In addition to the differences in appearance and color, what are the essential differences? Here’s a brief introduction.

1. First of all, cast steel valves cannot be acid and alkali resistant and it can only be used on ordinary pipelines, while forged steel valves can withstand high pressure. It can be used in some high temperature factories, such as power plants and chemical plants.
2. Secondly, the structure of forged steel valve is much finer than that of cast steel gate valve, showing better performance in mechanical properties. The structure obtained by casting is a structure with coarse grains, and the fine grains obtained by forging. In another popular way: the mechanical properties of forged steel gate valves are good, and the toughness is stronger. If the components are the same, the corrosion resistance of the forged steel is high, and the bearing capacity is high. Compared with cast steel, it has obvious superior performance.
3. Price difference. The price of forged steel valves is also much higher than that of cast steel gate valves. It’s better to choose the suitable valve according to different needs to make every amount of money produce the greatest value.
4. The difference in valve caliber. Generally, cast steel valves can be produced from DN15-DN1000, while forged valves are generally produced only from DN15-DN50.

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What is Casting?

The core of casting is in heating the component metal to a molten state and pouring it into a prepared mold. Though the mold is most often a die, sand and investment casting are often used for specific alloys or for parts with unusual dimensions and design. Once the metal cools into the basic desired shape, the metalworker then finishes the part with the details requested by the client either by hand or through further machining.

Casting production of blank cost is low, for complex shape, especially with complex cavity parts, more can show its economy; At the same time, it has wide adaptability and good comprehensive mechanical properties.

But the materials needed for casting production (such as metal, wood, fuel, molding materials, etc.) and equipment (such as metallurgical furnace, sand mixing machine, molding machine, core-making machine, shaker, shot blasting machine, cast iron plate, etc.) are more, and will produce dust, harmful gas and noise and pollute the environment.

History of Casting

Casting is a kind of metal hot working technology that has a history of about 6000 years. In 3200 BC, castings of bronze frogs appeared in Mesopotamia. Between 13 BC and 10 BC century, China has entered the heyday of bronze castings, the process has reached a fairly high level, such as the Shang Dynasty Simuwu square Ding weighing 875 kg, the Warring States Dynasty Jinghou Yi Zunpan and the Western Han Dynasty transparent mirror are the representative products of ancient casting. Early casting was greatly influenced by pottery, and most of the castings were tools or utensils for agricultural production, religion, life and other aspects, with strong artistic color. In 513 BC, China produced the first cast iron in written records in the world – the Jin Casting Ding (about 270 kg). Around the 8th century, Europe began to produce cast iron. After the industrial revolution in the 18th century, castings entered a new period of serving large industries. In the 20th century, the rapid development of casting, has developed the ductile iron, malleable cast iron, ultra-low carbon stainless steel and aluminum copper, aluminum silicon, aluminum magnesium alloy, titanium base, nickel base alloy and other casting metal materials, and invented a new process for gray cast iron to carry out the treatment. After the 1950s, new technologies such as wet sand high pressure molding, chemical hardening sand molding, core making, negative pressure molding, and other special casting and shot blasting were introduced.

Types of Casting

There are many kinds of casting. According to the modeling method, it is customarily divided into 0 ordinary sand casting, including wet sand type, dry sand type and chemical hardening sand type 3. (2) special casting, press molding materials and can be divided into natural mineral sand as the main special casting molding materials (e.g., investment casting, mold casting, shell mold casting foundry, negative pressure casting, mold casting, ceramic mold casting, etc.) and metal as the main mold material of special casting (such as metal mold casting, pressure casting, continuous casting, low pressure casting, centrifugal casting, etc.).

Casting Process

Casting process usually includes: (casting (containers) makes liquid metal solid casting, casting according to the materials can be divided into sand mold, metal, ceramic, mud, graphite, etc., can be divided by use disposable, semi permanent and permanent type, mold preparation quality are the main factors influencing the casting quality; The melting and pouring of casting metal, casting metal (casting alloy) mainly includes cast iron, cast steel and cast non-ferrous alloy; (3) casting treatment and inspection, casting treatment, including the removal of core and casting surface foreign bodies, casting riser removal, shovel grinding burr and other protrusion, heat treatment, shaping, antirust treatment and rough machining. Inlet pump valve

What is Forging?

