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How Forgings compare to Powder Metal Parts (P/M)

Forgings are stronger. Low standard mechanical properties (e.g. tensile strength) are typical of P/M parts. The grain flow of a forging ensures strength at critical stress points.
Forgings offer higher integrity. Costly part-density modification or infiltration is required to prevent P/M defects. Both processes add costs. The grain refinement of forged parts assures metal soundness and absence of defects.
Forgings require fewer secondary operations. Special P/M shapes, threads and holes and precision tolerances may require extensive machining. Secondary forging operations can often be reduced to finish machining, hole drilling and other simple steps. The inherent soundness of forgings leads to consistent, excellent machined surface finishes.
Forgings offer greater design flexibility. P/M shapes are limited to those that can be ejected in the pressing direction. Forging allows part designs that are not restricted to shapes in this direction.
Forgings use less costly materials. The starting materials for high-quality P/M parts are usually water atomized, pre-alloyed and annealed powders that cost significantly more per pound than bar steels.
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