Export Office: 21Floor, No.5 Nanhai Zhi Road,Qingdao, Shandong ,China
Work Shop: Beian Industrial zone, Qingdao,Shandong,China
+86 532 88256399
Martin
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Among the major manufacturing methods for industrial valves, two methods stand out: casting and forging.
Casting of the valves involves molten metals in pre-designed molds and after it gets cooled, gets solidified; they take off that valve casting out from that mold and carry finishing processes so it can come within those desired specifications.
Sand Casting: This is the most widely used casting process, which is primarily for large valves. A mold is prepared in sand, molten metal is poured into it, and after cooling, the sand is removed to get the valve. It is cost-effective but may not be able to achieve intricate details.
Investment Casting (Lost-Wax Casting): This is the method that involves the creation of a mold using a wax pattern that is covered in ceramic. After melting the wax away, there will be room for molten metal. This will provide more precision and detail than sand casting.
The other advantages of casting include good material flexibility because casting can use any variety of metallic and alloyed materials depending on the specific application needs. The process also benefits from a relatively short lead time to ensure fast production.
Nevertheless, cast valves have their downsides. In casting, the first solidification tends to result in a number of defects internally such as voids and cracks, causing shrinkage cavities thus impacting the overall mechanical properties in the final product. Cast valves are therefore likely to have low strength and not be as durable as the forged ones.
The metal is heated to increase its malleability, and then pressure is applied to achieve the desired shape and dimensions.
The open die forging is the process of shaping of metal between two flat dies. This allows it to be versatile in large, simple shapes, and it works best for custom or low-volume production runs. Closed die forging uses a sealed die cavity to precisely shape the metal for greater accuracy and higher production rates in more complex designs.
Increased Strength and Durability: Forging refines the metal's grain structure, enhancing tensile and yield strength, making the valves more resistant to deformation and failure under high stress.
Better Temperature Resistance: Thinner walls reduce thermal fatigue, allowing the valves to withstand rapid heating and cooling cycles without structural weakening.
However, forged valves have some negative impacts. Compared to casting, it is quite costly because its production requires the use of some special equipment and labor.
Forging also is more appropriate for smaller valve sizes and pieces, while larger valves call for several parts and extra junction processes. Sometimes this may add complexity and cost.
The following table summarizes the key differences between cast and forged valves, helping you make the right choice for your specific application:
Feature | Cast Valves | Forged Valves |
Manufacturing | Molten metal poured into molds | Solid metal shaped using compressive forces |
Strength | Lower | Higher |
Durability | Lower | Higher |
Fatigue Resistance | Lower | Higher |
Temperature Resistance | Lower | Higher |
Surface Finish | Rougher, requires more machining | Smoother, less machining required |
Cost | Lower | Higher |
Size | More versatile for large sizes and complex shapes | More suitable for smaller sizes and simpler shapes |
Lead Time | Shorter | Longer |
Applications | Low-pressure systems, large diameters | High-pressure systems, high temperatures, critical applications |
FLUIDO is one of the largest valve and pipe fittings manufacturers and exporters. It has a wide variety of high-quality products designed to meet the requirements of different industrial applications. FLUIDO specializes in a variety of valves, including the AWWA C515 Cast iron Gate Valve, according to the stringent standards of the American Water Works Association. The valve is especially designed for water management systems, providing high durability, reliability, and resistance to corrosion.
Both cast and forged valves play vital roles in various industrial applications. Understanding their strengths, limitations, and the factors influencing your decision will lead to selecting the best valve type for your specific requirements. Remember that consulting with experienced valve manufacturers and engineers can provide invaluable insights for optimal valve selection.
Export Office: 21Floor, No.5 Nanhai Zhi Road,Qingdao, Shandong ,China
Work Shop: Beian Industrial zone, Qingdao,Shandong,China
+86 532 88256399
Martin
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