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Cast Forging

The Ideal Synergy of Casting and Forging at the Grohmann Group

Cast Forging is a special casting process that stands out from other methods due to its low-turbulence mold filling and extremely high solidification pressures. In this process, liquid aluminum is dosed into an open, temperature-controlled mold half. The upper mold half then closes the mold and presses the metal into the final contour. Mold filling occurs in a laminar, low-turbulence manner, preventing air entrapment, as air can escape through the parting lines of the mold.

Once the mold is completely filled, a high pressure is applied, additionally compacting the still-soft metal. This results in a dense, fine-grained structure that offers outstanding mechanical and physical properties.

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Cast Forging – Superior Quality

WHY DOES CAST FORGING STAND OUT FROM OTHER PROCESSES?

  • Pore-Free Structure:
    Unlike other casting processes such as die casting or sand casting, cast forging provides a completely pore-free structure thanks to its static, controlled mold filling, high consolidation pressures, and extremely rapid cooling at the mold wall. This results in exceptional tightness, especially for components that must safely conduct fluids or gases.

  • Excellent Mechanical and Physical Properties:
    High metal pressures combined with controlled, rapid cooling create a fine-grained microstructure with outstanding mechanical performance. This leads to higher strength and hardness, as well as improved dynamic behavior compared to parts made using conventional casting methods.
    The refined microstructure also ensures excellent thermal and electrical conductivity.

  • Smooth Surfaces and High Dimensional Accuracy:
    By pressing the metal directly against the mold wall, cast forging produces exceptionally smooth, contour-accurate surfaces and top-level dimensional precision. This reduces or eliminates machining allowances and subsequent processing steps. The method is therefore ideal for components requiring high precision and visually appealing surfaces.

  • Productive and Sustainable:
    Cast forging is a process characterized by short cycle times and a high degree of automation. These aspects enable efficient and economical production.
    Metal temperatures can be kept low, and melting or holding the metal can be carried out electrically without issues. The process requires almost no additional material for gating or feeding systems, and the outstanding material properties allow the extensive use of recycled alloys.
    All these factors contribute to an optimal CO₂ balance compared to other processes.

  • Material Versatility:
    Cast forging is highly “material-open,” enabling the use of a wide range of alloys and materials. Material-related limitations, such as flowability or solidification morphology, play only a minor role. As a result, the process offers broad application potential across diverse industries.

Cast Forging – the perfect solution when no compromises can be made on quality, strength, or tightness.

With cast forging, Grohmann offers an ideal process alternative for components with special, highly specific properties and the highest requirements in tightness, load capacity, or surface quality.