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Squeeze Casting

What Is Squeeze Casting ?

Squeeze casting, also known as liquid metal forging, is a combination of casting and forging process by which molten metal solidifies under pressure within closed dies positioned between the plates of a hydraulic press.

The molten metal is poured into the bottom half of the pre-heated die, then the applied pressure and instant contact of the molten metal with the die surface produce an instant heat transfer condition in which coring can be used with this process to form complex geometry. The porosity caused by both gas and shrinkage can be prevented or even eliminated, meanwhile the mechanical properties are also improved, approaching those of a wrought product which reduces the need for surface finish.

The squeeze casting process is easy to realize robotization and produce near-net-to-net shape high-quality components. Both ferrous and non-ferrous materials can be produced using this method.

Six Squeeze Casting Parameters

  1. Casting temperatures depend on the alloy and the part geometry. Normally the starting point is 8 to 50°C higher than the aquiform temperature.
  2. Tooling temperatures ranging from 190 to 315°C are normally used depending on different alloys.
  3. Time delay is the duration between the actual pouring of the metal and the instant punch contacts the molten pool and starts the pressurization of thin webs that are incorporated into the die cavity.
  4. Pressure levels. Normally the applied pressure 50 to 140 MPa are applied.
  5. Pressure duration varying from 30 to 120s has been found to be satisfactory for castings weighing 5-12 kg.
  6. It is proved satisfactory that a good grade of colloidal graphite spray lubricant sprays on the warm dies before casting, for aluminum, magnesium, and copper alloys.

Squeeze Casting VS Die Casting

Casting blanks of squeeze casting and die casting are extremely similar especially after machining process. How to distinguish casting blank of the two casting processes? Let’s find the six main differences between squeeze casting and die casting below now :

Item Squeeze Casting Die Casting
Manufactured Part Application functional parts, such as engine cylinder block, wheel hub, piston, connecting rod, brake shoes, pneumatic or hydraulic valve body,etc. structural parts, such as vehicle door frame, instrument panel, engine housing,etc
Raw Material Most of metal alloys Only casting alloys
Surface Finish & Heat Treatment Much wider surface finish applications like anodizing and heat treatment methods like solid-melt strengthening limited surface finish like power coating. Not able to apply anodizing.
Metallographic Structure Typical crushing-grain texture as forging condition Typical dendrite-shape texture as cast condition
Surface Smoothness Extremely smooth surface like machining parts Microscopic pores on surface, so called “water streak texture”
Tensile Strength 400-600Mpa 200-300Mpa

Advantages of Squeeze Casting

  1. Little or no machining required post casting process. 
  2. Low levels of porosity. 
  3. Good surface texture.
  4. Fine micro-structures with higher strength components.
  5. No waste material, 100% utilization.
  6. Lessen the impurity restriction in raw material.

Disadvantages of Squeeze Casting

  1. Costs are very high due to complex tooling.
  2. No flexibility as tooling is dedicated to specific components.
  3. Process needs to be accurately controlled which slows the cycle time down and increases process costs. 
  4. High costs mean high production volumes are necessary to justify equipment investment.

Applications of Squeeze Casting

  1. The squeeze casting has been commercially succeeded in manufacturing parts include an Aluminium dome,ductile Iron mortar shell, and a Steel bevel gear. 
  2. Aluminium automotive wheels and pistons, and gear blanks made of brass and bronze. 
  3. Compared with the HPDC, the squeeze casting process with high applied pressure is a promising solution for thick magnesium castings.
  4. Other parts that have been Squeeze cast include stainless steel blades, super alloy discs.

 

For further information about our Squeeze Casting services, contact us via the convenient website form or submit a request for quote directly.

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