Currently, car modification has clearly become a popular trend. Especially for the original wheels of mid-to-low configuration models on the market today, both their design and size tend to be conservative. Therefore, wheel modification has become an entry-level option for minor car upgrades. Before modifying, when choosing wheels made with a specific process, it is necessary to understand the differences between aluminum alloy forged wheels and traditional cast wheels.

I. Process Differences

Simply put, casting is a process where metal is melted into a liquid that meets certain requirements, poured into a mold, and after cooling, solidification, and finishing, a casting (part or blank) with a predetermined shape, size, and performance is obtained.

Forging, on the other hand, is a processing method that uses forging machinery to apply pressure to a metal billet, causing it to undergo plastic deformation to obtain a forging with specific mechanical properties, shape, and size.

The casting wheel process is relatively simple, making it suitable for low-cost mass production; forged wheels have a dense structure, can withstand high stress, and offer greater freedom in design to meet personalized needs.

II. Material Differences

Generally speaking, forged wheels are made by forging 6061 aviation aluminum alloy; cast wheels are formed using molds with A356.2 aluminum alloy, a type of civilian aluminum material. The difference in materials between the two results in significant gaps in their product strength, fatigue resistance, and safety.

Under a microscope, observing the detailed structure of the wheels, the internal structure of forged wheels is denser, and their strength is higher.

III. Appearance Differences

Front-side judgment: Due to the casting process, cast wheels generally require a draft angle of 7° to 10°, while forged wheels typically have a draft angle of 0° to 3°, allowing for intuitive differentiation.

Back-side judgment: Cast wheels will definitely have material removed from the back (material relief). This is done firstly to reduce weight and secondly to facilitate marking symbols. Forged wheels may not have such material relief (there are exceptions, but the style of material relief will be different).

Sound judgment: Wheels made of high-quality aluminum are denser, so the echo when tapped is clearer. Wheels manufactured using liquid aluminum forging technology produce the clearest sound, and the echo may sometimes last for several seconds. If the echo is dull or almost non-existent after tapping, it is better to avoid choosing such wheels.

Touch judgment: Forged wheel rims are thinner than cast ones, so differentiation can be made through touch or weight.

IV. Summary

The above are the common differences between forged and cast wheels at present.