Cast vs Forged Steel Industrial Ball Valves: 8 Common Differences

In many industries, industrial ball valves are essential for controlling the flow of liquids and gases. But not all ball valves are made the same way. Two common materials used to make industrial ball valves are cast steel and forged steel. Both are strong, but they’re made differently and have unique features.

This article explores the differences between cast vs forged steel industrial ball valves. We’ll look at their strength, cost, resistance to wear, and more. By the end, you’ll understand when to choose cast steel and when forged steel might be better.

8 Common Differences Between Cast Steel and Forged Steel Industrial Ball Valves

Feature	Cast Steel	Forged Steel
Manufacturing Process	Melted and poured into a mold	Heated and pressed into shape
Material Strength	Solid but may have tiny air bubbles	Denser and stronger
Fatigue Resistance	Durable, but may wear faster with repeated use	High resistance to repeated pressure changes
Shape Complexity	Allows for complex and intricate designs	Limited to simpler shapes
Cost	Generally less expensive	More costly due to labor-intensive process
Corrosion Resistance	Good, especially with protective coating	Better due to denser material
Application Scenarios	Best for low to medium pressure, complex shapes	Ideal for high-pressure environments
Standards & Certifications	Meets general standards	Often meets stricter high-pressure standards

1. Manufacturing Process

The way cast and forged steel industrial ball valves are made is different. How is cast steel created? 

Cast steel is created by melting steel and pouring it into a mold. When it cools, the steel takes the shape of the mold, giving it a solid, fixed structure. This casting process is good for making complex shapes in one piece.

Forged steel, on the other hand, is made by heating steel until it’s soft, then pressing it into shape with a hammer or press. This forging process makes the steel very strong and dense. ONERO industrial ball valves are crafted with these methods to meet strict performance standards.

2. Material Strength

Forged steel is generally stronger than cast steel. This is because the forging process compresses the metal, making it more solid. In cast steel, tiny air bubbles or pores can sometimes form during cooling, which can make the material slightly weaker.

For jobs that need extra strength, a forged steel industrial ball valve may be the best choice. Forged steel valves can handle higher pressures without cracking. Cast steel is still strong, but forged steel’s density gives it an edge in high-pressure situations.

3. Fatigue Resistance

Fatigue resistance is a material’s ability to handle repeated use without breaking. Forged steel valves are more fatigue-resistant because the forging process aligns the grain structure, making the steel tougher. This means that forged steel industrial ball valves can last longer, especially in systems with lots of pressure changes.

Cast steel industrial ball valves are durable, but they may wear down faster in applications that involve heavy or repeated use. For industries like oil and gas, where valves are used constantly, fatigue resistance is essential.

4. Size and Shape Complexity

One benefit of cast steel is that it allows for more complex shapes. The casting process can create intricate designs and details that would be difficult to achieve with forging. This is useful for valves with unique shapes or designs, as casting molds can be made to create almost any form.

Forged steel is limited in shape complexity because it requires pressing or hammering the steel into shape. This process is simpler, so forged steel is usually used for basic shapes. ONERO offers both cast and forged steel valves to provide flexibility for different design needs.

5. Cost

Cost is an important factor when choosing between cast and forged steel industrial ball valves. Generally, cast steel valves are less expensive to produce because casting is a faster and simpler process. For large orders, cast steel valves are often more cost-effective.

Forged steel valves cost more due to the intense labor involved. The forging process requires more work to shape and strengthen the steel. However, for industries needing high durability, the extra cost of forged steel is often worth it.

6. Corrosion Resistance

Both cast and forged steel can resist corrosion, but forged steel has a slight advantage. The forging process creates a denser material, which makes it harder for water, chemicals, or air to get inside and cause rust. Forged steel valves are better for highly corrosive environments, such as chemical plants.

Cast steel industrial ball valves also resist corrosion, especially if they have a protective coating. They perform well in many environments, including water and oil. However, for the toughest jobs, forged steel’s density offers extra protection.

7. Typical Application Scenarios

The choice between cast and forged steel industrial ball valves often depends on where they will be used. Cast steel valves are great for systems with low to medium pressure, where shape complexity is required. They work well in water systems, food processing, and general industrial settings.

Forged steel industrial ball valves, however, are preferred in high-pressure environments. Industries like oil and gas, chemical processing, and power plants often choose forged steel because of its strength. For example, ONERO’s trunnion and floating ball valves are designed to handle these demanding applications.

8. Standards and Certifications

Both cast and forged steel industrial ball valves meet industry standards, but they are certified differently. Forged steel valves often meet stricter standards for strength and durability because they are used in high-pressure settings. Standards like API and ASME often apply to forged steel valves to ensure they perform well in extreme conditions.

Cast steel valves also meet safety standards, but they may not have the same high-pressure certifications as forged steel. For general applications, cast steel is usually sufficient, but industries that need heavy-duty performance may prefer the certifications available with forged steel.

Conclusion

Choosing between cast and forged steel industrial ball valves depends on your needs. Both types of steel have unique advantages. Cast steel is good for complex shapes and is usually more affordable. It works well in moderate settings where strength isn’t the main concern.

Forged steel, however, offers higher strength, better fatigue resistance, and more protection against corrosion. This makes it ideal for high-pressure environments and heavy-duty applications. 

ONERO offers both cast and forged steel industrial ball valves, including our reliable trunnion ball valves and floating ball valves, to suit different needs. Visit our products page or contact us today for more info!

Resources

• What is the difference between forged and cast steel valves?
• Why Are Forged Steel Ball Valves Generally Better Than Cast Steel Ball Valves?