Which wheels are better - stamped, cast or forged? Forged or cast wheels - which is better? Comparison, pros and cons

Car wheels are divided according to manufacturing technology into cast and forged. For drivers who are planning to purchase them, the question always arises: which ones to choose? It is not always possible to figure this out on your own. And when turning to car dealership employees, you can’t always hope for competent advice, since sellers need to sell stale goods. So their advice is often diametrically opposed to the truth. How do cast wheels differ from forged ones? And which ones are better?

Definitions

Alloy wheels are made by casting molten metals. In most cases, these metals are alloys of magnesium and aluminum. They belong to the category of light metals. That is why the wheels are called cast or alloy.

Cast drive

Forged wheels are made from the same metals as cast ones, but the production technology is different. Forged wheels are produced by industrial hot stamping. After this, they undergo a hardening process.

Comparison

The main difference between cast and forged wheels is the production technology. Cast discs are poured using special molds, and blanks for forged ones are stamped under high temperature and pressure. After this, the stamping is processed on special machines, spokes are cut out, as well as other design elements.

A cast disc is more fragile and has a high probability of forming voids and hidden holes. A forged disc is much more impact resistant. It also has much higher damping capacity. When subjected to a strong impact, it bends, but does not break, because when stamped, the metal is more durable and has a fibrous structure. You can even repair the damage yourself using a hammer. Alloy wheels cannot be restored after an impact.

However, forged wheels are seriously inferior to cast wheels in terms of design. The latter have a much wider design variety; foreign cars are often equipped with them. Forged wheels are installed on domestic cars and SUVs. It is recommended to install them in winter, but we must not forget to periodically clean their inner surface from accumulated dirt. Otherwise, it noticeably worsens car control. As for dynamics and handling, as well as driving comfort, a car equipped with forged wheels has much higher parameters.

Conclusions website

1. Their production technology is different: cast wheels are cast into a mold, forged wheels are stamped on special equipment.
2. Cast ones are much more fragile, voids form in them.
3. Forged wheels are lighter than cast wheels.
4. A forged disc is impact-resistant and has a higher damping capacity than a cast disc.
5. In terms of design, forged wheels are inferior to cast ones. They are used to equip domestically produced products and SUVs.
6. Driving dynamics and controllability are higher with forged wheels.
7. Forged wheels are more expensive than cast wheels.

The problem of choosing between steel and alloy wheels continues to cause a lot of controversy among car enthusiasts. Manufacturers add fuel to the fire by advertising their own products in every possible way for the purpose of sale. Therefore, stereotypes have been formed about the characteristics of products made from different metals that do not correspond to reality. Hence the purpose of this material - to tell how stamped, forged and cast wheels differ, how to distinguish them from each other and which ones are better suited under different operating conditions of the car.

Light alloy wheels

The name “light alloy” is given to these products due to the properties of the materials from which they are made. This is an alloy of light metals - aluminum and magnesium; titanium and copper are added to it in small quantities for strength and ductility. Hence the second name for such discs - titanium. There are 2 types of alloy rims:

• cast;
• forged (pressed).

These 2 groups of products differ from each other in manufacturing technology, performance properties and cost. To understand which ones are better, you need to look at disk production in more detail.

Note. Sales representatives often impose on motorists the opinion that, unlike cast products, forged rims are made from incredibly durable and expensive metals, almost platinum. In fact, this is a myth; the composition of the alloy for the manufacture of both groups of products is absolutely the same. Manufacturers can slightly change the ratio of base and additional metals in the melt at their discretion.

About production technology

As the name suggests, cast products are made by pouring molten metal into special molds (casting method). The sequence of technological operations looks like this:

1. Metals - ingredients are placed in an oven, melted and mixed.
2. The alloy is fed to the mold and poured into it with a special ladle.
3. After hardening, the workpiece is removed from the mold and moved for machining. In this case, the structure of the rim and spokes has already been formed, all that remains is to remove excess material around the edges and refine the holes for the bolts, as well as balance the disc.
4. The last stage is testing under certain speed and shock loads.