Though the heating of the component metal is also essential to forging, heating for this method never gets so intense as to make said metal melt. Instead, it’s merely made hot enough to make it possible for the metalworker to conduct hammer forging or otherwise manipulate it into a prepared die. Gigantic presses are used for larger products and the method of forging can vary depending on the desired final product; forging may be a hot or cold forging process, for example, or may make use of an open or closed die.

Forging: is the use of forging machinery on the metal billet pressure, plastic deformation to obtain a certain mechanical properties, a certain shape and size of forgings processing method.

One of the two main components of forging. Through forging can eliminate the metal as cast loose, welding holes, the mechanical properties of forgings is generally better than the same material castings. For the important parts with high load and severe working conditions in machinery, forgings are mostly used in addition to the plate, profile or welding parts with simple shape that can be rolled.

Types of Forging

Forging according to the forming method can be divided into: 0 open forging (free forging). The use of force or pressure to make the metal between the upper and lower two anti-iron (anvil block) deformation to obtain the required forgings, mainly manual forging and mechanical forging. ② Closed mode forging. The metal blank is deformed under pressure in the forging die chamber of a certain shape, and the forging can be divided into die forging, cold forging, rotary forging, extrusion and so on. According to the deformation temperature forging can be divided into hot forging (the processing temperature is higher than the recrystallization temperature of the blank metal), warm forging (lower than the recrystallization temperature) and cold forging (normal temperature).

The forging material is mainly a variety of components of carbon steel and alloy steel, followed by aluminum, magnesium, titanium, copper and its alloy. The original state of the material includes rods, casting chains, metal powders and liquid metals. The ratio of the cross sectional area of the metal before deformation to the die sectional area after deformation is called the forging ratio. Correct choice of forging than to improve product quality, reduce the cost has a great relationship.

Forging Process

The basic process of forging consists of a few traditional steps:

1. the raw material (steel blocks, ingots, billets) is cut into smaller parts if needed
2. the raw material is heated to reach the required forging temperature (the application of heat is necessary to make the material ductile and malleable); the forging temperature depends on the type of metal and is achieved by positioning the material into a furnace/oven;
3. the heated metal is shaped into the required form by applying mechanical forces (pressure).
4. the semifinished part undergoes machining, finishing and heat treatment

At the end of the process, the resulting product features extreme strength, impact toughness and wear resistance thanks to the metallurgical recrystallization and grain refinement resulting from the applied thermal and mechanical treatment.

Why use Castings?

The main benefit of casting is to create components that are too large, complex, or otherwise unsuitable for the forging. We can forge part sizes up to 18” in length and weights up to 100 pounds. But if you are in need of an end product weighing 5000 pounds, casting would be a more suitable option. So use casting when:

• Your part is too large to forge.
• The part is complicated (contact us for advice on this)
• Part requires custom alloys added

Why use Forging?

If your end piece is able to be forged, it should be forged. This will give your part better strength, more consistency, a tighter grain structure, and longer lifetime. Reach out to our engineers to see if forging is right for your project.

Is Cast or Forged better?

All in all, casting tends to be the less expensive, more versatile option, however; forging offers superior strength and wear resistance. The question of which is better depends on the top priorities for your project. If low cost, exotic alloys, and complex geometries are a priority, casting would probably be the way to go. However, if strength and structural integrity are concerned, forging may be the better option.

Forged vs Cast

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Valve Casting

The valve is used to change the passage section and the flow direction of the medium. It has the functions of diversion, cutoff, regulation, throttling, check, split or overflow relief. Valve castings are control components in pipeline fluid delivery systems. They come in a wide variety of sizes and sizes.

Valve castings are widely used in chemical, petrochemical, petroleum, paper, mining, electric power, liquefied petroleum gas, food, pharmaceutical, water supply, and drainage, municipal, mechanical equipment, electronics industry, urban construction, and other fields.

Types of Valve Casting

Lost Wax Casting: Is able to make cast steel valve components, like carbon steel, stainless steel, and other cast steel alloys. Lost wax casting is a precision casting method for valve components, so we can achieve good dimensions and tolerances, smoother surface. Stainless steel valve casting parts are widely used in silical sol casting process, which is another lost wax method. We can use this casting process for butterfly valves, ball valves, ect.

