The Differences Between Forged Flanges and Cast Flanges

ARE FLANGES FORGED OR CAST?

Flanges can either be forged or cast. Both manufacturing methods have their advantages and disadvantages, depending on the application you have in mind for your flange. Here at Texas Flange, we primarily deal with forged flanges due to the outdated nature and lower standard of quality of cast flanges. Below, we will delve into the advantages and disadvantages of both forged steel flanges and cast iron flanges.

CAST IRON FLANGES

Casting is the process in which the metal is heated until molten then poured into a mold or vessel to create the desired shape. They are often used in cases that are too large, complicated, or other wise not suitable for forgings. Some of the advantages of flanges manufactured in this way include lower costs of production, the ability to make more intricate parts at lower costs, as well as having no true upper limit on size when it comes to your part.

There are, however, some drawbacks to cast iron flanges. The most important of these being how susceptible they are to internal defects. Due to this, cast flanges are not suitable for high pressure applications or applications in which the probability of corrosion is high. Despite advancement of casting technology and computer optimization of the casting process and designs, it is still difficult to meet the standards required for petrochemical industry applications.

FORGED STEEL FLANGES

Forging is the application of mechanical and thermal energy to steel billets or ingots to cause material to change its shape while still in solid form. Forgings offer consistency in composition and structure. Due to the nature of the production of forged flanges, the production costs are higher than that of cast flanges. Though they cannot have the complex shapes that cast flanges can be made in, their internal structure is more compact and therefore seldom have the defects the often affect cast flanges. Forging eliminates defects found in casting such as shrinkage, porosity, cavities, or cold pour issues.

Generally, forged flanges are stronger and more reliable than cast flanges because the grain flows of the steel are altered, confirming to the shape of the part. The tight grain structure of forgings makes the pieces mechanically stronger, and more resistant to general wear and tear than cast flanges. The higher quality, reliability, strength, and durability are why we deal mostly in forged flanges rather than cast flanges.

Here at Texas Flange, we offer forged flanges from 1/2″ nominal pipe size to 203″ OD in over a dozen different material grades. We value quality and strive to ensure that you are getting the right part for your application at a price and lead time that works for your business. Our salesmen work with you to ensure this. If you need a flange, give us a call at 281-484-8325 or send an e-mail to sales@texasflange.com to begin your inquiry. While you’re here , feel free to peruse our free informational blog posts, free 3-D and CAD drawings, or flange charts.

Different Types of Flanges and Their Uses

Used to connect valves, pipes and other equipment, flanges are forged rings that come in many different shapes and sizes and are used in a wide range of industries around the world. With so many varieties and specifications, it might be difficult at first to recognise which is the right one for you. Here's a rundown of some of the most common and popular types of the flange and their uses:

Weld Neck Flanges

Named for their protruding necks, these bulky flanges share the environmental stress of the pipe to which they are affixed and can, therefore, be used in extreme temperature or pressure situations.

Slip-on Flanges

Slip-on flanges slip onto the pipe – aptly named indeed – and are then welded on both the inside and outside. They're cheap, popular and best used in low-pressure, low-temperature applications.

Threaded Flanges

Threaded pipe flanges are similar in design to slip-ons but has a tapered thread, meaning it can be attached to pipes without welding. Like slip-on flanges, they're best used in low-pressure, low-temperature environments.

Blind Flanges

Blind flanges don't have a bore and are used to shut off sections of pipe. They're suitable for high-pressure applications, as well as for testing the flow of gas or liquid through a pipe.

Socket Weld Flanges

Typically used on small, high-pressure pipes like hydraulic pipes, socket weld flanges are able to accept pipe into the socket to create the fitting.

Orifice Flanges

Orifice flanges are used in conjunction with orifice plates to measure or restrict pressure or flow of gases and liquids in pipelines. They're often sold together with the plate and jack screws as a complete product.

The railway wheel

A typical railway wheel carries a load of about ten tonnes, roughly twice the equivalent for a road-going truck. The outer surface is called the tread. With a diameter typically of 1.0 m or less, the tread is roughly 100 mm wide. Like a pneumatic tyre, the railway wheel must handle the various forces needed to propel the vehicle forwards, slow it down, and hold it centrally on the track. But there are three striking differences. First, each railway wheel has a narrow lip or flange on the inside edge whose purpose is to stop the wheel from slipping off the rail. Second, the contact stresses between the wheel and the running surface are much more concentrated than those associated with a pneumatic tyre, reaching values that, paradoxically, exceed the yield point of the steel from which they are made. Third, railway wheels are almost always coupled together in pairs, each pair joined by a rigid axle to form what is known as a wheelset. A wheelset is extremely heavy by comparison with its equivalent on a road-going vehicle, and when you look at the various components, it’s not difficult to see why. Let's start with the disk.