Aluminum forging vs. aluminum casting: How to choose between the “twin brothers” in the field of metal processing?
- Comparison of process principles
Aluminum forging is a process that uses pressure processing to cause plastic deformation of aluminum billets and eventually form the desired shape. The core is to use a forging press to apply impact force or static pressure to the metal to refine the grains and form a streamlined structure (Figure 1).
Aluminum casting, on the other hand, is to inject liquid aluminum into a pre-made mold and obtain a molded part after cooling and solidification. Depending on the type of mold, it can be divided into sand casting, metal mold casting, die casting, etc. (Figure 2).
- Differences in equipment and processes
Aluminum forging requires special equipment, such as mechanical presses, hydraulic presses, etc. The process includes:
- Heating the billet to 350-500℃
- Multiple forging and forming
- Precision machining
Casting equipment is relatively simple, with the core being a furnace and a mold, and the process is:
- Melting of aluminum ingots (above 660℃)
- Casting into molds
- Demolding and cleaning
- Product performance comparison
Aluminum forgings have significant advantages:
- Strength increased by 30-50% (Figure 3)
- Fatigue life extended by 2-3 times
- Dimensional accuracy of ±0.1mm
Castings are more suitable for complex shapes:
- Thin-wall structures with a wall thickness of less than 1mm can be achieved
- Suitable for large and complex shell parts
- High surface roughness (Ra 6.3-25μm)
- Application field analysis
Aluminum forging is widely used in:
- Automobile wheels (weight reduction of 20%) while improving strength)
- Aerospace structural parts
- High-end tool handles
Casting technology dominates the following areas:
- Engine cylinder block and cylinder head
- Architectural decorative parts
- Daily necessities hardware
To sum up: the product performance of aluminum forgings is better than that of aluminum die castings