Lost Foam Casting: This casting method is more suitable for making precison cast iron valve parts, which can also get good surface finish and sizes, such net shape or near net shape valve castings will need no machining or just little machining allowance.

Sand Casting: Also a casting process for valve casting parts. Sand casting is suitable for both steel and iron valve castings. Compare with lost foam and lost wax castings, it is more suitable to make larger valve components, so normally, we will need to leave more machining allowance for further machining operation. The max weight we can cast is around 2 tons per piece.

Valve Sand Casting Process

Valve Investment Casting Process

Each of our valve body casting process is executed in strict accordance with the Standard Operation Procedure (SOP). The main valve body casting process of valve body casting manufacturing is as the following: Pouring simulation, Mold development, Raw material inspection, Wax pattern, Shell preparation, Metal pouring, Cleaning and Heat treatment, Inspection, Warehouse packaging, and Shipping.

• Mold Development
  • The technical department develops the mold, and the quality department uses the three coordinates to carry out the dimensional inspection.
• Wax Pattern
  • The workshop uses automatic waxing machines to set the waxing pressure, holding time, etc. and to produce high quality was patterns.
• Shell Preparation
  • The workshop has 4 automatic production lines, able to produce 1800 sets of shells. We use hygrothermograph, aerometer, and PH to monitor humidity, temperature, and concentration of liquor aluminum chloride.
• Metal Pouring
  • 4 sets of 500KG furnaces are in production, and 3 sets of 500KG spare furnaces are ready when capacity increases. The operators conduct rigorous tests to fulfill material requirements.
• Clean And Heat Treat
  • The workshop is fully equipped with 8 heat treatment furnaces, 3 quenching furnaces, 1 central shot blasting machine and 11 large shot blasting machines.
• Inspection
  • All blank dimensions are checked using a CMM. We have rockwell hardness machine, dynamic balance instrument, roundness meter, etc. The company’s quality department has certified employees to do UT, PT, MT testing.

Valve Sand Casting Process

Each of our valve body casting process is executed in strict accordance with the Standard Operation Procedure (SOP). The main valve body casting process of valve body casting is as the following: Pouring simulation, Mold development, Raw material inspection, Modeling (Core-Making), Melting, Metal pouring, Cleaning and Heat treatment, Inspection, Warehouse packaging, and Shipping

• Mold Development
  • Design and produce molds according to the requirements of the drawings. Generally, wood molds can be used for single-piece production, plastic molds and metal molds are made for mass production, and templates can be made for mass castings. Our mold is mainly made of aluminum.
• Modeling (Core-Making)
  • Includes modeling (forming the cavity of the casting with molding sand), core-making (forming the inner shape of the casting), and mold matching (putting the core into the cavity and closing the upper and lower flasks). Modeling is a key process in valve body casting process.
• Melting
  • According to the required metal composition, the chemical composition is matched, and the appropriate melting furnace is selected to melt the alloy material to form a qualified liquid metal liquid (including qualified composition and qualified temperature)
• Metal Pouring
  • Pour qualified molten metal into the sand box equipped with the mold. The pouring stage has high safety requirement, and we have rigorous process control to protect the safety of our employees.
• Clean And Heat Treat
  • After the molten metal is poured and solidified, the molding sand is removed, and the gate and other attachments are knocked out to form the required casting.
• Inspection
  • All blank dimensions are checked using a CMM. We have rockwell hardness machine, dynamic balance instrument, roundness meter, etc. The company’s quality department has certified employees to do UT, PT, MT testing.

Materials of Valve Casting Parts are as following:

Carbon Steel (mainy for high pressure valve castings): WCA, WCB, ZG25, ZG200-350, ASTM A216 WCA/WCB/WCC, GS25.

Stainless Steel: SS304, SS316, PH17-4, ASTM A351 CF8/CF8M/CF3/CF3M, ZG0Cr18Ni9, zg0Cr18Ni12Mo2, ZG00Cr18Ni10.

Gray Iron: HT200, HT250, HT300, HT350,GG15, GG20, GG30, FC200, FC250, FC300, ASTM A48 CLASS NO.20,NO.25,NO.30, NO.35.