Reference. At factories of famous brands, the process is fully automatic using CNC machines, even casting is performed by a robot. Manual labor is practically eliminated.

The name “forged” does not accurately reflect the production method of these discs, since they are not forged, but extruded from a heated alloy using high-power hydraulic presses. The manufacturing algorithm is as follows:

1. As in the previous case, an alloy is prepared in the furnace, from which cylindrical blanks are cast.
2. Each blank undergoes several pressing operations, where it is formed into a solid wheel rim without spokes or holes.
3. Products undergo 2 heat treatment operations - hardening (strengthens the alloy) and tempering to relieve internal stresses in the metal.
4. Using mechanical processing on a variety of machines, holes are made in the disks, the pattern of the spokes is cut out, excess material is removed from the edges and balancing is carried out.
5. Testing at critical loads is performed on special equipment.

Note. So the second myth is dispelled - that due to the manufacturing technology, forged wheels cannot boast of a varied design. On CNC milling machines, you can cut any, even the most complex, pattern into the body of a workpiece.

Pros and cons of cast products

The main advantage of wheels made from light alloy casting is their attractive appearance, which makes a car of any age and make look much prettier. And the choice of products in terms of configuration and number of knitting needles is incredibly wide. This is the main reason prompting car enthusiasts to replace steel wheel rims with light alloy ones.

Other advantages are also important, but they are of a technical nature:

• the reduced weight of the products results in lower fuel consumption and improves vehicle handling;
• for the same reason, the acceleration dynamics of the car improves, and the braking distance is reduced;
• products are initially balanced due to production technology;
• long service life.

Of the listed positive aspects, only the durability and balance of alloy wheels is really noticeable when the car owner changes tires in a tire shop. The improvement in handling and acceleration dynamics can only be felt by an experienced driver, and the change in fuel consumption is so insignificant that it is completely unnoticeable (0.1-0.2 liters per 100 km). Therefore, the beauty of alloy wheels remains a priority, and only then their technical parameters are valued.

Now about the disadvantages:

1. The products are resistant to strong and sharp impacts. A crack appears in the thinnest place or where an air pocket has formed inside the metal. Manufacturers claim that casting cannot be repaired.
2. The price of the product is higher than that of stamped steel wheels. Due to price variations, the difference can range from 50 to 200%.
3. Cast rims cannot be used on minibuses and small trucks as they are not designed to withstand such loads.
4. Maintenance operations for such products at a tire shop (changing tires, balancing) are more expensive.

Reference. In the post-Soviet countries there are many workshops where specialists have become accustomed to soldering cracks in aluminum castings. But such a repair cannot be called complete, and restored discs cannot be installed on the front axle of the car.

Advantages and disadvantages of forged wheels

The significant and only drawback of forged rims is their high cost, which is 2-5 times higher than casting, depending on the manufacturer. But for this money you will get the following advantages:

• reliability and strength;
• durability, the pressed rim will last as long as the car itself;
• light weight of the product (even compared to casting), which improves the car’s behavior on the road and reduces fuel consumption.

Thanks to pressing and hardening in the manufacture of such rims, the metal does not have hidden holes and acquires increased strength, so cracks from impacts are an extremely rare occurrence. In addition, the spokes of the product can be made thinner and more openwork, giving the wheel design additional lightness and beauty. This is what you pay money for when you buy a forged wheel.

How to make cast alloy wheels - video

Stamped steel rims - the secret of popularity

More than 60% of all cars in the post-Soviet countries are equipped with disks made of sheet carbon steel. The vast majority of these cars are equipped with these wheels from the factory, since they are cheaper than others. Exceptions are cars in luxury configurations or luxury brands, for which the “stamping” frankly does not suit the appearance.

