What is the Difference Between Casting & Forging?
Casting and forging are popular metal forming processes used to create parts and components for a variety of industries. However, these processes are very different from each other, and yield products with varying characteristics. As a leading outsourcing authority for metal forming and fabrication, we're here to clarify what distinguishes casting and forging from each other, and help you decide which is better suited to your project's requirements. Let's begin by breaking down the definitions of each.
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What is Forging?
Forging uses dies, pressure, and temperature to shape a solid piece of round metal bar into a shape. There are three ways forging can be classified: 1) temperature (hot, warm, or cold forging), 2) type of process (open or closed die forging), or 3) material used (steel forging, aluminum forging, brass forging, or bronze forging).
What is Casting?
Casting is the process in which molten metal is poured into a hollow cavity mold and later cooled to form a solidified part. Types of casting vary based on the molding materials, casting process, and filling pressures. Die casting, investment casting, permanent mold casting, and sand casting are the main metal casting methods.
Forged vs Cast
To summarize, castings are melted, poured, and solidified, while forgings are physically forced into a shape while remaining in a solid state. As a result, these two processes form end products with very different characteristics. When deciding which process is best suited to your project, it's important to narrow down your priorities. Is it a complex shape? Is it large in size? Does it require high levels of strength? Refer to the chart below for the most common considerations to keep in mind when choosing between casting and forging.
Factors to Consider When Choosing Between Casting & Forging
Metal Forging
Metal Casting
Structural Integrity
Far superior in strength compared to castings. High level of material predictability
Products tend to be more porous and more susceptible to breakage compared to forgings
Tolerance
Not well suited to highly complex geometries
Allows for a high level of detail. Able to adhere to tight tolerances
Product Size
Limited in terms of the size and thickness of the metal (larger = more difficult)
Compatible with a wide range of sizes
Material Selection
Selection of alloys is limited
Compatible with nearly all types of metal
Secondary Operations
Usually requires secondary operations to refine and finish product to exact specifications
Provides primary product that will usually require very few secondary operations
Cost
Tends to be most cost effective for medium to large production runs
Generally, less expensive compared to forging, but it depends on the specific casting method used.
Grain Flow as a Factor
Grain flow is at the center of what separates these processes from each other. In forging, the metal is pounded and deformed, but the grain flow remains unbroken, allowing it to retain its strength. In casting, the metal is melted down, which breaks the grain flow and causes the metal to lose some of its initial strength once it solidifies. As a result, forged metal is less likely to shatter than cast metal.
Which is Better, Casting or Forging?
All in all, casting tends to be the less expensive, more versatile option, however; forging offers superior strength and wear resistance. The question of which is better depends on the top priorities for your project. If low cost, exotic alloys, and complex geometries are a priority, casting would probably be the way to go. However, if strength and structural integrity are concerned, forging may be the better option.
Explore examples of our past work to see what Compass & Anvil's metal forging sourcing services can do for you and your planned project.
Discuss Your Forging or Casting Needs with Compass & Anvil
With over 30 years of industry experience, Compass & Anvil is an expert on castings and forgings. As a leading outsourcing authority, we can find a domestic or international manufacturer to take care of all your metal forming needs. We provide hands-on facilitation from initial design all the way through fulfillment to ensure you receive the high quality products you need. Backed by our quality guarantee, we can make certain the parts you receive match your exact specifications, or your money back. Contact us today for a free, no obligation consultation.
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In nearly every man-made environment, metal-based products comprise the many conveniences we use on a daily basis. From lamps and kitchen appliances to automobiles and skyscrapers, we are reliant on the manufacturers and original equipment manufacturer (OEM) suppliers who produce the components that, when compiled into final products, create the world we live in.
There are many processes when it comes to manufacturing metal components and products. The metal fabrication process includes cutting, folding, welding, machining, punching, stamping, shearing, casting and forging. However, while many of these reshape the alloy, only casting and forging manipulate the shape of the metal at the interior level, allowing for a more significant reshaping of the metal.
The key differences between casting and forging are as follows:
- Casting is the process in which metal is heated in a furnace until molten. While in the liquid state, the metal is poured in a die, or mold, to create a component shape.
- Forging is the process in which thermal and mechanical energy is applied to ingots to cause the alloy to change shape while in a solid state.
In this blog post, we go over the difference between casting and forging, several benefits of both processes and the industries in which each are commonly used.
Casting: Benefits, Defects, and Common Products and Industries
Casting is one of the most popular manufacturing processes due to the complex and large volume of industrial parts and components. Here are the primary benefits of this process:
Although there are many benefits to casting, there is the potential for contamination while the metal is in liquid state. In the cooling state, defects such as interior tears or cracks can develop as the mass cools at different rates. However, quality assurance that implements current technology, including X-ray machines, allow for accurate readings of the components prior to packaging and shipment.
Casting in the Automotive Industry
In , the global metal casting market size was valued at $123.8 billion. This value is expected to expand at a CAGR of 5.3 percent from to . The increasing demand comes, in part, from the automotive sector that anticipates to drive this market growth over the six year period.
Leading this increase in metals is aluminum, not only because it is less expensive than steel but because it creates more lightweight vehicles, which require less fuel. The stringent regulations regarding pollution and energy efficiency in vehicles plays a role in the growth of the casting industry: Casting is one of the primary processes of automotive component manufacturing due to the complexity of the components.
Forging: Benefits, Defects, and Common Products and Industries
With forging, the metal is heated to a plastic stage so that the application of compression, applied manually or automatically, elongates the material and decreases the cross section. As one of the oldest approaches to reshaping metal, it provides several benefits:
- Stronger products: Shaping and reshaping the metal changes the internal microstructure to disperse alloy concentrations and eliminate voids to create a denser component.
- Higher fatigue strength: Forging strengthens the mechanical properties to increase stress level, thereby curbing failure of the component.
- Low operating cost: With the combination of fewer required materials and less machining, forging provides lower operating costs.
- Variety of shapes accomplished: Forging creates components often found in industries that require high levels of resistance and reliability, such as the automotive, aerospace and agricultural industries.
Manufacturers choose forging for components and products that require significant strength. With this comes higher initial costs, secondary finishing processes required by hot foraging and limits to the complexity of the shapes.
Forging in the Oil and Gas Industry
In , the metal forging market size was estimated at $1.08 billion and expected to increase at a CAGR of 2.1 percent from to . One of key drivers for market growth is the oil and gas industry, which requires components and products to have high overall strength and fatigue strength. The metal components include ball valves, electric motors, turbines, wellhead equipment, pumps and more.
An OEM Supplier With a Full Range of Services
When partnering with VPIC Group, you don't have to wonder about the difference between casting and forging. Instead, our team of technicians can offer the metal manipulation process that works best to produce your desired product. Whether the components are complex and need to be produced at a high volume or they require higher resistance, our manufacturing services have you covered.
Ready to get started on your casting or forging project? Contact us today.
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