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Why Drop Forging is Better than Casting?

Both drop forging and casting process are all the metal forming process used in production of metal components for different industries. Sometimes, a metal parts can be made in casting and drop forging at the same time, but by contrast, people prefer drop forging process for its advantages, then why drop forging is better than casting (drop forging vs. casting)?

Drop forgings are stronger. Casting cannot obtain the strengthening effects of hot and cold working. Drop forging surpasses casting in predictable strength properties - producing superior strength that is assured, part to part.

Drop forging refines defects from cast ingots or continuous cast bar. A casting has neither grain flow nor directional strength and the process cannot prevent formation of certain metallurgical defects. Preworking forge stock produces a grain flow oriented in directions requiring maximum strength. Dendritic structures, alloy segregation's and like imperfections are refined in drop forging.

Drop forgings are more reliable,less costly. Casting defects occur in a variety of forms. Because hot working refines grain pattern and imparts high strength, ductility and resistance properties, forged products are more reliable. And they are manufactured without the added costs for tighter process controls and inspection that are required for casting.

Drop forgings offer better response to heat treatment. Castings require close control of melting and cooling processes because alloy segregation may occur.This results in non-uniform heat treatment response that can affect straightness of finished parts. Drop forgings respond more predictably to heat treatment and offer better dimensional stability.

Drop forgings' flexible,cost-effective production adapts to demand.
Some castings, such as special performance castings, require expensive materials and process controls, and longer lead times. Steel forgings are examples of forging processes that adapt to various production run lengths and enable shortened lead times.

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