Despite their cheapness, iron wheels have many advantages:

• Compared to aluminum alloy, steel has ductility and elasticity, so the rim partially absorbs impacts when driving over large uneven surfaces;
• for the same reason, steel products are easy to repair - deformed areas can be straightened, and cracks can be welded;
• scope of application - transport of any purpose and carrying capacity;
• low prices for wheel maintenance;
• There are no problems with fastening the wheels, for which factory (standard) bolts are used.

The most valuable advantage when driving on our roads is the high maintainability of stamped wheels and the ability to absorb shocks. Combined with low cost, these features make traditional iron rims the most attractive in the eyes of ordinary users. To understand how their cost is formed, it would not hurt to familiarize yourself with the manufacturing technology of such products.

Production by stamping

Thick sheet steel is used to make iron rims. Two types of workpieces are cut from it - a circle and a strip, sent for further processing. The process looks like this:

1. On a hydraulic press, the core of the future disk with holes for bolts and technological openings is stamped from a steel circle.
2. The strip is sent to rollers, where it is bent into a cylinder shape. The ends of the sheet are welded together, after which the seam is cleaned.
3. A hydraulic press squeezes the finished rim out of the cylinder, then a hole for the valve is drilled in it.
4. Both elements are connected by welding, then covered with primer and painted.

In the manufacture of stamped products, expensive CNC machines and furnaces are not used, which is why energy costs are significantly lower. Hence the low price of the final product.

Video of the assembly process of stamped products

Weaknesses of steel wheels

Compared to attractive products made from light aluminum alloy, stamped iron rims are inferior in appearance, which often becomes the reason for their replacement. Plastic decorative caps, which always get lost on potholes on our roads, do not solve the problem, and the car owner has to buy new ones.

For reference. To prevent the hubcaps from flying off the wheels, many drivers fasten them to the rims with plastic electrical clamps. This helps, although it somewhat spoils the appearance of the car.

There are other negative aspects in the operation of “stampings”:

• due to the large weight of the wheels, the car’s handling is worse and fuel consumption is higher;
• increased braking distance;
• products made of stamped iron cannot boast of good balancing;
• metal rusts and therefore requires maintenance.

Judging by the statistics, the listed shortcomings do not bother most Russian drivers too much. Again, some of the negative aspects are misinterpreted by sellers. For example, there is no basis for the statement that steel can rot in 2 years and the disk will become unsuitable for further use. To bring the metal to this state, it will take twice as long, and with timely care, the product will last no less than light alloy.

Note. There is a myth that the paint of stamped rims is easily scratched and quickly becomes unusable, but the light alloy surface cannot be damaged. The second part of the statement is incorrect; alloy wheels can also be scratched, but painting them is much more difficult.

It is best to select the type of wheel rims based on three criteria:

• depending on the operating conditions of the machine;
• car class and make;
• active driving in cold or warm periods of the year.

Advice. If you expect to use one set of rims all year round, then, taking into account Russian road conditions, it is better not to risk money and install steel “stamping”.

The ideal option is to have 2 sets of discs, using them in the warm and cold seasons. For summer driving on asphalt surfaces, light alloy rims are perfect, but for the winter you need to use stamped ones. The problem is ice that appears on the asphalt due to unremoved snow, causing a smooth road to be covered with continuous potholes. The same ice along the edges of the roadway will easily scratch your beautiful titanium wheels when pulling onto the side of the road or approaching close to the curb.

When choosing a set of new disks, it doesn’t hurt to take into account other recommendations:

1. You shouldn’t shell out money and buy light alloy products if you drive an SUV across the fields. Conversely, luxury cars driven on smooth roads should not be stamped; it looks reprehensible.
2. Forged wheels are suitable for any passenger car and various driving conditions, except outright off-road.
3. Do not try to install alloy rims on a minibus that is used for commercial transport, you risk quickly making them unusable.

