In this fast-growing industrial age, there are two words that often hang on the lips of metalworking people - forging and casting.
While both processes are important means of metal forming, the differences between them are as similar as the light and dark sides of Star Wars, with both similarities and essential differences.
If you still don't know the difference between the two, then let's unveil the mystery of forging and casting today, and see what kind of drama they play out.
First, let's dissect the massive bodies of these two processes.
Casting, to put it simply, is to turn the metal into a liquid state, then pour it into a pre-made mold, cool and solidify it, and then take it out, and we get the part we want.
It's a bit like making a cake, first stir flour, milk, eggs and other ingredients well, pour it into a mold, bake it and then remove it, and a delicious cake is born.
The advantage of casting is that complex shapes can be made, just like you can make cakes of various shapes, and the cost is relatively low.
Forging, on the other hand, is more like the process of a master carver carving stone with a hammer and chisel.
It does not require the metal to be melted, but rather to change the shape and size of the metal by applying an external force (e.g., hammering, pressure).
It reminds me of the clay I used to play with when I was a child, and it can be turned into various shapes when you pinch it, and after pinching, the clay becomes firmer, which is the magic of forging.
Through forging, the microstructure of the metal changes, making the finished product stronger and more durable.
When it comes to microstructural changes in metals, we have to talk about the science behind them.
In the casting process, because the metal is cooled and solidified from the liquid state, it is inevitable that some pores, inclusions or uneven crystal structures will be formed, just like the occasional bubbles in a cake, which will affect the mechanical properties of the material to a certain extent.
Forging, on the other hand, extrudes and hammers the metal with strong force, which can refine the grains inside the metal and reduce defects, resulting in a more uniform and compact material structure, just like a muscle that has been exercised countless times, becoming stronger and more powerful.
Due to these differences in properties, forging and casting also have their own stage in terms of application.
Casting, because it can manufacture parts with complex shapes and relatively low cost, is very suitable for high-volume production of parts that are relatively not subject to huge pressure, such as engine covers, door handles, etc.
Forging, due to its excellent mechanical properties, is more often used in parts that need to withstand high pressure or are used in extreme environments, such as aircraft wheel axles, high-pressure valves, etc.
It can be said that the forged parts are all tough guys who have withstood many tests.
In this battle between forging and casting, there is no one good or bad, they are all indispensable and important players in metal processing.
Like an oven and a carving knife in the kitchen, one is responsible for making dishes of different shapes, and the other is responsible for carving ingredients into works of art.
Knowing their respective characteristics and scope of application, I believe that when you are faced with the choice of forging or casting, you will be able to make the most suitable decision for you.
So, the next time someone asks you the difference between forging and casting, you can proudly tell him, "One is a master baker in the metal world, and the other is a master sculptor." Different creative processes give birth to their own brilliance. ”
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