Are Forged Steel Fittings Better than Cast Fittings?

Forged or cast steel fittings have many similarities as both require the heating of steel until it gets malleable. The manufacturing of steel products can happen with forging or casting steel. For the flanges we provide, all material is typically made from forgings or plate.

Steel casting is one of the processes where the metal is heated until it reaches a liquid state and then poured into a mold that shapes the desired product. Steel forging implies the application of mechanical forces to heated solid steel blocks shaped permanently into the desired products.

Forged Steel

Meaning of forged steel fittings

Forged components are manufactured from steel which is heated and hammered for a specific shape. The process realigns the metal grains that result in the final product that is much stronger, harder, and wear-resistant than the base metal or its cast counterparts. Forged components have 26% higher tensile strength compared to the same parts made from cast steel.

As per the studies by the Industrial and Manufacturing Engineering Department, forged components respond to better heat treatment. It can withstand more mechanical force and more substantial impacts. It is more effective in pairs subject to high loads and stress. Forging helps to limit the formation of pockets, gas voids, and, cavities within the piece.

Meaning of cast components

Cast parts are created by super-heating steel until it changes into a liquid. You can then pour the liquid steel into a mold. Cast parts cost less compared to forged parts but are much less common in today’s marketplace. These are usually considered the best choice when it comes to mass-produced parts for non-ASME applications.

Castings also work best in parts with internal cavities. Apart from this, another advantage of the castings includes alloy use. It involves anything that uses a high amount of nickel and it’s difficult to forge. Casting can also produce a large number of parts more consistently. Forged parts can be limited by the size of the available equipment. There are two common types of castings used: investment casting and sand casting.

In sand casting, the liquid steel is poured into a mold made from specialized clay or pressed sand. It is usually used for larger parts. In investment casting, the liquid steel is injected into the ceramic coating or metal dye. It is mostly used for smaller and more delicate parts.

Casting vs. steel forging

Both the manufacturing processes need the application of high temperatures to steel raw materials and the execution of CNC machining work during the end of the process, so it becomes easy to obtain the final product. The final product may also undergo surface finish treatment like polishing, powder coating, painting, wear hardening/protection, and types of coating like zinc plating.

Apart from that, forged and cast parts may be hard-faced, brazed, welded, and assembled before shipping the final product. The products resulting from forging and casting processes have different properties in terms of surface porosity, grain structure, tensile strength, and fatigue resistance.

Benefits of using castings and forgings

Below you can find the difference between using castings or forged steel fittings:

Benefit of castings

The prominent benefit of casting is to create components that are too complex, large, or otherwise unsuitable for the forging process. We can forge part sizes in various lengths and weights of several thousand pounds. But if you need an end product that weighs 5000 pounds, casting would be a more suitable option. You can use casting when:

. Parts need the addition of custom alloys

. Part is complicated

. Part is too large to forge

Benefits of forging

If you can forge the end piece, it must usually be forged. It gives the part more consistency in construction, better strength, tighter grain structure, and a longer lifetime. You can reach out to the engineers to see if forging is right for your project.


If you are still not able to understand which option is good for you, remember that it depends on the project. You must understand what you need the part to do. If you are looking for strength, forged is an option for you. However, if you want detail or a special alloy, the cast is an option you can opt for.

If you need assistance and want to know among forged steel fittings or cast fittings, is the right option for you, contact Texas Flange today!



Things to Know Before Buying Flanges

Flanges are one of the most crucial elements of assemblies in the oil and gas industries, but it is an undeniable fact their selection can be a bit mysterious to the average consumer. Most piping systems today rely on flanges to function correctly. However, flange maintenance is something that most people don’t understand properly. The more you know about flanges, the less risk there will be in operation.

Below are a few of the facts that you might not be aware of about flanges. They are the key things that are necessary to help continue the functioning of components in pipeline service industries.

Offer Different Grades Of Material

You need to buy the best material grade for your application. When corners are cut, things can become challenging and can cost even more in repair and maintenance. You should invest in purchasing flanges that suit your project’s overall needs.

So, what are the different grades of material?

The material grade comes in with a combination of letters and numbers and is indicative of the use, chemical composition, and mechanical properties of the product. You must study the material grades very carefully before you decide to purchase.

Also, note that if the placement of flanges is not correct, the assembly can fail. It may even result in people, especially workers, getting injured or even claiming life. You must pay careful attention to the types of flanges, their steel and manufacturing origins, and the manufacturing quality.

Things to Know Before Buying Flanges

There are a few key material grades for pipe flanges. These are:

1. ASTM A182 F51, ASTM A182 F53/55 (super duplex and duplex flange), and high grades (Monel Hastelloy, Inconel flange).

2. ASTM A182 F321, F316, F304 (stainless steel flange)

3. ASTM A182 F11 to F91 (alloy steel flange)

4. ASTM A694 (MSS SP-44 high yield carbon steel flanges for line pipes)

5. ASTM A350 LF1, LF2, LF3, LF6 (CS flange for lower temperature service)

6. ASTM A105 (carbon steel flanges for normal to high-temperature services)

The flange and pipe material must match as per the ASTM piping materials selection charts.

Manufacturing from different materials

Common materials include bronze, cast iron, aluminum, stainless steel, carbon steel, and plastic (although we do not deal in polymers, nor are they included in B16.5). At times, the different materials are beneficial in creating the same single flange types.

Different forms of flanges

Flange distributors offer many types of flanges. There is no single type of flange which suits every situation. The selection of the flange must happen carefully by taking care of all the measures. If the wrong flange is used in the project, it can be disastrous.

A few popular pipe flanges include orifice, socket, threaded, lap joint, slip-on, weld neck, and blind. Each of these flanges serves different purposes.

The meaning of an orifice flange is that it must house an orifice meter that can easily track the speed of flow within a pipe, as well as temperature and pressure. It is one reason why the orifice meter has become one of those complex parts to create. On the other hand, blind flange is one of the most uncomplicated flange designs and pairs well with a ring flange which does not require much to assemble.

If you need multiple kinds of flanges in a single project, it would be wise to work with a single provider for all of them. It helps avoid sourcing issues and ensures that all the products are made with the same quality standards.

Casting and forging of flanges

There are two kinds of methods that are useful for the creation of flanges. These include forging and casting. Both the cast and forged flanges may work well, but each production method has certain disadvantages and advantages. Cast are seen as outdated and not useful for high-stress service.

The creation of cast products can be seen when they pour the molten metal into a mold or vessel to create the desired shape. Billets and steel ingots are useful when it comes to the creation of forged products. Exposure to thermal and mechanical pressures helps them to manipulate different shapes.

The issue with the cast flanges is that they are much more prone to internal defects. It means that you cannot use them in extremely high-pressure situations as there is a possibility of sudden failures without any warnings. As there would be a risk of internal flaws, the cast flanges are also most likely to be heavily affected by corrosion.

In contrast, forged flanges are not only reliable but also able to withstand more pressure. Forged parts come with around 37% fatigue strength. It is higher than other types, and it means that they last longer. Therefore, it is best to invest in high-strength that forge products as it is usually better for long-term investments using the high-pressure application.


If you are not fully aware of varied types and applications before buying flanges, the above facts will help you understand and make the right choice for your industrial project. We hope that with the help of this guide, you will be able to identify the key things before purchasing flanges. To learn more about flange basics, visit