Ductile Iron: QT400-18, QT500-7, QT600-3,GGG40, GGG50,GGG60, FCD450-70, FCD400-15, FCD500-7, FCD600-3, ASTM A536 ( 60-40-18,65-45-12, 80-55-06).

In recent years, the China Casting Valve Manufacturers realized the valve unattended strong automatic control, so the quality of the valve manufacturers to choose the valve to pay attention to which point?

I. parameters and specifications

So-called the parameters of the valve specifications can also be in short calls it the types of products, the principle of the valve consistent but the details are different, so is applicable to different places, such as the valve manufacturer of fire dampers in the mainstream of 3 c contains smoke fire damper and automatic smoke fire damper and so on all sorts of types, main control parameters and specification is the basis of choosing fire damper.

Ii. Applicable place and operating temperature

Cost-effective Cast Iron Gate Valve Manufacturer product identification will be clearly marked in the product operating temperature, it will directly determine its application, some inexpensive valve has certain versatility and generality, but as far as possible choose to install it in the main area, such as public buildings action temperature of fire dampers in exhaust system is relatively high, and the ordinary residential or commercial air conditioning system of action temperature of fire dampers in the 3 c is relatively low.

Iii. Functional requirements

For valve factory valves in the same product in different places have different requirements, so you choose 3 c before either from above or below the line of fire dampers in the choose and buy depends on its basic function and the applicable scope, such as fire damper, for example, still depends on whether you need 3 c fire valve has the function of automatic open and close, whether can meet the needs of normally open, if there is a remote control and signal output, and other functions.

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The main difference between cast iron and carbon steel valves is the difference in carbon content, which directly affects the strength and plasticity of steel.

Carbon Steel vs Cast Iron

Cast iron is an alloy of Iron; it contain iron as its main metal together with a Carbon percentage which is greater than 2%. Generally, the amount of carbon present varies from 2-4%. Silicon is also found to be another alloying element in Cast Iron with a rough percentage around 1-3% by weight. The presence of these different elements affects the color and the quality of the Cast Iron produced. Certain other impurities such as carbide and graphite can also influence the initiation of cracks in the metal.

Cast Iron has a lower melting point than the Iron element. This is because Iron contains other material as impurities. Therefore, it is easy to be casted into molds. Casting is a manufacturing technique where the liquid material is poured into molds and left to solidify. The solidified material is called the ‘casting’ and, once the solidifying is complete, the material can be removed from the mold. Cast Iron is a brittle material which is often cheap. It also has higher heat tolerance level with a high thermal capacity. However, the electric and thermal conductivity is relatively low.

Steel is composed of Iron as the main alloying metal with Carbon as the principal second component with a weight percentage around 2.1%. The inclusion of elements such as Chromium makes it possible to produce better quality grades of steel, such as stainless steel. As the name implies stainless steel is resistant to corrosion. This is because Chromium has a higher oxidation potential which in turns protects the Iron from being oxidized upon the exposure to air and moisture.

Steel possess several desirable properties which make it a suitable construction material. Steel has a relatively high viscosity and is difficult to cast as its melting point is higher than cast Iron. It is also milder than cast iron. Unlike cast Iron, steel doesn’t break easily. Instead, it forms chips when grinded and is malleable. Steel has more tensile strength than cast Iron. However, the strength of each material differs on the context of usage. Steel is mainly used for construction, for beams and also for the production of utensils.

Cast iron is cheaper than steel, and it has a low melting point with an ability to mold into any form or shape because it does not shrink when it gets cold. Steel is made with a controlled amount of carbon, whereas cast iron can have any amount of carbon. Carbons and other metals like chromium are added to the iron to make alloys and different qualities or grades of steel, such as stainless steel.

Comparison Talbe Between Steel and Cast Iron

Cast Iron Gate Valve

Cast Iron Gate Valve is suitable to fit between PN6, PN10/16 or ANSI 150 flanges (subject to configuration) and designed for general purpose, industrial and HVAC applications; hot and cold water heating installations and where a tight shut off is required. A flanged, handwheel operated manual gate valve with Brass stem, Cast Brass seat or Cast Bronze (ANSI 150) and GG25 Cast Iron body.

