Enhancing Mechanical Performance and Reducing Aluminum Casting Cost
CEX started to research and develop the squeeze casting process in 2015. As China’s leading squeeze casting manufacturer, we have a patented squeeze casting process and equipment (300t-1100t) and one squeeze casting manufacturing base.
From the mold design to the process parameters determination and product refinement, all these steps reflect the rich experience and wisdom of our engineers. The products we have developed have been used in various fields and have helped many customers to improve the mechanical properties of their products and significantly reduce their production costs.
Squeeze casting, also known as liquid die forging, is a type of casting process in which molten metal solidifies under pressure within closed dies positioned between the plates of a hydraulic press.
The pressure applied and the instant contact of the molten metal with the die surfaces produces a rapid heat transfer, which yields a pore-free, fine-grained casting with mechanical properties similar to those of a wrought product.
The squeeze die casting process is easily automated to produce near-net to net-shaped, high-quality casting products.
There are two types of squeeze casting processes: direct squeeze casting and indirect squeeze casting. The difference between the two types is how the high pressure is applied to the molten metal.
Direct squeeze casting is a process in which the molten metal is poured directly into the mold cavity and pressure is introduced when the top punch is lowered into the bottom die.
This process is much like forging and that is why squeeze casting is also called liquid forging.
Indirect squeeze casting is a process in which the molten metal is injected into the cavity from a plunger.
The pressure is applied by the plunger in the indirect squeeze casting.
The squeeze die casting process combines the advantages of casting and forging processes and has been widely used to produce quality castings.
Because of the high pressure applied during the solidification, porosities caused by both gas and shrinkage can be prevented or eliminated.
The cooling rate of the casting can be increased by applying high pressure during solidification since contact between the casting and the die is improved by pressurization, which results in fine-grained structures.
At CEX Casting, the internal structure of our aluminum squeeze casting parts can achieve virtually no porosity.
It can avoid defects in traditional aluminum casting methods such as shrinkages, cracks, and other common defects.
The above figure shows the near-zero porosity internal structure detected by our X-ray machine.
The biggest advantage of the squeeze casting process is that the castings can be heat treated to achieve improved mechanical properties.
After T6, the mechanical properties of the squeeze casting parts could be much higher.
Mechanical property comparison of the squeeze casting parts from different materials:
Note: Density 2.72g/cm³, tested pieces cut from casting parts. The data from the test bar will be higher.
| Material | Tensile Strength MPa | Yield Strength MPa | Hardness HB | Elongation % |
|---|---|---|---|---|
| AlSi9Mg | 240 | 160 | 80 | 3 |
| A356 | 260 | 180 | 80 | 5 |
| A356.2 | 300 | 220 | 90 | 7 |
| Al-Ti Alloy | 320 | 230 | 100 | 9 |
| 6061-T6 | 330 | 240 | 110 | 10 |
| 7075-T6 | 500 | 300 | 160 | 11 |
✔ Good roughness similar to aluminium vacuum die casting & precision casting.
✔ Parts are made with high accuracy, like die casting & aluminium precision casting.
✔ No additional material costs and extra machining, better than forging.
✔ Can be T6 treated, better than vacuum assisted high pressure die casting, and similar to forging.
✔ Parts come with high sealing performance.
✔ High mechanical properties similar to forging, and better than investment casting or sand casting.
