Billet vs Cast vs Forged Aluminum: Differences and Benefits
Aluminum materials have multiple grades; each grade has a unique property, which makes it different from the other grades. However, along with the grade, you can also have a different texture of the aluminum material. You can have it in the form of a billet, cast, or forged, and they can all be used for varied applications.
If you want to know more about billet vs cast vs forged aluminum, read the guide below.
What is Billet Aluminum?
Billet aluminum is an aluminum type that is manufactured using the process of roll forging or extrusion. This process consists of heating the metal and then forcing it into a cavity, which helps create the designated shape. It is usually in the form of a beam or rod.
The aluminum billet is not the final part, but rather, it is a type of raw material that has to be processed further. Processes like CNC machines are used to make components out of it.
Benefits of Billet Aluminum
There are multiple benefits of billet aluminum, and some of these are as follows:
- Billet aluminum is easy to machine, and hence, components with high precision can be achieved.
- It also has components customized with exact specifications and have tight tolerances.
- Billet aluminum is strong and has a consistent structure. Hence, it resists internal flaws.
- Billet aluminum offers excellent heat dissipation; it is therefore preferred for applications that require high thermal management.
What is Cast Aluminum?
Cast aluminum is the aluminum that passes through the process of metal casting. The process consists of heating aluminum till it reaches its melting point and then pouring it into the mold, which allows it to take its shape upon solidification. It helps create parts with different sizes and shapes and is useful for various applications.
Benefits of Cast Aluminum
The benefits of cast aluminum are as follows:
- Cast aluminum is affordable, and it is suitable for bulk production. It just requires a mold; once the mold is created, it can reproduce the part again and again.
- Aluminum casting also helps to create intricate and complex parts; hence, components with complex shapes can be easily achieved.
- Aluminum casting reduces the materials wastage as the aluminum can be melted again and reused in various ways.
- Components made using aluminum are lightweight and yet have excellent strength.
What is Forged Aluminum?
Forged aluminum attains aluminum parts by applying a force that helps shape the material. The process of forging uses a hammer and heat, which helps to roll the aluminum pieces and achieve the desired shape. Forging is mainly focused on rearranging the structure of aluminum metal grain. It makes aluminum stronger and denser, which makes it suitable for high-stress applications.
Benefits of Forged Aluminum
Forged aluminum has multiple benefits, and some of these are as follows:
- It is the strongest form of aluminum as the process of forging compresses the material and gives it high strength. Hence, it can withstand heavy loads.
- Forged aluminum components can pass through repeated strain and stress without any failure and, hence, can be subjected to dynamic loads.
- Forged aluminum components offer improved impact resistance, that’s why they are suitable for applications where sudden shocks are common.
- Forged aluminum develops internal defects and hence has minimal weak points.
Compare Billet vs Cast vs Forged Aluminum
The section below highlights a detailed comparison of billet vs cast vs forged aluminum, so let's take a look.
Mechanical Characteristics
When it comes to comparing three of these in terms of mechanical characteristics, forged aluminum takes the lead. The process of forging produces Aluminium with high density and strength.
The billeted aluminum alloy also adds to its mechanical characteristics as it is very close to forging. The process of aluminum die casting usually makes the aluminum metal pass through different cavities, which impacts the strength of the aluminum.
The mechanical strength of cast aluminum is between 23000 and 34500 PSI; for billet aluminum, it is between 30000 and 45000 PSI. The strength of forged aluminum is above 50000 PSI.
Machining Properties
In terms of machinability, billet aluminum is one of the best choices. Its uniform structure ensures the manufacture of highly precise components with complex features.
Forged aluminum is a little more rigid, which makes it challenging to machine. Cast aluminum also offers improved machining, but it does have internal defects that pose some challenges.
Finishing
Aluminum components made using billet aluminum have excellent finishing and require a very minimal amount of post-processing. Whereas forged aluminum needs post-processing as they are hard and have a high chance of developing burrs.
Cast aluminum, on the other hand, needs extreme finishing using sanding and polishing so that it may have a smooth surface.
Anwendungen
Each type of aluminum has its suitability for different applications based on its chemical and physical properties. Billet aluminum is highly versatile as it offers excellent machining. Hence, precision components used in the aerospace and automobile sectors can be manufactured using billet aluminum.
Forged aluminum, on the other hand, has mechanical features that make it suitable for high-stress applications. It can be used to manufacture the components of cars, such as suspension parts and structural parts. Cast aluminum is used in simpler components that are cost-effective, like gearboxes.
Kosten
Cast aluminum is the cheapest type of aluminum and is used in applications where cost-efficiency is crucial. It offers cheaper parts in high volume. However, the billet and forged aluminum are expensive, and they can increase the overall cost of the components.
Quick Chart of Summarizing Billet vs Cast vs Forged Aluminum
| Eigenschaften | Cast Aluminum | Billet Aluminum | Forged Aluminum |
| Stärke | Moderate strength | Gute Stärke | Excellent Strength |
| Kosten | Geringe Kosten | Moderate Cost | Hohe Kosten |
| Surface Finish | The low surface finish needs post-processing | Excellent surface finish | Moderate surface finish |
| Anwendungen | Cost-effective applications | Highly precise manufacturing | Heavy duty applications |
| Bearbeitbarkeit | Mäßig | Ausgezeichnet | Niedrig |
Billet vs Cast vs Forged Aluminum: Which is the Best for Your Project?
When choosing between the billet, forged, and cast aluminum, you need to assess the project requirements.
If you are opting for custom manufacturing, billet aluminum proves to be a better choice as it offers tighter tolerance. Moreover, it has high machinability, which helps create accurate components. Compared to cast aluminum, it is expensive but is suitable for highly precise applications.
Cast aluminum is suitable when looking for cost-effective manufacturing processes. It can help create complex shapes on a low budget and can produce parts in large volumes. However, the strength of cast aluminum is not as high as that of billet and forged aluminum.
In applications where you need external hardness and strength, forged aluminum can be a great choice. The process of forging makes the part equipped with no internal defects, and it helps with enhanced impact, stress, and fatigue resistance.
DEK: Your Reliable Partner for Machining Aluminum Parts
If you are starting a new project and looking to source high-quality aluminum components that are machined with perfection, we at DEK can help you. We offer components manufactured using all types of aluminum, be it forged, cast, or billet. We can provide you with customized parts based on your application requirements.
Schlussfolgerung
In order to have the right type of aluminum, you must know the differences between these three forms. So, as you have read the guide above, you must have now learned everything about these forms of aluminum and their suitability in applications. So, using them in your projects must be easier for you now.