When choosing forged products, a natural question arises - how to distinguish them from casting when they are externally similar. After all, an unscrupulous seller may sell you a cheaper product at the price of forged wheels. There are a number of tips on this matter:

1. Forging is easier than casting. For example, a forged rim measuring 15 inches weighs no more than 5 kg, and a cast one weighs 7-8 kg.
2. On pressed products processed by milling machines, you will not find burrs or small flash around the edges, as is the case with casting.
3. As a rule, inscriptions on cast wheels protrude above the surface, while on forged ones they are recessed because they are applied by extrusion.
4. If the product is branded and accompanied by documents, then in the specification of the forged rim you will find the corresponding English word - FORGED.

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Advice. There are many exceptions to these rules, which appear when studying products from domestic or Chinese manufacturers. The best option is to buy forged car wheels at retail outlets with an impeccable reputation or from authorized dealers.

Despite the numerous advantages of alloy wheels, they cannot conquer even half of the Russian market. A similar situation is observed in the countries of the former USSR, where stamped products are more relevant and practical than aluminum ones. A change in trend should not be expected until there is a dramatic improvement in paved roads.

Are forged wheels any good compared to cast ones, what are the advantages and disadvantages of these two types, and what are the pitfalls in operating forged and cast wheels - you will learn about all this in our material.

The car owner asks:

— I went to auto stores to look for alloy wheels for the summer season. But the manager at the company store advised me that it was better to overpay, but buy not cast, but forged wheels, which, as he claims, are significantly superior to cast ones in strength and durability, while being just as light in weight and aesthetically pleasing. Is this true?

We forwarded his question to the specialists of VSMPO-AVIMA Corporation, a well-known manufacturer of forged automobile wheels.

“Indeed, without compromising aesthetics, forged wheels are significantly superior to alloy wheels in terms of strength and service life, which during trouble-free operation is practically unlimited and is comparable to the service life of the entire car.

This is due, first of all, to the manufacturing technology of the discs themselves, where forging is initially stronger than casting. In addition, each manufacturer has its own technological innovations that increase the durability of discs.

For example, VSMPO uses a new technology for manufacturing wheels, which can be briefly described as “forging plus rolling”, which improves the structure and mechanical properties of the wheel rim. Forging technology provides certain advantages over casting. Namely, it provides the wheels with unique properties: strength, durability, shock resistance, improved acceleration and braking dynamics of the vehicle, increased service life of suspension and transmission parts. Rolling increases the strength of the thinnest (read: critical) part of the wheel - the rim.

By the way, in Russia the VSMPO company is the only one that uses such technology for the production of forged wheels.

Perhaps, if not for the higher cost, forged wheels would have long ago supplanted all others. They are so reliable in operation that, if it were not for the desire to change the design, they could be installed on the car once and for life.

What is the difference between lightweight wheels and forged ones?

The market for light alloy wheel rims is crowded: they offer both cast and forged ones; and Russian production, and Turkish, and German. In short, there is plenty to choose from. Moreover, a huge assortment makes it much more difficult to choose, and sometimes you come across unscrupulous sellers.

Car owners expect that light alloy wheels will solve two problems - improve the driving characteristics of the car and its appearance. However, after purchasing and installing “beautiful” wheels, many do not notice any changes in the behavior of the car. Why? The reason is very simple - sometimes car owners benefit only in design, since the weight of “light-alloy” wheels turns out to be the same as that of stamped steel ones. The driving characteristics with the “native” offset (as with standard wheels) remain the same, so you are unlikely to feel any improvements in acceleration dynamics, suspension and braking system performance. But if the offset has changed, some characteristics may even worsen (see “AC” No. 4 "2006).

Being keen on tuning, car owners often strive to install tires with a lower profile and larger diameter light alloy wheels. Often the wheel ends up being much heavier than the original one, which entails a number of negative consequences:

How to distinguish a forged wheel from a cast one? Externally, based on the nature of the surface treatment, it is very difficult to find the difference between modern cast and forged wheels. There is only one surefire option - compare the weight of the disks. Forged ones, regardless of size, weigh 1.5 and even 2 times less than steel ones, and cast ones are only one third lighter than steel ones. Although our market survey showed that sometimes alloy wheels are heavier than stamped steel ones. So if not only the design is important, it is better to go with a dealer when purchasing, having first weighed the original wheel of your car.

