Forging Compared to Other Processes

Vs. Castings

• A casting cannot compare to a forging in strength. By working the material twice, through extrusion of the bar stock and hot working at forge. A forging has superior properties than that of a casting.
• Because the forging process is very repeatable, costs can be improved compared to a cast part. The forge process redefines grain with heat and pressure. Castings contain porosity which may cause defects not discovered until the part is machined, costing valuable time and money.
• Tooling costs for some casting processes can be prohibitive. This is especially true for medium and low volume applications. In comparison, forging tools require relatively low capital.
• During the machining operation it is very important to maintain dimensional control. Fixturing a forged part is very consistent due to the stable condition of the material and less process variability of the forging process. Reduced distortion of a forging during heat treatment is also an improvement because of material and process stability.

Vs. Machined Bar or Plate

• Forged configurations can reduce machining time, generate less scrap and lower assembly costs. Material is used where necessary and removed from areas where it is not required reducing raw material and excess machining costs. In some cases features can be incorporated into a forged design that will eliminate an assembled component and possible leak path and reduce secondary machining.
• Bar stock and plate have grain structures that run in one direction. A forging redefines the grain structure so that strength is imparted into all areas of the part. This improves the metallurgical properties of your design adding strength where bar stock cannot.