Casting and Forging

Casting is a 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 design shape.

Forging is the application of thermal or mechanical energy to steel billets or ingots to cause the material to change shape while in a solid state

casting

We use castings for a wide range of wearparts and components that are too large, complicated, intricate or otherwise unsuitable for the forging process. We can forge parts up to 50kgs but the sheer energy required to forge large items make casting a much more viable alternative.

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
Complicated/complex parts are no problem
* For general GET as well as large and complex components – casting is a fantastic method of manufacture.

Forgings

Forging offers uniformity of composition and structure. Forging results in metallurgical recrystallization and grain refinement as a result of the thermal cycle and deformation process.

This strengthens the resulting steel product particularly in terms of impact and sheer strength.

Forge steel is generally stronger and more reliable than castings and plate steel due to the fact that the grain flows of the steel are altered, conforming the shape of the part.

The advantages of forging include:

* Generally tougher than alternative
Will handle impact better than casting
* The nature of forging excludes the occurence of porosity, shrinkage, cavities and cold pour issues
* The tight grain structure of forgings making it mechanically strong. There is less need for expensive alloys to attain high strength components
* The tight grain structure offers great wear resistance without the need to make products ‘superhard’. We have found that, on a blank HRC 38-42 forged grinder insert wear / wash is about the same as a high alloy HRC 46-50 cast grinder insert. The difference being a HRC46-50 casting does not have the ductility to handle high impact grinding.