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Much has been said and written recently by the forging industry about the advantages of forged products over castings. Such articles with headlines such as "Upgrade to Forgings" intend to imply that castings are in some way inferior and less reliable. It should be recognized that castings and forgings start from very similar beginnings and castings can have some very distinct advantages over other product forms, including forgings.
The Process
Most steel components start as castings: metal that has been melted, poured into a mold and solidified. In the casting process at the foundry, because the mold has the shape of the desired component, all that remains to be done after casting are the various finishing operations.
With forgings, the first shape is an ingot or continuously cast billet. Ingots are large, usually rectangular in form and weigh up to several tons. Ingots or continuously cast billets are forged into shapes by hammers or presses. Extensive machining to final configuration usually is required, and welding also may be necessary before finishing operations can begin.
Table 1 shows typical casting and forging procedures for producing a 10-in. valve. Although no two foundries are identical, all would essentially follow the same procedures identified in Table 1.
