Forged vs Cast vs Flow Formed Wheels: What Is the Difference?

Cast, flow formed and forged wheels can look the same in a photo. Here is how each one is made, what that does to weight and strength, and which one makes sense for your car.

Cast wheels

A cast wheel is made by pouring molten aluminum into a mold. It is the cheapest way to make a wheel, which is why most factory and budget aftermarket wheels are cast.

The trade off is the metal itself. Cast aluminum has a looser grain and can have tiny air pockets, so the wheel needs extra material to be strong enough. That makes it heavier than the other two types at the same size.

Flow formed wheels

A flow formed wheel starts as a casting. The barrel is then heated and spun while rollers press and stretch it, which makes the barrel thinner and stronger. You will also see it called rotary forged or flow forged.

Only the barrel gets that treatment, so the face is still cast. Flow formed wheels sit in the middle on price and weight, and they are a solid step up from a plain cast wheel.

Forged wheels

A forged wheel starts as a solid billet of aluminum, usually 6061-T6. The billet is pressed under thousands of tons of force, which packs the grain tight and lines it up with the shape of the wheel. The forging is then CNC machined into the final design.

Because the metal is so dense and strong, a forged wheel needs less material than a cast one to do the same job. That is why forged wheels are the lightest and strongest of the three, and why they cost the most. It is also why nearly every high end and motorsport wheel is forged.

Weight and why it matters

Wheels are unsprung weight, which means the suspension has to control every pound of them over every bump. Cutting wheel weight helps the car turn in sharper, brake and accelerate harder, and ride better. On a heavy SUV or a fast car with big wheels, the difference between cast and forged is easy to feel.

Which one should you buy?

If you want the cheapest way to change the look, cast is fine. If you want a better wheel on a budget, flow formed is a good middle ground. If you care about weight, strength, a custom size or a design nobody else has, forged is the one to get.

Every Corsa wheel is fully forged from 6061-T6 and built to order for your car, in monoblock, 2-piece or beadlock. Pricing starts at $765 per wheel for an 18" monoblock. See the full price list or read how much forged wheels cost.

Questions

Are flow formed wheels the same as forged?

No. A flow formed wheel has a cast face and a pressed barrel. A forged wheel is made from a solid billet all the way through, so it is lighter and stronger.

Are forged wheels worth it?

If weight, strength or a custom design matter to you, yes. They cost more because the process takes more material, more force and more machining time.

What aluminum are forged wheels made from?

Most forged wheels, including every Corsa wheel, use 6061-T6, a heat treated aluminum alloy also used for aircraft parts.

Do forged wheels bend or crack?

Forged aluminum is tougher than cast and tends to bend before it cracks, which is one reason it is used on track cars.

Ready to see your car on Corsa wheels? Get a free render or request a quote. Every set is designed in house in Tampa, Florida, built to order from 6061-T6, and ships free worldwide.