When it comes to selecting wheels for your vehicle, there are a few key factors to consider. One of the most important is the manufacturing process used to create the wheel. Cast, flow form, and forged wheels are three common options, each with its own set of benefits and drawbacks. In this article, we’ll delve into the differences between these three types of wheels and help you decide which option is the best choice for your needs.
First, let’s define each type of wheel:
- Cast wheels are created by pouring molten aluminium into a mould. The aluminium is allowed to cool and solidify, and then the wheel is removed from the mould. Cast wheels are the most common type of wheel and are often the most affordable option.
- Flow form wheels are created by heating a cast wheel and then using rollers to press the wheel into its desired shape. The process creates a wheel that is stronger and lighter than a cast wheel, but not as strong as a forged wheel.
- Forged wheels are created by hammering a block of aluminium into the desired shape. This process creates a wheel that is stronger and lighter than a cast or flow formed wheel, but it is also the most expensive option.
Now that we’ve defined each type of wheel, let’s take a closer look at the pros and cons of each:
Cast Wheels
Pros:
- Cost: As mentioned earlier, cast wheels are typically the most affordable option. If you’re on a budget, cast wheels may be the best choice for you.
- Availability: Cast wheels are the most common wheel type, so they are widely available and easy to find.
Cons:
- Strength: Cast wheels are not as strong as forged or flow form wheels. They are more prone to bending or cracking under heavy loads or hard use.
- Weight: Cast wheels are generally heavier than forged or flow form wheels, which can have an impact on the performance and handling of your vehicle.
During the casting process, molten aluminium is poured into a mould that is shaped like the desired wheel. The mould is usually made of steel or iron, and it has a cavity in the shape of the wheel. The molten aluminium is allowed to cool and solidify, and then the wheel is removed from the mould.
One advantage of cast wheels is that they can be made in a variety of shapes and sizes, which makes them versatile and suitable for a wide range of vehicles. They are also relatively affordable, as the casting process is relatively simple and requires less expensive equipment than the processes used to create forged or flow form wheels.
Flow Form Wheels
Pros:
- Strength: Flow form wheels are stronger than cast wheels, but not as strong as forged wheels. They can handle moderate loads and hard use without bending or cracking.
- Weight: Flow form wheels are generally lighter than cast wheels, which can improve the performance and handling of your vehicle.
Cons:
- Cost: Flow form wheels are more expensive than cast wheels, but not as expensive as forged wheels.
- Availability: Flow form wheels are not as widely available as cast wheels, so they may be harder to find.
Flow form wheels are created using a slightly more complex process than cast wheels. The process starts by heating a cast wheel until it is soft and malleable. The wheel is then placed between a series of rollers that press the wheel into its desired shape. The pressure from the rollers causes the material to flow and stretch, which creates a wheel that is stronger and lighter than a cast wheel.
One advantage of flow form wheels is that they offer a good balance of strength and affordability. They are stronger than cast wheels, but not as expensive as forged wheels. They are also generally lighter than cast wheels, which can improve the performance and handling of your vehicle.
Forged Wheels
Pros:
- Strength: Forged wheels are the strongest type of wheel available. They can handle heavy loads and hard use without bending or cracking.
- Weight: Forged wheels are the lightest type of wheel, which can greatly improve the performance and handling of your vehicle.
Cons:
- Cost: Forged wheels are the most expensive option, so they may not be a viable choice for everyone.
- Availability: Forged wheels are not as widely available as cast or flow form wheels, so they may be harder to find.
Forged wheels are created using a process called forging, which involves hammering a block of aluminium into the desired shape. The process is done using a machine called a press, which applies enormous pressure to the aluminium block. The pressure causes the material to flow and stretch, which creates a wheel that is stronger and lighter than a cast or flow form wheel.
In addition, forged wheels are the strongest and lightest type of wheel available. They can handle heavy loads and hard use without bending or cracking, and they can greatly improve the performance and handling of your vehicle due to their lightweight.
Cast, Flow Form, or Forged Wheels?
When deciding which type of wheel is right for you, there are a few key factors to consider:
- Cost: If price is a major concern, cast wheels may be the best choice. If you’re willing to spend a bit more, flow form wheels offer a good balance of strength and affordability. Forged wheels are the most expensive option, but they offer the best combination of strength and lightweight.
- Strength: If you plan on using your wheels for heavy loads or hard use, forged wheels are the best choice.
What About Hybrid Forged Wheels?
The hybrid forged wheels process involves shaping a piece of metal by applying pressure to it while it is rotated at high speeds. The process is typically used to manufacture wheels for high-performance vehicles, as the resulting wheels are generally stronger and lighter than wheels made using low-pressure casting or flow forming techniques.
In the hybrid forging process, a piece of metal, typically aluminium or magnesium alloy, is heated to a temperature that allows it to be easily shaped. The metal is then placed on a mandrel, which is a cylindrical tool that is used to hold the metal in place during the forging process. The mandrel is mounted on a machine called a hybrid forge, which rotates the mandrel at high speeds while applying pressure to the metal. As the metal is rotated and subjected to pressure, it is shaped into the desired shape, typically that of a wheel.
Hybrid forged wheels are a variation of rotary forged wheels in which the metal is first cast into a rough shape using a low-pressure casting process, and then subjected to the rotary forging process to achieve the final shape and strength. This hybrid process allows manufacturers to combine the benefits of both casting and forging, resulting in wheels that are strong, lightweight, and have a more precise final shape than those made using casting or flow forming techniques.
This article has been more of a utility base. Make your car, SUV, or 4WD look the way you want it to look with the right wheels and tyres setup. If you need help with the fitment for your vehicle, contact our wheel specialists for fitment advice. We stock an extensive range of wheels and tyres for most vehicles and offer free fitting and balancing on packages.
