Aerospace Forging vs. Casting: Comparing the Processes

Since the aerospace industry’s inception, precision metal forging remains one its most crucial manufacturing methods.

At Forge Resources Group (FRG), we specialize in achieving high-strength aerospace parts through our complete closed-die forging solutions. We begin with the highest quality materials – and further refine the physical/mechanical properties through precise forging operations.

Backed by more than 35 years of quality American manufacturing experience, our company continually evolves to meet the ever-changing demands of the aerospace industry in terms of safety, reliability, and performance.

The Advantages of Forged Aerospace Parts vs. Castings:

Increased Strength through Grain Refinement

The forging process refines the grain structure of metal within the workpiece further from its original state as delivered from the mill.  The grain flow of the part will also follow the exterior contours of the component with no grain run out.  The superior metallurgical structure means that forged aerospace parts can withstand stresses better than any other manufacturing method for a metallic component.

Cast parts lack the grain alignment and structural enhancement of the forging process. Parts machined from stock often undergo substantial grain run out during finish machining operations. This is why the design engineering teams at Aerospace companies often specify the need for components to be forged.

Improved Material Consistency and Heat Treat response

Our starting stock is produced using the finest melting practices to ensure internal material defects such as voids and inclusions are not present. It is then reduced to a fine grain bar often 5:1 or better on the reduction ratio.  The bar stock material is then shipped from a steel mill to our forging facility to be put into process.  Precise process controls during the forging process promote improved consistency from one forged component to the next.

Cast materials can be prone to alloy segregation during the solidification process resulting in a non-homogenized microstructure.  This presents challenges during subsequent heat treat processing and can result in varied strength throughout the part. The refined structure of forgings offer a better response to the heat treatment processes required in many aerospace applications and will offer more consistent strength readings across the entire component.