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Forging uses intense heat and/or pressure to transform a solid slug of alloy material into the final shape of a wheel. During forging, a billet (piece) of aluminum is forced (forged) into the shape of a wheel by using a tremendous amount of pressure. Once the wheel is spun to the desired size and shape of the wheel, the design of the wheel is then machined into the face. Forged wheels are typically lighter and stronger than their cast counterparts; however they also tend to be more expensive do to the cost of the manufacturing and machining processes.

Casting is a relatively inexpensive way to produce a high-quality, strong alloy wheel. There are two methods used. One, system is known as gravity casting whereby the molten material is poured into a mold and allowed to cool. These molds are usually made by machining a piece of material on CNC machine equipments to produce a wheel that only requires minor finishing (like drilling or possibly trimming of some excess metal) to be considered complete. The other and better system used is the low pressure or negative pressure casting. Here instead of pouring the molten material into the mould, the molten alloy is drawn up into the mould using a high-pressure vacuum. This eliminates much of the trapped air found in gravity casting process, producing a stronger wheel that is less porous than a gravity-cast wheel.



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