FORGED Irons - CAST away the misconception

When purchasing a new set of irons consumers generally run into the question of whether they want forged irons or cast irons.  In this blog post I will discuss the main difference between the two types of irons and which ones I would suggest.  I would first like to say that although I feel that I have a fairly comprehensive knowledge about the subject at hand I am not insinuating that I am an expert in the field.  I do however feel that my opinion is quite valid due to 1) My background as a metallurgical engineering student specializing in manufacturing and physical metallurgy 2) The countless hours I have spent on the golf course growing up, using, purchasing, and testing all kinds of golf clubs 3) The years I spent working in the proshop at the local golf course selling golf clubs and advising customers on their purchases.

"Forged" and "Cast" refer to the manor in which the heads of the golf clubs are manufactured.  Forging is the process of shaping a metal using localized compressive forces.  Although the process is generally done when the metal is hot, all that is required is enough force to cause plastic deformation to the metal.  Plastic deformation, unlike elastic deformation is permanent and will remain once the force is removed.  Forging is the picture that you get when you think of a blacksmith shaping a piece of glowing red hot metal by hammering it on an anvil.

Casting is the process of heating the metal to the liquid state, pouring it into a mold, and allowing it to solidify into the desired shape.

It is a common view and perhaps misconception that higher quality irons are forged while cheaper, lower-end irons are cast.  The reason for this view is due to the fact that forged irons generally take the shape of a blade, or muscle back iron.  This shape of iron is the traditional look and has been around for years.  A muscle-back iron is generally less forgiving making it difficult for higher-handicapped players to hit.  The shape of the iron also allows a player to "work" the ball.  Work being the act of hitting a slice, or hook.  This is the reason that most professionals play forged irons as they allow the player to shape their shots.  However most everyday players are incapable of choosing the shape that their ball flight will take and therefore should look for a "forgiving" iron.  That is one that minimizes the amount of side spin induced at impact.

 

This brings us to cast irons.  As golf has grown immensely in popularity in the last decade or two, there are more amateurs playing who may only get out to play once or twice a month.  It is no longer limited to the rich and retired who get to practice all day long.  This has opened up much research and development in the area of improving the "forgiveness" of irons.  The forgiveness of an iron refers to the ability of club to produce higher and straighter shots irregardless of the perfection of the golf swing behind the club.  Although they have yet to produce a magic golf club technology has made great advancements and has allowed even the ugliest of swings to produce a competent golf shot.  The hotspot in golf technology lately has been the COG or center of gravity.  By moving the center of gravity back and lower on the clubhead the iron becomes "easier" to hit.  This basically means that the club helps the player get the ball in the air.  This introduced the "cavity-back" iron.  The cavity back iron allows the center of gravity to be relocated without the addition of any relevant weight.  The intricate shape of the iron is what has made the casting process so popular in the club manufacturing business.  It is much more difficult and costly to produce a cavity-back iron through forging than casting.  

 

The difference between the quality of the metal produced between the two processes is very minimal.  When asked why they prefer forged, many professionals state the feel of the softer metal.  However it has been proven that 95% of the time the difference in hardness can not be felt at impact.  The major difference between the two manufacturing processes is the cost.  Castings can be mass produced much more effectively and therefore the savings are passed on to the consumer. The forged vs cast labels have very little meaning and consumers would be better off to chose a club based on head shape (ie. muscle-back vs cavity-back)  As newer, more intricate head shapes are designed it is my opinion that the market will see less and less desire for a forged product.  I believe that the only reason that forged clubs have stayed popular is because of the misconception that they are a higher quality.

PS. The clubs that I currently play are a higher-end forged muscle-back from Titleist.  I guess I need to learn to practice what I preach.  I do however place some of the blame on club manufacturers as they continue to produce higher-end clubs with the forging process.  Unfortunately the only reason for this is that they are able to charge more for these clubs and until the misconception is wiped out they will likely continue to take advantage of it. 

Check back for my next post which will likely discuss the technology implemented in the manufacturing of woods.

Sean.