Advantages of Forging
Forging refines and redirects anisotropic grain flow, conforming the inherent raw material flow lines to the shape of the part, providing tensile strength.
Forging drives dynamic recrystallization in the microstructure, enhancing fatigue properties and impact toughness.
Forged metal products have more consistent microstructure, providing reliable machinability.
Machining hours are cut down saving time and money.
The forging process generally works for most metals including ferrous and non-ferrous.
Forging results in more efficient inspections and manufacturing
Forged products contain no gas pockets, voids, or shrink defects that can lead to product failure.
"Wrought Properties", the standard other processes seek to achieve, are the properties achieved by forging.
The mechanical properties are is improved with forging.
Porosity is eliminated by forging.
Forging Weaknesses
While net and near-net forging processes are possible in some materials and for some configurations, forging is limited to geometry of forming between tools and dies. Complex configurations with internal cavities and voids either cannot be produced/forged or will require subsequent machining.
Size limitations on different types of products may occur due to the equipment size and capacity.
Raw materials are generally limited to those commercially available alloys that can be obtained from raw material producers in ingot, billet or bar form as input to the forging process.
Casting Process
Casting is a process in which a material in liquid form is poured, injected under pressure, or drawn by vacuum into a mold. With molten metals, after the mold is filled the casting must cool and solidify. The casting is then removed from the mold. In the case of hard molds, such as in sand, shell, or investment processes used to cast metals, the mold is used once and must be broken to release the casting. In the case of permanent mold castings, such as die casting, the dies containing the casting are separated to free the casting, then cleaned and prepared for the next casting to be made.
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