| Items | Squeeze Casting | Forging | Investment Casting | High Pressure Die Casting | Low Pressure Die Casting |
|---|---|---|---|---|---|
| Surface | Fine | Fine | Bad | Fine | Medium |
| Roughness | Ra3.2~1.6 | Ra3.2~1.6 | Ra6.3~3.2 | Ra3.2~1.6 | Ra6.3~3.2 |
| Inside | Fine Grain & Compact Microstructure | Fine Grain & Compact Microstructure | Coarse Grain & Loosen Microstructure | Inhomogeneous Grain & Loosen Microstructure | Coarse Grain & Loosen Microstructure |
| Heat Treatment | T6 | T6 | T6 | – | T6 |
| Structure Level | Complex Structure | Simple Structure | Complex Structure | Complex Structure | Simple Structure |
| Forming Accuracy | High | Medium | Medium | High | Low |
| Extra Machining | Minor | More | More | Minor | More |
| Production Efficiency | High | Low | Low | High | Low |
| Mechanical Properties | Same or Close to Forging | Highest | Medium | Low | Low |
| Application | Parts |
|---|---|
| Automobile Stressed Parts | Automobile Piston, Wheel Hub, Beam (Cross Beam), Knuckle, Lower Arm, Brake Caliper, Engine Mounting, Gearbox, Air Compressor, Connecting Rod |
| Pressure Parts / Airtight Parts | Air Conditioning Compressor, Turbine Disk, Cylinder, Front and Rear Cover, Steering Valve Housing, Oil Pump, Manifold, Fuel Distribution Pipe, Brake Block, Clutch Cylinder |
| Wear Resistance Parts | Shift Fork, Pump Casing, Rocker Arms, Air Compressor Piston and Swashplate, Aluminum Composite Brake Hub |
| Motorcycle Stressed Parts | Upper and Lower Connecting Plate, Gearbox Housing, Rear Hanger, Crank, Frame Body, Joint, Frame Joint, Direction Axis |
| Motorcycle Pressure and Wear Parts | Aluminum Piston, Shock Absorber, Disc Brake, Pump Body |
| Electrical Parts / Power Parts | Disk Drive Housing, Electrical Spindle Bushing, Electrical Compression Ring, Sonar Shell, Computer Parts, Rotors, Crimping Clamp, Suspension Clamp, Parallel Groove Clamp |
| New Energy Vehicles | Electric Automobile Parts, Hybrid Power Automobile Parts, Bumpers, Body Shell, Body Frame |
| Advanced Field | Military Parts, Aerospace Accessories, Aircraft Accessories, Optical Frame Shell, Medical Equipment Accessories, Fitness Equipment Accessories |
| Others | Marine Propellers, Pneumatic Instrument Housing, Pressure Cooker and Cooker Equipment Parts, Furniture Accessories, Valve Body, Valve Accessories, Garden Tool Parts, Fan Blades |
CEX casting is China’s leading squeeze casting company. Our Squeeze Casting Service Helped Many Companies To Improve The Mechanical Properties Of Different Parts. Those squeeze casting products have better mechanical characteristics than conventionally cast Parts because of their higher density, the finer scale of grain, and more homogeneous microstructure.
Part Name: Steering Knuckles Trailer Connector
Material: A356.2
Heat Treatment: T6
Unit Weight: 2.25kg
Unit Weight by Steel: 4.92kg
Weight reduced by 54%, passes 100W Bench Test.
Part Name: Electric Scooter Folding Part
Material: A356.2
Heat treatment: T6
Reduces the machining process, and saves at least 40% cost of aluminum casting.
Part Name: Tent Folding Part
Material: A356.2
Heat Treatment: T6
Strength is 50% higher than traditional HPDC to give better support over longer distances.
Part Name: Valve parts
Material: A319
Heat Treatment: No Need
No porosity pits, dents, or scratches on the entire surface.
For more applications, you can click the link below to get the whole squeeze casting case studies.
✔ 280T- 1100T Squeeze Casting Equipment
✔ 4 Sets of CNC Machining Center
✔ 5 Sets of Precision Engraving Machine for Mold
✔ 50 Sets of Other Assistance Equipment
CEX Casting is certified under ISO 9001:2015 and IATF 16949:2016, ensuring strict quality management and process stability across our squeeze casting production process. These certifications guarantee that every phase of production, from mold design and molten aluminum pouring to heat treatment and precision machining, delivers aluminum components with exceptional mechanical properties, reliability, and dimensional accuracy.
We invested in an advanced internal quality inspection laboratory, equipped with a range of quality inspection instruments and experienced quality inspectors:
CEX Casting is certified under ISO 14001:2015 and ISO 45001:2018, highlighting our commitment to sustainable and safe squeeze casting production. We implement advanced environmental and safety management practices to minimize waste, reduce energy consumption, and protect employee well-being, ensuring that our aluminum squeeze casting operations remain both responsible and efficient.
