FAQs

The distinction between cast, flow formed, and fully forged wheels lies in the manufacturing process and its impact on the final product. Pound for pound, fully forged wheels stand out as the strongest with the lightest weight, offering superior load capacity and resistance to damage. This makes them the most durable and secure choice in the market, especially for those seeking peak wheel performance. While cast and flow formed wheels can be excellent depending on specific applications and driving goals, they may have metal inconsistencies due to casting. For less demanding use, forged wheels may not be essential.

Undoubtedly, forged wheels surpass others not only in terms of performance, quality, and safety but also in cost—a natural outcome for those pursuing the utmost quality. A common question we encounter is, “Are forged wheels worth it?” The answer hinges on the specific application. For a car enthusiast prioritizing quality without extensive track use, flow formed or cast wheels might suffice. However, for a high-performance vehicle with frequent track time, the clear choice is forged wheels.

Undoubtedly, forged wheels surpass others not only in terms of performance, quality, and safety but also in cost—a natural outcome for those pursuing the utmost quality. A common question we encounter is, “Are forged wheels worth it?” The answer hinges on the specific application. For a car enthusiast prioritizing quality without extensive track use, flow formed or cast wheels might suffice. However, for a high-performance vehicle with frequent track time, the clear choice is forged wheels.

The manufacturing process of forged wheels:

The preferred choice for racing professionals.

1. Solid Starting Point: Unlike cast or flow formed wheels that begin with a cast wheel, fully forged wheels initiate from a solid piece of aluminum billet rather than liquid alloy cooled in a mold.
2. Application of Pressure: Shaping the metal into a wheel involves subjecting the billet to intense pressure through methods like mold forging or machine forging. In both cases, the billet is exposed to high heat and then shaped through extreme pressure.
3. Final Touches: The wheel undergoes additional processes such as trimming, drilling, or any necessary adjustments to achieve the desired final design.

This outlines the wheel forging process that sets forged wheels apart.

Understanding the manufacturing process sheds light on why racing professionals favor forged wheels. Here’s a simplified breakdown:

1. Solid Foundation: Unlike cast or flow formed wheels that begin with a cast wheel, fully forged wheels commence with a solid piece of aluminum billet.
2. Application of Pressure: Shaping the metal into a wheel involves subjecting the billet to intense pressure, forging it using heat and pressure.
3. Finishing Touches: The disc is then flow-formed in a spun blank.
4. Heat Treatment: The spun blank undergoes heat treatment to achieve the desired condition.
5. Lathe Turning: The heat-treated spun blank is lathe-turned to meet the customer’s final configuration.

This meticulous process results in significantly stronger wheels compared to cast or flow-form manufacturing. As the aluminum is pressed, the internal structure of the alloy adapts to the wheel’s shape, creating a structurally stronger wheel with less material.

The advantages of forged wheels extend beyond strength. The intense pressure applied eliminates potential failure points common in cast wheels, such as porosity and cavities. The metal compression enhances wheel longevity, resistance to wear and tear, and overall performance and handling.

The choice between cast, flow-formed, or forged wheels boils down to the intended use of the car. The selected manufacturing process significantly influences the metal’s structure, determining the wheel’s load capacity, stiffness, and durability.

In the case of forging, the process involves extreme heat and intense pressure to shape an aluminum billet into a wheel. This transformative process results in a denser metal with a grain that conforms to the wheel’s shape.

Consequently, the benefits include:

1. Lighter wheels (requiring less alloy for shape and strength)
2. Stronger wheels (due to increased density eliminating failure points like porosity, while enhancing tensile and yield strength).
3. Enhanced durability (the increased density enables the wheel to withstand misuse and overloads, signaling improved fatigue strength)
4. Heightened safety (Alcoa’s study indicates that, overall, forged wheels exhibit resilience in impact tests, whereas cast wheels may not consistently meet the same standards, posing a more challenging task for cast wheel designers to comply with impact test requirements.)
5. Greater design flexibility (The heightened strength at a reduced weight allows designers more leeway to tailor the wheel’s appearance, encompassing its finish.)

Clearly, the manufacturing process significantly influences the ultimate outcome of the wheel. The suitable choice depends on your car’s usage.

To quote Speed Academy, “A properly designed and manufactured wheel is going to be perfectly safe on your road car, regardless of whether it’s cast, flow-formed, or forged. All other design parameters being equal, you simply gain the advantages of less weight and greater stiffness and elongation should you decide to step up to a flow-formed or forged wheel.”

However, for performance drivers, the advantages offered by a forged wheel, if nothing else, are crucial for safety reasons.

While strength has been a focus, safety takes centre stage when it comes to load rating.

A professional race driver emphasizes the importance of load rating, stating,

“Whatever the case may be, as a racer, I certainly want to know that the wheels going on my cars, especially if they’re going to see track time, have a serious safety factor built into their designed load rating as well as the best possible construction characteristics (like weight and elongation) my wallet can handle.” – David Pratte, Speed Academy.

In essence, the load index of a wheel indicates its weight-carrying capacity, also referred to as load rating. This numerical representation can be found on the wheel’s sidewall. The wheel load is calculated by taking 50% of the vehicle’s heaviest axle rating (GAWR – gross axle weight rating). For instance, if the heaviest axle weight rating is 3000 lbs, the wheel load requirement would be 1500 lbs.

Locate the axle rating on the driver’s side door jamb, gas tank door, truck lid, or in the glove compartment. Understanding how the car’s weight is distributed is crucial, ensuring proper wheel placement for a safety margin in the wheel load.

It’s important to note that these are static load figures. When engaged in racing, technical off-roading, or similar activities, the added strength from a forged wheel provides superior performance and a safety margin compared to cast wheels and, in some instances, even flow-formed wheels.

As a buyer, understanding the specific qualities your customers seek in a wheel is crucial. When selecting a supplier, you aim for a product that reflects positively on your company. Where can you find forged wheels that meet these criteria?

At NEX2UNE, this approach revolves around providing a comprehensive range of engineering and manufacturing capabilities, allowing us to innovate and uphold a genuine reputation for excellence. Our market strategy is built on unparalleled design flexibility, swift lead times, stringent quality standards, and a dedicated commitment to customer service.

Our global trust stems from:

Expertise

NEX2UNE stands as a leading industry supplier of top-tier forged wheel products worldwide, boasting over 5,000 distinctive designs and corresponding tooling for both one-piece and multi-piece wheels.

Stringent Quality Control Standards

Every aspect of manufacturing and engineering is meticulously handled in our facility with over 100 professionals in the industry of automotive manufacturing, performance and technology.

Swift Lead Times

Bid farewell to extended lead times and rigid customization options. Our commitment lies in developing new products promptly and expediting when necessary. As a cornerstone of our approach, we collaborate with you to surpass expectations, including offering short lead times.

Versatile Design Options

Next Tune effortlessly provides customers with diverse designs, offsets, and widths. We deliver a comprehensive range of premium automotive, motorcycle, off-road, racing, and military wheels, available in sizes up to 34” in diameter. While most products utilize 6061-T6 material, other alloys are also accessible.

If you’re in need of forged wheels, let’s have a conversation! We are eager to discuss your specifications and explore how we can assist you in achieving your goals with forged wheels.

When comparing cast wheels, flow-formed wheels, and forged wheels, the optimal choice hinges entirely on your specific needs. The manufacturing process plays a pivotal role in determining the safety, quality, and performance of the wheel.

For applications involving premium automotive, motorcycle, off-road, racing, and military wheels, opting for forged manufacturing is likely the most advantageous due to its enhanced strength, performance, and safety. It’s crucial to note that wheel load also significantly influences performance and safety.