is the process in which metals are formed and shaped through compressive forces which are hammering, pressing or rolling. This is one of the most fundamental metalworking processes in the metal manufacturing industry. It’s especially essential in the iron and steel industries and is viewed as a tremendous source of productivity.
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.
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.
Browse through this category for various cast and forged products available in Zambian stores.