This question, “Forging vs. Casting: Which is better?” is one that I have been asked many times. To properly explore the answer, let’s first consider the process of each.
In this process, the metal is heated until molten. The molten metal is then poured into a vessel or mould to get the desired shape.
In this process, the metal is heated and then bent or beat into the desired shape using external physical force.
Why use Casting?-
We use casting for wear parts that are too large, complex and can’t be easily forged. For forging large pieces of a metal huge amount of sheer force is required so casting is a better alternative. There is no such size limits for metals in casting. It is way more beneficial because –
-No such difficulty in casting complex parts.
-No size limitations
-Comparatively easier than forging
Why use Forging?
Forged steel is stronger and more reliable than castings. Forged parts have higher tensile strength than cast parts. Forged parts also have higher fatigue strength. Forging is used because-
-Will handle impact better than cast one
-The nature of forging excludes the occurrence of porosity, shrinkage, cavities and cold pour issues.
-The tight grain structure of forgings making it mechanically strong. There is less need for expensive alloys to attain high strength components.
-The tight grain structure offers great wear resistance without the need to make products “superhard” We have found that on a blank HRC 38-42 forged grinder insert wear/wash is about the same as a high alloy HRC 46-50 cast grinder insert. The difference being an HRC 46-50 casting does not have the ductility to handle high impact grinding.