Design & Manufacture Standards of Cast Iron Gate Valve

Cast iron gate valves may be designed and manufactured in accordance with a series of international standards:

• American Standards: MSS SP 70; MSS SP 128; API 595; API 604; AWWA C-509; AWWA C-515; AWWA C-500; AWWA C-560; ASME B16.10; ASME B16.1; ASME B16.42; ASME B1.1, B1.5, B1.8, B1.20.1, B18.2.1, B18.2.2.
• ISO & Chinese Standards: GB/T 12232; GB/T 12221; GB/T 12220; GB/T 12226; GB/T 12227; GB/T 13927; GB/T 1047/ 1048; GB/T 17241; JB/T 9092; ISO 5996; ISO 7259; ISO 5209; ISO 5752; ISO 5208; ISO 7005-2; ISO 5211; ISO 185; ISO 1083; ISO 5922.
• European Standards: BS 5150; BS 5151; BS 5163; BS 3464; EN 1171; EN 545; EN 558; EN 1092-2; EN 12266-1/ 12266-2; EN 12351; EN 12516-3; EN 12516-4; EN 1047; DIN 3352; DIN 3202; DIN 2501; DIN 3230; NF E29-324.
• Japanese & Korean Standards: JIS B2031; JIS B2062; JIS B2043; JIS B2044; JIS B2052; JIS B2002; JIS B2212; KS B2350; KS B2306; KS B1511; KS B2304.
• Common Pressure Ratings: PN10, PN16, 5K, 10K, Class 125, Class 250, Class 150, Class 300.

Functions and Appications of Cast Iron Gate Valve

The cast iron gate valve, furnished with cast gray iron or ductile iron body and bonnet, is a linear-motion manual valve that uses a typically flat closure element perpendicular to the process flow, which slides into the flow stream to provide shutoff. It is designed primarily for on-off services as a block valve, where the valve is operated frequently. Cast iron gate valves do not handle throttling applications well because they provide inadequate control characteristics. They are widely applied for low-pressure and ambient-temperature utility services such as water supply, sewage treatment, gas supply, district heating piping, irrigation projects, air conditioning systems, as well as food processing industry, chemical and petrochemical industry, pharmaceutical and powder industry.

Cast iron gate valves may be optionally furnished with a series of construction characteristics:

• Outside screw & yoke (OS&Y) rising stem; non-rising stem (NRS).
• Solid wedge disc; flexible wedge disc; double disc, split wedge; double disc, parallel disc; resilient wedge (rubber encapsulated).
• Metal seated; soft seated/ resilient seated.
• End connections: RF/FF flanged; threaded.
• Operation: handwheel; gear box; electric or pneumatic actuator.

We are a Cast Iron Valve Supplier, please feel free to contact us if you need them.

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Forging is Stronger than Casting.

One of the main reasons we choose to provide forging services is that it provides a stronger end product for our partners. According to a study performed by the Industrial & Manufacturing Engineering Department at the University of Toledo:

• Forged parts had a 26% higher tensile strength than the same cast parts.
• Forged parts had a 37% higher fatigue strength resulting in a much longer lifespan than cast parts.
• Cast iron only had 66% of the yield strength of forged steel, a measurement that indicates the load amount metal can hold before deforming.
• The forged parts had a 58% reduction in the area when pulled to failure, compared to 6% reduction for cast parts. That means forge parts allow for much greater deformation before failure than cast parts.

Forged Steel vs Cast Steel

The casting process is preferred for:

• parts and components that would be too complex or expensive to manufacture by steel forging (example: large valve bodies);
• parts that have internal cavities;
• large sized parts (there are virtually no size limits in terms of the weight of the parts that can be produced with the casting process);
• parts in special alloys (some specific alloys are more difficult to forge than cast, for example, those with a high content of Nickel and Moly, which have considerable resistance to mechanical forces);
• parts requiring mass production and small lots.

The forging process is preferred for:

• parts requiring extremely high strength, toughness, and resistance (indeed, during the forging process the steel grain structure gets modified to conform to the shape of the final product – with high uniformity of composition and metallurgical recrystallization);
• parts that have to withstand stronger impacts and mechanical forces;
• parts where porosity, the risk of a gas void, pockets, and the possible formation of cavities (even micro-granular) are not acceptable;
• production of mechanically strong parts without using expensive alloys;
• parts that require high wear resistance;
• parts subject to high loads and stress;
• high-end applications when the integrity and the quality of the part are the main objectives in the production process, rather than time and cost.

