Forged Wire Rope Clips VS Casting Wire Rope Clips

Wire rope cable clips are one of the most commonly used accessories in the rigging industry. They are easy to install and allow for adjusting wire rope lengths. They are widely used in various rigging and non-lifting applications, such as winch ropes, crane hoist ropes, suspension cables, isolation cables, and guy wires.

If a wire rope clamp is installed incorrectly, you could not only suffer property damage but also be in danger of injury to yourself or others. Today, we will discuss the two manufacturing processes for wire rope clips and which one is more suitable for your situation. We hope this will be helpful in your practical application.

Two Manufacturing Processes for Wire Rope Clips

A steel wire rope clamp consists of a U-bolt, two nuts, and a forged steel base (sometimes called a saddle). There are many types of wire rope clips, suitable for different applications, and each has its own correct method of use. In terms of manufacturing process, there are forged wire rope clamps and cast wire rope clamps. The components of these two types of wire rope clamps are the same, with the only difference being the clamp base: one is made of forged steel, the other of malleable cast iron. Although the base materials differ, they significantly impact the performance and reliability of the wire rope clamp.

1. What is a forged wire rope clip?

The base of a forged steel wire rope clamp begins as a solid piece of metal. This solid block is heated and hammered until softened, then press-formed into the desired shape, resulting in a uniform grain structure. This hammered clamp eliminates voids, resulting in increased strength and resistance to fracture under load, making it suitable for use in heavy-duty applications with high-rated equipment.

2. What is a casting wire rope clip?

The base of a casting steel wire rope clamp is made by pouring molten metal into a mold. While highly malleable, it is typically brittle. However, during the casting process, premature cooling or loosening of the mold sand can create voids within the casting, weakening the clamp and making it invisible to external inspection.

Different Applications Of Wire Rope Clips

Forged wire rope clamps and casting wire rope clips have different bases, but their strength differs significantly. When choosing between forged and casting wire rope clamps, consider the strength and whether the application is heavy-duty or lighter.

Forged Wire Rope Clamps’ Applications

Forged wire rope clamps are made of forged steel and are designed for heavy-duty applications because they can withstand high tension and heavy loads. They are suitable for overhead lifting, crane hoist lines, winch lines, and creating safety loops for anchor points. They are also suitable for logging operations, towing, ship salvage, and factory lifting.

Casting Wire Rope Clips’ Applications

Cast wire rope clamps are made of malleable cast iron and are designed for lighter loads, offering significant cost advantages. Cast wire rope clamps, such as American malleable cast iron clamps, are only used to manufacture eye-end assemblies with wire ropes with a correct conventional lay and are intended for light-duty applications with light loads, such as handrails, fences, and guardrails. They may break under frequent use and lack the desired metallic properties of steel or the beneficial grain structure of a forged base.

Different Appearances and Dimensions

Forged and cast wire rope clamps differ significantly in appearance and dimensions. Below, I’ll use American-style forged wire rope clamps and DIN741 clamps as examples to explain the differences in their basic parameters.

Type	US Drop Forged Wire Rope Clip	DIN741 Wire Rope Clip
Standard	US Standard	DIN Standard
Body Material	45# Carbon Steel	Malleable Steel
U Bolt Material	Q235 Carbon Steel	Q235 Carbon Steel
Technology	Drop Forged	Casting
Surface	Electro Galvanized, Hot Dip Galvanized, Self Color, Dacromet, Powder Coated	Electro Galvanized
Application	Heavy Duty	Light Duty
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We hope this article helps you understand the differences between forged and cast wire rope clips and help you choose the right one to ensure safety and reliability in your application. You can also visit our website for more information about wire rope clips. Safety is a priority. Don’t say it should be okay, or usually isn’t a problem. Rigging must be 100% safe.