Liquid Die Forging, also popularly known as Squeeze casting, is one of the best casting processes at this time. This method utilizes two dies are squeezed into the metal formation using molten metal.
If you are somewhat familiar with casting processes, then you must already know that almost all casting processes involve pushing the two dies together. But unlike other casting processes where metal is added before the dies are squeezed, this process does that before the metal is added. Hence the Name Squeeze Casting.
In the manufacturing world, there are various types of casting processes available. And depending on your specific requirement, choosing the right casting technique is crucial. If you can choose the right casting method, it is already half of the decision on the road towards a better-quality component.
So without any further ado, let us dive right in and find out the benefits of squeeze casting and how it can elevate your component quality.
What Are The benefits of Squeeze Casting?
Squeeze casting is the perfect marriage between forging and casting. This results in a significantly better yield with precise designs. It also offers a far better component that has superior mechanical properties than something bade from normal casting.
In a Squeeze casting process, everything is done with pressurized sealed dies. This ensures very low shrinkage and better components.
Squeeze casting can also leverage the power of software programming to make mass production streamlined for manufacturers. As a result, you can get more done in less time. Moreover, there is no extra material cost that you might need if you are opting for forging.
These significant savings on both time and money open up more resources that can be spent elsewhere to elevate the business to a new level.
Another big advantage of Squeeze casting is the ability to be T6 treated. Contrary to popular belief, Heat treatment does not only make it harder but sometimes can also make it softer. The softening of the steel allows the component to work under pressure and makes the overall system more flexible and stronger. It also introduces features like wear resistance to the material.
Components made by Squeeze casting also offer a longer lifetime. As the heat treatment leaves a long-lasting effect on the material, it provides you with nothing but the best result.
The cooling method of this casting also forms better grains if we compare it with any other casting techniques. That means the metal will be stronger and will be able to take more load and stress during operation.
A low level of porosity is also another significant advantage that is making Squeeze casting even more popular these days.
The defects that you can avoid through Squeeze Die-Cast
Truth be told, there are no die-casting techniques that can completely get rid of all forms of defects from the components. That being said, Squeeze Die-Cast can take a lot of these defects heads on and solves them seamlessly.
For instance, one of the most common defects found while die casting is the air void inside the cavity. These can make your Aluminum Alloy more fragile than expected. Although High Strength Lightweight Aluminum Alloy Squeeze Casting Processing does not get rid of all the air void, less porosity can significantly improve the quality of the product.
If you are ever worried about Shrinkage after solidification, then you are not the only one. It is arguably the second biggest defect of casting. This shrinkage occurs because it does not have enough density prior to ejection when the metal is in a liquid state. As squeeze die-cast utilizes high pressure to win the top die, it significantly reduces the chance of shrinkage after solidification.
Things to consider for squeeze Die Casting
For such a versatile and effective die casting process, there are certain things you have to keep in mind. Here is a list of parameters one has to keep a sharp eye on in order to ensure the best casting experience and yield.
Pressure level
The pressure Level is one of the most important factors to keep in mind when opting for a squeeze casting. Anything between 50 to 150 Mpa is perfect for casting weighing around 8 KG for regular casting. Also, the pressure level needs to stay in place for the ideal amount of time to yield to best result.
In general, to achieve a satisfactory result, pressure duration should be between 30 Seconds to three minutes.
Casting temperature
This one is a no-brainer. Temperature is one of the driving factors while casting. Not opting for the right temperature can be the difference between flawless casting or a fragile component. This is why we advise you to also look for a professional squeeze casting service provider before getting started on any project.
It is because experts in this field know the right temperature and have the necessary skillset to regulate it between 190 to 315 degrees Celsius. The temperature can also depend on other factors like the metal you are using.
Application of squeeze casting
Being among one of the most popular casting methods, squeeze casting offers a lot of application. As the cast parts are lightweight, have a better density, and can be precise to the design, this method can be used to cast various parts.
Some of the most popular applications of squeeze casting are,
- Automotive parts like Engine blocks and Pistons.
- Bombshells, Dome roofs, or Gears for the defense industry.
- Brackets, Steering knuckles.
- Pipes, Alloy discs, and also SS blades.