Impact resistance

There is one more requirement for wheel rims used on rough Russian roads - they must have high impact resistance. This is especially important when installing low-profile tires.

Cast aluminum alloy wheels are inferior in this parameter. Casting technology cannot eliminate the formation of cavities inside the disc structure, therefore, in the event of increased load on this particular area, the disc is easily destroyed. In addition, the cellular structure of the alloy also increases the fragility of the cast disk.

Stamped steel discs have low impact resistance, so they are more easily deformed. However, they do not collapse and in 90% of cases can be straightened using special equipment.

Forged wheels during a frontal impact, due to the fibrous structure of the metal obtained during stamping, are generally deformed, like steel ones. And since the viscosity of aluminum is higher than steel, the deformation will be directed inside the disk without affecting the tire seat. This allows you to maintain tire pressure or at least prevent its sudden drop, which leads to loss of vehicle controllability.

What to buy?

From all of the above, we can draw the following conclusion. For those who like fast driving and long journeys on unfamiliar roads, especially at night, it is advisable to equip the car with forged wheels. If you are a relaxed driver and mainly use your car in the city, you can save money by purchasing cast ones. However, in this case, the likelihood of contacting repairmen is much higher.

Forged wheels are 1.3-2 times more expensive than cast wheels (depending on the manufacturer), and they are more difficult to find on sale. In addition, the design of cast ones is more varied, which allows you to make the appearance of the car more individual.

Choosing wheels for a personal car is a responsible decision and it is made according to such important criteria as technical parameters, quality, and safety. There is a wide variety of types of disks that are widespread in the world. With such a large selection, the question inevitably arises, which discs are better? Each disc has its own strengths and weaknesses. Discs are produced using two methods:

• casting;
• forging.

Most often, aluminum is used as the main material of both types, and magnesium is used less often. Let's compare the advantages and disadvantages of cast and forged wheels.

Advantages of cast and forged wheels

Alloy wheels are made from light metal alloys by casting. The advantages of alloy wheels include:

• they are comparatively cheaper;
• repairable only for minor cracks.

Forged wheels are produced by hot stamping. The advantages of forged wheels are:

• increased strength. The structure with this manufacturing method is fibrous;
• plastic;
• shock resistance. Upon impact, the disk is deformed without being destroyed at all;
• subject to repair, there are a sufficient number of repair services;
• relatively light weight due to reduced wall thickness. They are two times lighter than steel, and a third lighter than cast ones;
• corrosion resistance;
• beautiful appearance, can be used without painting.

Reducing the weight of the disk in the tire assembly reduces unsprung inertial masses and improves the performance of car suspensions. This leads to a comfortable trip and safe movement. The car handles better, the braking system works well, and it consumes a little less gasoline. High manufacturing precision and good characteristics of light-alloy wheel materials allow for better tire retention on the rim.

Flaws

Alloy wheels have a number of significant disadvantages, these are:

• fragility. On impact they can split due to their granular structure. The discs cannot be repaired.
• not suitable for rough roads. The resulting cracks lead to imbalance of the wheel.

Due to such serious deficiencies, there is an increased risk when driving on the roads. Of course, for vehicles such as the MZSA 817701 trailer, there is no need to buy too expensive wheels. The risk of getting into an accident increases especially in winter due to poor road conditions. It is difficult for the driver to maneuver when dangerous situations arise on the roads.

Despite all the advantages, forged wheels have disadvantages:

• higher cost than other drives on the domestic market;
• in demand for racing cars.

Conclusion

Each driver himself chooses whether alloy wheels or forged ones are suitable for his car. The cost of forged ones is much higher than that of other disks. If it were not for the high cost of forged wheels, there would be no alternative to them. VIP class cars are equipped with just such discs. On the Western market they cost ten times more.