Forged steel vs. Cast Flanges

What is a Cast Iron/Steel Flange?
Casting is one of the oldest metalworking methods. It involves heating the
metal until it is molten and then pouring it into a pre-shaped mold. Once
cooled, the metal solidifies into the shape of the flange.

Key Characteristics of Casting:
High Production Efficiency: Casting allows for high-volume production of
complex shapes that would be difficult or impossible to forge.
Low production cost: Due to lower energy requirements and less labor-intensive
processing, cast flanges generally come at a lower price point.
Precision and Complexity: Modern casting (such as investment casting) can
achieve very accurate dimensions, reducing the need for extensive CNC
machining.
Inherent Risks: The cooling process in casting can lead to “casting defects”
such as porosity (air bubbles), shrinkage cracks, and non-metallic inclusions.
These internal flaws are often invisible to the naked eye but can fail under
high pressure.
What is a Forged Steel Flange?
Forging is a mechanical process where the steel is heated to a plastic state
and then hammered or pressed into shape using localized compressive forces.
This “working” of the metal physically changes its internal structure.

industrial forged steel flanges
Key Characteristics of Forging:
Structural Integrity: Forging refines the grain flow of the steel, aligning it
with the shape of the flange. This results in superior mechanical properties,
including higher tensile and shear strength.
Density: The high pressure of the forging process eliminates internal voids and
gas pockets, creating a dense, compact molecular structure.
Durability: Forged flanges exhibit better resistance to fatigue and impact,
making them the standard for critical infrastructure.
Costs are higher than those of cast flanges: The forging process requires
massive machinery and multiple heating cycles, which reflects in a higher unit
cost compared to casting.

Minimum Order: 100 sets

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