Before going over the benefits of aluminum forging alloys over casting, it’s important to understand the differences. Forging is a manufacturing process in which metal is hardened and crushed under high pressure to produce a strong product. While the usual forging method is heating, some forgings are produced without the heat. Forging and casting are two different manufacturing methods. The material is poured into a mold and solidifies as a cast when heated above its melting temperature.
Aluminum forging is a better manufacturing process than aluminum casting because it has less environmental impact, is more durable, and can create products more precisely. The following are five reasons why aluminum forging is a better alternative to aluminum casting.
Cast aluminum vs. forged aluminum
Cast aluminum is a lightweight, versatile metal that has many uses. It can be easily molded and cast into almost any shape, perfect for creating objects with intricate details. It is also non-toxic and non-corrosive, making it a safe choice for products that contact food or skin. Cast aluminum is often used in cookware since it heats up quickly and evenly. It is also used in transportation, construction, and manufacturing industries.
Cast aluminum may be more common, but when it comes to forged vs cast, forged aluminum is stronger and lighter. The main benefit of forged aluminum is its strength-to-weight ratio, which makes it ideal for applications that require a high level of durability, like aircraft and cars. Cast aluminum is also strong, but it can be more brittle, leading to greater risks in applications that involve sudden force or vibrations.
Cost-effective
In general, die forging tools are less expensive than die-cast tooling. When various fabrication options are available for a given application, price becomes a major deciding factor. Forging also has a faster rate of production than casting. Many forgings are used instead of castings in highly stressed applications because they are more affordable.
Exceptional strength
Aluminum forgings exhibit mechanical properties that make their strength-to-weight ratio superior to castings when heated. Forging, unlike the latter, has no porosity. This means that heat treatment processes can greatly improve the mechanical properties chosen. This increased strength demonstrates that, unlike other methods, aluminum forging can achieve good strength.
Improved surface finish
Forging can produce a variety of different surface finishes. The casting’s surface finish isn’t particularly appealing or smooth. On the other hand, aluminum forging makes it simple to create smooth surfaces or sharper serrations. Some alloys, such as 6061, have the best anti-corrosion properties without surface finishes. Click here for products and to learn more about 6061 aluminum.
Increased flexibility
There are some exceptions to the rule that not all shapes must be forged. Forging, which a die tooling designer creates, can produce various shapes. The use of 3D modeling and drawings has also greatly increased the model’s flexibility during the early stages of development. In contrast to casting, where the physical size of the component may limit design flexibility, forged components are open to new design suggestions from customers.
Reduced lead time
A standard forging can be produced in about 6-7 weeks. Today, toolmakers use cost-effective technology to shorten the time to complete a project. Less time means less spending. Self-contained spaces are common in forging production centers to reduce lead times. As a result, they have more regulation and control over the creation process and more time to make revisions.
Conclusion
Make sure to inspect the materials and products for quality. Quality materials aren’t cheap, but they’ll save you money in the long run. They deliver better results and have a longer lifespan.
When finding components for a product that must exhibit maximum properties and durability, forged products will be the choice every time. The process of forging produces a much stronger and harder component than cast. In addition, forgings can be made from various metals, meaning the perfect material can be chosen for each application. Finally, forgings are known for their excellent fatigue resistance; they can withstand many stress cycles without breaking.
