Choosing the right wheels for heavy-duty trucks is crucial, particularly when deciding between cast and forged options. Both methods have advantages, like strength, weight, and costs. The quality of your wheel and the safety it will provide are other factors to consider. In this article, we will break down the key characteristics of cast and forged wheels to help you decide which option best suits your needs.
Cast Wheels
Cast wheels are made by pouring molten metal — often aluminum or steel — into a mold that takes the form of a wheel. There are two primary methods to cast: gravity casting and low-pressure casting.
Gravity-cast wheels are made using the Earth’s gravity to fill the mold with the molten metal. While often seen as the lowest quality method, this method can also be the most cost efficient. The metal is usually not as densely compacted into the mold as other methods, leading to defects and air bubbles. Gravity-cast wheels often use extra material in the process to account for the porosity, which also makes the wheels heavier.
Low-pressure casting is the most common method of casting. This method involves inserting molten metals quickly into the mold using applied pressure. This method helps solve the density issue that regular gravity cannot. This method, while seen as the premium version of cast wheels, is lighter, stronger, and holds a higher quality.
Once the metal has cooled, the wheel is formed. Intricate details are then added to each wheel depending on the manufacturer and purpose of the wheel.
Forged Wheels
Often seen as the strongest and lightest wheels on the market, forged wheels are made by heating a large metal cylinder under high controlled temperatures. Once the cylinder is completely heated through, it is then put into a hydraulic press, where it is pressed into a smaller block. These blocks are shipped to different manufacturers, where they each uniquely design their wheels using machines and craftsmen to create the final details and finishing touches. This tedious and often costly process allows the metal to retain its true grain flow, making the wheels stronger and durable with less material. Failure points that cast wheels hold, such as porosity, air bubbles, and more, are eliminated due to the extreme pressure that is applied to the wheels.
Which Wheel is Right for You?
While we may not provide a definitive answer, Iron Wing is here to help you define the factors most important to you.
Weight
Weight is a factor that might be considered. With cast wheels, due to the material irregularities during the cooling process, many manufacturers must add additional material to the spokes and barrels to increase their strength, often making the wheels heavier. Forged wheels are lighter than cast wheels due to the ability to use less materials with the same strength. Many forged wheels have slimmer spoke designs and contain weight reduction pockets in the back, reducing their overall weight.
Strength
Regardless of the method, all wheels must undergo physical tests to meet the required regulations and safety standards. Under heavy impact, however, it is important to note each show's differences. Cast wheels often crack or break due to failures in the casting process. Due to your safety and that of your vehicle, it is important to choose a reputable brand when choosing cast wheels. While cast wheels snap under pressure, forged wheels bend out of shape. While neither is ideal, a bent wheel offers more safety for drivers than a snapped one, as the driver has more control and thus has time to pull over.
Cost
Cast wheels are the most cost-effective path if you are looking for appearance and feel of metal wheels, without paying a higher premium. Because of the manufacturing process and ability to mass produce, cast wheels are your least expensive option. Forged wheels are the most premium products. Not only do they look good, but they are also strong and light. The forging process takes more time, thus costing more in the long run.
Heavy Duty Truck Wheels & Parts at Iron Wing
Knowing what is important to you and your heavy-duty truck is the most important part of your answer. Whether it is the weight, the strength, the cost, or additional factors, Iron Wing supplies wheels and truck parts of any size. Check out our line of CWS wheels, or find parts for your Volvo, Mack, and more. Our parts are in stock and ready to ship! Browse by category, or use our search function to sort by description, part number, or manufacturer. We also offer free shipping on qualifying orders >$100.