Comparison of forged components with cast components

COMPARISON OF FORGED COMPONENTS WITH CAST COMPONENTS

Forging

1. Forging is the application of thermal and mechanical energy to steel billets or ingots to cause the material to change shape while in a solid state

2. Components produced by the forging process are much stronger because forging refines the grain structure and improves physical properties (such as strength, ductility and toughness) of the metal.

3. It has less chances of defects in forged components. 

4. More material waste occurs during production.

5. The process is longer process to make than casting.

6. It is more economical for mass production.

7. Components produced using forging may not meet the requirements for high tolerances.

8. Many forged components require secondary processes to refine and finish to exact specifications.

9. Tooling costs are generally less.

10. Production rate is less.

11. It reduces labor costs and lowers tooling equipment expenses than casting.

12. Components having complex shape cannot be produced.  

13. Forged components are expensive than cast components.

14. Examples of forged components are spanners, screw drivers, connecting rod, IC engine valves, etc.

Casting

1. Casting is the process where metal is heated until molten state. While in the molten or liquid state, it is poured into a mold or vessel to create a desired shape.

2. Components produced by the casting process are not stronger as forged components.

3. Cast components often suffer from defects such as voids and porosity.

4. Less material waste occurs during production. 

5. Process time is less as compared to forging.

6. It is expensive for mass production. 

7. High tolerance on cast component is possible.

8. Cast components require very few secondary machining operations.

9. Tooling costs are generally higher for die casting than for forging.

10. Production rate is high.

11. Labor cost is high and tooling equipment is more expensive than forging.

12. Cast components are not limited to the shape and complexity.

13. Cast components are cheaper than forged components.

14. Examples of lathe bed, anvil, machine bed, IC engine block, flywheel etc.