With the development of machinery industry and manufacturing industry, more and more metal products are in demand. In order to cater to different working conditions in varied industries, there are many manufacturing methods for metal components. Among them, casting, forging and
stamping are the most commonly applied technologies. This paper will focus on differences between casting process and forging process.
Casting process is to heat metal until it becomes fusional, then it is infused into a container to have the required shape when it hardens. As to forging process, it is also a manufacturing technologies for metal products. Nevertheless, steel billets or ingots are shaped in solid state during this process.
Reasons for casting.
Casting can help us deal with big or complex spare parts and components. In some cases, casting can be used to manufacture products that are not suitable for the forging process. Forging can make components about 50kgs. However, more energy are needed when manufacturing larger items. Therefore, casting is a much more feasible way.
Usually, we cast 80kg components of mining and earth moving. It is also possible for us to cast up to 150kg if it is needed. It has been detected that we are able to manufacture good-quality, firm and hard-wearing castings. The casting process is used to making parts where internal cavities are needed. With good alloys and suitable heat treatment, casting can do better work.
Strengths of casting:
1. There is no size restriction in the weight of casting.
2. There are a series of alloys to choose.
3. Casting can be applied to manufacture small items.
4. Forge dies are usually more expensive than tools of casting.
5. No problem exists in making complicated/complex components.
6. It is not easy for custom alloys to get into production during forging process. Nevertheless, alloys include Chrome, Nickel and Moly can be added by casting at the molten stage.
7. Casting is a wonderful approach to production for general items, as well as big and complicate parts.
Reasons for forging:
Forging process can help unit composition and structure. Due to the thermal cycle and distortion process, it brings about metallurgical recrystalization and grain refinement. This enhances the resulted steel product especially in the aspect of influence and shear strength.
The grain flows of the steel are altered according with the form of the component. Therefore, forged steel is normally firmer and more dependable than castings and plate steel.
Strengths of forging:
2. Compared with castings, it has better abilities to deal with influence.
3. There is no existent of porosity, shrinkage, cavities and cold pour problems.
4. It is mechanically strong resulted from its firm grain structure. Therefore, expensive alloys don’t need to get high strength parts.
5. The tight grain structure result in superior wear-resistant feature. There is no need to make products “superhard”.
In actual manufacture, one must choose the most suitable technologies according to the work conditions of components. Products made with correct process technologies can play their roles better.
