Forged Versus Cast
When a piston is cast, the alloy is heated until liquid, then poured into a mold to create the basic shape. After the alloy cools and solidifies it is removed from the mould and the rough casting is machined to its final shape. For applications which require stronger pistons, a forging process is used.
In the forging process, the rough casting is placed in a die set while it is still hot and semi-solid. A hydraulic press is used to place the rough slug under tremendous pressure. This removes any possible porosity, and also pushes the alloy grains together tighter than can be achieved by simple casting alone. The end result is a much stronger material.
Hypereutectic pistons can be forged, but typically are only cast, because the extra expense of forging is not justified when cast pistons are considered strong enough for stock applications.
Aftermarket performance pistons made from the most common 4032 and 2618 alloys are typically forged.
Read more about this topic: Hypereutectic Piston
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