Manufacturers utilize various manufacturing methods to shape metal products to their specifications. Though casting and forging allows reshaping of metal at interior levels. Both are widely used in the industry to execute outcomes based on intended applications.
Knowing the difference between casting and forging can help you decide on the right die casting metals for your project.
What is Casting?
It’s a manufacturing process that crafts specific metal shapes using pre-cast or readymade molds. Molten metals are directly poured into hollow cavity molds (casting) for subsequent cooling and hardening to form a solid shape.
What is Forging?
It’s another manufacturing process to change metal parts into specific metal shapes through mechanical and thermal forces. This method involves hammering, pressing, rolling, and otherwise shaping the metal in solid or hard conditions.
Difference Between Casting and Forging
Many aspects define the difference between the casting and forging processes. And we have a well-categorized highlight from multiple perspectives.
Casting vs Forging – Characteristics
| Parameters | Forging | Casting |
| Tensile Strength | Nearly 26% higher than casting | Lower value compared to forging |
| Fatigue Strength | Usually greater than cast parts | Only 66% strength of forged parts |
| Workable Lifespan | Considerably higher (nearly six times) lifespans than cast metals | Somewhat lower life expectancy due to lesser fatigue strength |
| Yield Strength | Around 37% higher than casting | Lower value compared to forging |
| Reduction in Area | 58% reduction during failure, so high deformation before breaking. | Only a 6% reduction during failure, so little deformation before breaking. |
| Compressive Strength | Lower in value than cast parts | Higher strength than forged parts |
| Material Consistency | More consistency in materials provides refined forged metal | Lower consistency in materials can affect some minor properties |
| Flexibility | Excellent flexibility of the metal | Slightly inferior metal flexibility |
| Heat Treatment | Better response to heat treatment | Complicated response to heat treatment |
| Ductility/Porosity | Less porosity ensures high ductility, making forged parts sturdy and durable | High porosity leads to poor ductility, making cast parts comparatively weaker |
Casting vs Forging – Material Selection
| Parameters | Forging | Casting |
| Material Selection | Selection of suitable alloys is limited | Well-compatible with almost all metal types |
| Suitable Materials | Carbon Steel, Stainless Steel, Alloyed Steel, Aluminum, Brass, Copper, Nickel, and Titanium | Steel, Graphite, Bronze, Iron, Aluminum, Bronze, Copper, Brass, Nickel, Titanium, etc. |
| Tolerance | Not well-suited to complex details or geometries | Adherence to high tolerance, allowing for high levels of detail |
| Meting Point | Materials have high melting point | Melting point is considerably lower |
| Product Size/Shape | Limited options of available size and thickness of forged metals | Virtually suitable for nearly any size/shape and complexity level |
| Design Flexibility | Difficulty in modifications and molding | Easy and simple modifications and molding |
Casting vs Forging – Surface Finish
| Parameters | Forging | Casting |
| Primary Surface Finish | Higher degrees of finishing | Slightly compromised finishing |
| Secondary Operations | The primary product barely requires any secondary operation to the exact specifications | Usually needs secondary operations to polish, refine, and finish to exact specifications |
| Wastage of Materials | Fewer disposable waste with no secondary operations | Considerable waste due to secondary operations |
| Supervision | Forging requires minimal observation | Casting needs careful and intense monitoring |
Casting vs Forging – Cost Comparison
| Parameters | Forging | Casting |
| Capital Cost | The initial cost is often higher | The initial cost is low to medium |
| Suitability | Effective for medium to large production operations | Less expensive, depending on specific casting methods. |
| Labor Requirement | Forging is more tedious | Casting is comparatively easy |
| Production Volume | Mostly suitable for medium to bulk volume | Suitable for any volume, but the cost is minimized for higher volume |
| Time Requirement | Initial production time is less as prototyping or tooling is not required | More production time is needed initially, but highly efficient in long-term production |
| Overall Cost | Cost-effective for a larger quantity of custom designs | Mostly cost-effective but expensive for custom designs |
Applications of Casting and Forging
Lots of architectural and construction works of development projects utilize customized cast metals. The global market size of casting was $129.5B in 2021. And the estimated compound annual growth rate (CAGR) is 5.8% for 2030, valuing $226.8B.
Meanwhile, high strength and great durability make forged parts good for heavy, stressful uses. The global market size of forging was $74.36B in 2021. And the estimated compound annual growth rate (CAGR) is 7.7% for 2030, valuing $145.44B.
Applications of Cast Metals
Casting metals are virtually everywhere. Nearly all industries benefit from the custom and complex shapes achievable through casting metals. Almost universal compatibility with all metals makes it more consumable for everyday sectors.
Some common applications of die castings in various industries include Automotive casting, Medical casting, Marine casting, Telecom casting, etc.
Applications of Forged Metals
The automotive industry uses forged parts in shock, impact, and stress points. It includes – an axle beam, wheel spindle, ball joint, kingpin, and steering arm. Transmission components, connecting rod, and clutch also benefits from their longevity.
Superior mechanical properties make covers and casings of oil valves and fitting parts. Pressurized parts like flange, reducers, and saddle also feature forged metals. Agricultural machinery and connectors have these to withstand harsh conditions.
From hand tools to heavy machinery, most have forged metals. Many forms of standard weaponry utilize forged metals. And their high strength-to-weight ratio with other good properties make them necessary in the aerospace industry.
Forging vs. Casting – Which is Better?
The better one concerning casting and forging differences depends on the priorities and requirements of your project. Casting is more versatile yet less expensive. But forging offers strength, integrity, and simplicity.
With 10+ years of experience, Sunrise Metal is a well-reputed die-casting expert. Feel free to contact us for all your metal casting needs.