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Plug and socket Catalogue

Notice: All product images serve to illustrate our manufacturing capability and enquiries for products will be directed to our customers.

Mining Products Catalogue

Notice: All product images serve to illustrate our manufacturing capability and enquiries for products will be directed to our customers.

Plug and socket Videos

How it's made - Plug and socket

Test - Impact strength of the 250 amp plug

Forging vs Casting

Forging vs Casting

Wam Metals (Pty) Ltd is a non-ferrous forging company which specialises in the art of forging. WAM is over 30 years old, over 30 years of perfecting the forging manufacturing process, over 30 years of experience.

What is forging?

Castings are manufactured by pouring molten metal into a sand mould, forging is an entirely different process which involves forging a hot billet to shape by force.

The forging process:

  1. A solid extruded section is taken in long lengths and cut into the required length billet.
  2. This cut billet is heated up to 650 degrees C.
  3. This heated billet is then placed into a forging die positioned in a forging press.
  4. The press is then activated and the forced impact of the press forms the forged product.

Note: It is important to note the following:

- Castings are susceptible to blow holes and or porosity.

- Forgings are 100% clear of any blow holes or porosity.

Main benefits of Forging

Forgings are much stronger:

Castings are poured as a liquid into or through moulds whereas forgings are hot-worked under pressure which yields higher strength and reliability. The Forging process causes recrystallization and refinement of the grain structure of the material being forged which leads to a homogenised grain structure; the homogenised grain structure makes the metal much stronger and less resistant to impact, shear and wear damage.

Forgings are more refined:

Castings do not have the grain flow or directional strength of forgings which allows for the possibility of metallurgical defects such as segregation and dendritic structures. Castings are susceptible to critical flaws like blowholes, porosity and shrinkage. Forging creates metal flow with compact grain structures and refines these conditions into a strong and very reliable product.

Forgings are more reliable:

Castings require very strict foundry practice and control. Defects are only detected once the metal has cooled, removed from the mould and cleaned and in most cases are only detected after machining.
Forgings with refined grain structure imparts high strength, ductility and resistance properties.

Forgings respond better to heat treatment:

Castings have alloy segregation and non-uniform cooling; this leads to inconsistent heat absorption during heat-treatment and results in warping and bending. Forgings are more uniform and respond predictably to heat-treatment which ensures dimensional stability.

Forgings are more cost effective with flexible production output:

Due to possible Casting flaws during the Casting process stricter process controls are needed which results in longer lead times while Forgings production runs are more adaptable and have shorter lead times.

Forgings are more economical to machine:

Castings are produced with excess allowances to reduce defects whereas forgings are produced with tighter tolerances to minimise material removal, leading to lower machining costs or eliminate the need for machining completely.