Forged Steel Ball Valve vs Cast Steel Ball Valve

Cast steel ball valves are ball valves formed by pouring liquid into a mold and allowing it to solidify. Alloy steel is the most common casting material. Cast steel is divided into cast carbon steel, cast low alloy steel, and cast special steel. Cast steel refers to steel castings produced by casting methods. Cast steel is mainly used to make parts with complex shapes that are difficult to forge or cut and require high strength and plasticity.

Forged steel ball valves are made of forged steel and forgings by the forging process. Forged steel ball valves are stronger than cast steel ball valves and can withstand larger impact forces. Its plasticity, toughness, and other mechanical properties are also higher than castings, so for some important mechanical parts, should use forged steel parts.

Casting is liquid forming while forging is a plastic deformation process. The internal structure of the forged workpiece is improved, the mechanical property is good, the grain is uniform, and it is the best choice for important heavy-duty parts. Casting may cause structural segregation and defects, but casting has its own advantages. The forming of complex parts is not easily accomplished by forging, in which case the casting process is more advantageous.

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The key differences between casting and forging are as follows:

• Casting is the process in which metal is heated in a furnace until molten. While in the liquid state, the metal is poured into a die, or mold, to create a component shape.
• Forging is the process in which thermal and mechanical energy is applied to ingots to cause the alloy to change shape while in a solid state.

What is Forging?

Forging is a kind of process that uses metal forming machinery pressed to metal billet, making it deform plastically to acquire mechanical properties, shape, and size. Forging is a common forming process widely utilized in machinery. Forging can eliminate cast loose and welding holes inside the metal. The mechanical properties of forging are more excellent than castings.

Based on temperature, forging can be classified into cold forging and hot forging. Generally, cold forging is in progress under room temperature. Hot forging is conducted under a temperature that is higher than the recrystallization temperature of the metal. The forging whose temperature is lower than recrystallization is called warm forging.

Advantages of Forging

• Generally tougher than alternatives
• Will handle impact better than castings
• The nature of forging excludes the occurrence of porosity, shrinkage, cavities, and cold pour issues.
• The tight grain structure of forgings makes them mechanically strong. There is less need for expensive alloys to attain high-strength components.
• The tight grain structure offers great wear resistance without the need to make products “superhard” We have found that on a blank HRC 38-42 forged grinder insert wear/wash is about the same as a high alloy HRC 46-50 cast grinder insert. The difference being an HRC 46-50 casting does not have the ductility to handle high-impact grinding.

What is Casting?

Casting is a kind of injection molding, injecting molten liquid metal into a prepared mold. It forms castings after cooling. Based on technique, casting can be classified into sand casting, pressure casting, investment casting, shell mold casting, cavityless casting, low-pressure casting, gravity casting, etc.

Advantages of Casting

• No real upper size limit in casting weight
• Large range of alloy choices
• As forgings remain solid, custom alloys are far more difficult to get into production whereas, with casting, alloys including Chrome, Nickel, and Moly can be added at the molten stage.
• Tooling is often less expensive than forge dies
• Smaller production “runs” required
• Complicated/complex parts are no problem

Forging vs Casting

To summarize, castings are melted, poured, and solidified, while forgings are physically forced into a shape while remaining in a solid state. As a result, these two processes form end products with very different characteristics. Refer to the chart below for the most common considerations to keep in mind when choosing between casting and forging.

Casting Valves

Castings of valve mean the components are cast, including body, bonnet, and hand wheel. Casting is used to manufacture components having large sizes for cost savings. However, forging is used to manufacture small sizes valves.

Valves contain the body, bonnet, stem, and disc. Stem adopts forging. Forging can be replaced by the rolled bar. The rolled bar can be also acceptable under low pressure. Disc, body, and bonnet can be made of the bar directly. Components having large sizes adopt casting. Casting materials can be classified into carbon steel, alloy steel, and stainless steel. Carbon steel: WCA, WCB, WCC; Alloy steel: WC6, WC9; Stainless steel: CF8, CF8M, CF3, CF3M.

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