Forging and Casting Process

Forging

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.

There are different classifications of forging that can be used. The choice is based on process temperatures (hot or cold forging) and the type of die utilized (open- or closed-die forging). The forging method used depends on the metal or alloy being worked, and the application(s) for which the parts will be used.In forging, the state of the metal can be made cold, warm and hot depending on the requirement of the final product.

Forging offers uniformity of composition and structure. Forging results in metallurgical recrystallisation and grain refinement as a result of the thermal cycle and deformation process. Forgings respond more predictably to heat treatment and offer better dimensional stability. Open die forging processes adapt to various production run lengths and enable shortened lead times.The main metals used in forging include carbon steel, alloy steel, bronze, steel, magnesium and other alloys

Metal forging provides several distinct industrial advantages, some of which include: 

  • Better structural integrity and increased mechanical strength due to the altered grain structure
  • Cost savings due to less material scrap and reduced labour requirements
  • Forging process eliminates surface porosity, cavities/voids, and discontinuities
  • Greater reliability and consistency in ductility, known yields, and increased strength

 

Casting

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

Castings is done for a wide range of wear parts and components that are too large, complicated, intricate or otherwise unsuitable for the forging process. Casting involves pouring of molten metal into a mold for cooling.The original matter used in casting include the state of ingot, metal powder or molten metal. Casting process involves materials of metal, wood, fuel and mold

 

The advantages of casting include:

  • No real upper size limit in casting weight
  • Large range of alloy choices
  • As forgings remain solid, custom alloys are far more difficult to get into production whereas with casting, alloys including Chrome, Nickel and Moly can be added at the molten stage.
  • Tooling is often less expensive than forge dies
  • Smaller production “runs” required

 

There are several methods for casting a part. The most popular methods include, die, sand, and investment casting. Each method uses a slightly different process but delivers the same results. The casting method used depends on the metal or alloy being cast, and the dimensions and geometry of the part design, among other factors.Some castings, such as special performance castings, require expensive materials and process controls, as well as longer lead times.

Castings require close control of melting and cooling processes because alloy segregation may occur, which results in non-uniform heat-treatment response that can affect straightness of finished parts.

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