From Casting to Forging: Don’t Let Traditional Processes Hold Back Performance and Cost Advantages

As metalworking technologies continue to advance, an overlooked opportunity is emerging—parts that have long relied on casting, especially rings, may be long overdue for a switch to forgings.

If you’re still struggling with casting defects such as porosity, repeated repairs, or sudden failures, it’s worth understanding this first: the core differences between casting and forging go far beyond just “manufacturing methods.”

170-Ton Giant Ring Forged Instead of Cast

● Why Forgings Are the Better Choice: A Core Comparison

The fundamental difference between casting and forging determines the “built-in DNA” of rings:

Casting is “liquid forming”—metal is melted, poured into a mold, and cooled into shape. Think of it like pouring molten wax into a mold: it’s efficient, but often leaves internal voids (porosity), and grain structures become uneven due to inconsistent cooling. That’s why castings are always compromised when it comes to strength and stability.

Forging is “solid-state shaping”—metal is heated to a plastic state and shaped by hammering or pressing, much like kneading dough to squeeze out air bubbles and make the texture denser. In this process, grains are refined, structures compacted, and porosity eliminated. For rings, this “compacted shaping” dramatically improves stress uniformity across the structure.

High-Deformation Multi-Directional Forging Breaks Up Large Cast Grains in the Metal Billet

Don’t Let the ‘Short-Term Convenience’ of Castings Hold You Back

In the past, limitations in part shapes and structures made casting the default option in many industries. Today, as technologies advance, the advantages of switching rings from castings to forgings are increasingly clear. Yet many companies still stick with castings—more out of habit than because it’s the optimal choice. In reality, castings often come with significant “hidden costs.”

Porosity in castings is “inherent.” For rings, these defects often hide in curved inner surfaces or thicker cross-sections. At best, they require repeated welding and repairs, consuming man-hours; at worst, they lead to scrapped parts and wasted raw materials. More dangerously, some defects surface suddenly during operation or load-bearing, causing bearing rings, flanges, and other critical components to fail. This can result in unplanned downtime, production interruptions, or even safety hazards.

Forged rings directly address these issues:

● Material is fully compacted during forming, with virtually zero porosity or voids, reducing rework and scrap from the source

● Refined and uniform grain structures deliver superior impact and fatigue resistance, ideal for critical load-bearing, high-frequency components

● Performance targets can be met using standard alloys, lowering raw material costs

Not Every Part Is Suitable For Forging, But You Can Start With These 8 Evaluations

From a full lifecycle cost perspective, the long-term benefits of forging far exceed the short-term cost advantages of casting. However, this does not mean all products are suitable for forging, as casting remains indispensable in many scenarios. To determine if “casting should switch to forging,” you can evaluate these 8 aspects:

● Is the ring used in core equipment or load-bearing components where safety requirements are high?

● Does internal porosity frequently cause premature part failure?

● Does production often involve repeated welding repairs or rework of cast parts?

● Is the scrap rate high, affecting production schedules?● Is it a critical part that determines overall equipment performance?

● Does your team have the authority to adjust part designs to accommodate forging processes?

● Is the ring a core functional component whose performance variability directly impacts reputation?

● Do you want to reduce supply chain risks by consolidating suppliers (e.g., merging “casting + repair” steps)?

If three or more of the above answers are “yes,” switching from casting to forging is likely to save significant hidden costs and even enhance your competitiveness.

Integrated Forged Ring for a 10,000-Ton Cement Rotary Kiln

Over the past decade, forging technology has made breakthrough progress. Complex parts once considered cast-only can now be produced via forging, providing companies with alternatives beyond casting. If a company has design autonomy and is willing to implement design changes, transitioning from casting to forging becomes much smoother.

Breaking the perception that “rings can only be cast” allows you to seize the benefits of technological advancements and achieve better results. Take the first step now: send us your part drawings and production challenges, and we will provide a customized evaluation report within 24 hours. Transitioning your rings from casting to forging could be the key step in boosting your competitiveness.