Valve Body Casting vs. Forging: Pros and Cons

Two Routes to a Valve Body

Valve bodies are manufactured by casting molten metal into molds or by forging solid metal under pressure. Each process produces different material properties, cost profiles, and size limitations that affect the final choice.

Casting Advantages

• Complex body shapes and internal geometries achievable

• Cost-effective for medium and large valve bodies

• Wide range of alloys available in cast form (CF8M, WC6, WC9, LCC, etc.)

• Better suited for sizes above DN 50 where forgings become expensive

Casting Disadvantages

• Porosity, shrinkage, and inclusions require radiographic inspection

• Lower notch toughness than forgings at sub-zero temperatures

• Internal defects may not be detected until pressure test or field service

Forging Advantages

• Denser, defect-free grain structure from working the metal

• Superior impact toughness—preferred for cryogenic and high-pressure applications

• Higher reliability in critical service: HIPPS, wellhead, and subsea valves

• F316, F51 duplex, F11 alloy steel forged grades available

Selection Guidance

Choose forgings for: cryogenic service, high-pressure class 900+ valves, sour service where casting defects increase SSC risk, and safety-critical isolation. Choose castings for: standard pressure classes, complex geometries, and economic procurement of mid-size valves. NDE and hardness requirements apply to both.