It’s a combination of casting and forging, known as squeeze casting or liquid metal forging. Bottom half of pre-heated die is filled with hot molten metal. The top half of the die shuts as the metal begins to solidify, applying pressure to the solidification process. Forging requires a little of pressure, and this method uses a lot less of it. This method may be used to create holes and recesses. Improved mechanical characteristics and lower porosity.

This process may be used to produce both ferrous and non-ferrous materials. With the use of two dies that are pushed together, metal may be formed into various forms via the process of squeeze casting.

Squeeze casting differs from other casting methods in that the metal is added to the two dies after they have been pressed together.

In this case, the top die must be removed only after the liquid metal has cooled.

The metal produced by this method is often stronger, has a superior grain, and shrinks less than metal produced by other methods.

Magnesium and aluminum, as well as their alloys, are often utilized in this process, although a wide variety of metals may also be used.

Instead of using two dies as in other casting methods, squeeze casting makes use of only one. Liquid metal is often poured into the casing while the two castings are joined together.

A lower die holds a pool of liquid metal, while an upper die squeezes the metal into a desired form. In order to develop a hybrid process, the top die is being used to provide pressure, therefore this isn’t exactly casting.

This application requires the use of liquid metal. This method is not ideal for casting plastic, even though plastic may be melted at high temperatures.

Once the top die is set, the metal is allowed to cool fully before moving on. As soon as the metal has cooled, the top die may be removed, revealing the newly formed shape.

Using this procedure, non-ferrous alloys such as aluminum, magnesium, and copper alloy components may be easily produced

The squeeze casting method, which combines the benefits of casting and forging, has been extensively employed to make high-quality castings.

Porosities induced by gas and shrinkage may be minimized or reduced because of the high pressure utilized during solidification.

Pressure applied to the die during solidification improves the contact between the die and casting, which leads to fine-grained structures being able to be formed. Squeeze casting has two types.

Squeeze Casting Process

Squeeze casting includes a modification of the usual die casting method.

To comprehend the squeeze casting process, it is first important to grasp casting on a broad level.

During casting, a maker pours a liquid, generally molten metal alloys or plastic, into a mold.

A mold is just a cavity that molds the liquid and enables it to cool into a certain form. As molten metal solidifies, it assumes the form of the mold cavity.

Casting is a process that uses either temporary or long-lasting molds to produce a wide range of things.

Surface details may typically be reproduced by the manufacturer. Short-lived or long-lived molds are both possible.

In most cases, they’re used to produce finer surface distinctions. High-pressure yet non-turbulent forging is used in squeeze casting as a version of die casting.

Squeeze casting is used to make several common and inexpensive consumer goods, including as aluminum and zinc alloy metals.

Squeeze Casting Materials

Squeeze casting is different from other methods of die casting in that it involves a few different steps.

Metal alloys like zinc, aluminum, and magnesium, which are lightweight, may be used in this method. There are lengthier cooling periods.

In order to get the ultimate outcome, lubricants are also required. Bunty, a company that specializes in outsourcing this kind of work, is a good option because of this criterion.

Aluminum castings should be free of iron aluminide needles if they are utilized. Mechanical characteristics, which are important for high-quality goods, might be hindered by these.

Several tools are required for successful squeeze casting, including raw materials:

• Oil Die Heating System
• Squeeze Casting Machine
• Vacuum System
• Process Monitoring System

Direct Squeeze Casting

Direct squeeze casting is comparable to the forging process. In this process, molten metal is poured into the bottom portion of the mold.

The top part is closed, forcing the whole mold to fill with molten metal. With pressure exerted throughout the complete cavity, the solidification process starts.

This technique allows greater heat transmission to generate stable components.

Indirect Squeeze Casting

Direct squeeze casting is comparable to high-pressure die casting. Using a vertical or horizontal shot sleeve, molten metal is pumped into an indirect squeeze-casting process.

On the other hand, with a low-pressure die casting process, the liquid metal is pumped into the die chamber at a higher velocity and with a thinner gate.

Applications of Squeeze Casting

An Aluminium dome, a ductile Iron mortar shell, and a Steel bevel gear have all been commercially manufactured via squeeze casting.

Automobile wheels and pistons are constructed of aluminum, as well as brass and bronze gear blanks.

The squeeze casting method with high applied pressure is a possible alternative to the HPDC.

Stainless steel blades and super alloy discs are examples of squeeze casting items.

Characteristics of the Squeeze Die Casting Process

It is widely utilized in the production of high-quality castings because it combines the benefits of casting and forging techniques.

Because of the high pressure used during solidification, gas, and shrinkage porosities may be avoided or minimized.

Because high pressure during solidification improves contact between the casting and the die, it is possible to speed up the cooling rate of the casting by doing so.

Casting Parameters

• Temperatures for casting are based on the alloy and component shape. Normally, the starting point is 6 to 55°C higher than the liquidus temperature.
• Temperatures of 190 to 315°C are often utilized for tooling.
• Normally, pressures of 50 to 140 MPa are utilized.
• Lubrication If sprayed on the heated dies before casting, a suitable quality colloidal graphite spray lubricant has proven adequate for aluminum, magnesium, and copper alloys.

Advantages of Squeeze Casting

• Offer a wide range of components and shapes.
• After the casting process, little or no machining is necessary.
• Porosity values are low.
• The surface texture is excellent.
• Fine microstructures with stronger constituents.
• There is no waste and everything is used.

The aluminum squeeze casting process has great advantages over the conventional high-pressure die casting process.

This advantage has been applied by us in various fields.   Learn more about the “squeeze casting VS high pressure die casting process”.

Disadvantages of Squeeze Casting

• Because of the complicated tooling, costs are quite expensive.
• Because tooling is dedicated to certain components, there is little flexibility.
• The process must be precisely managed, which slows the cycle time and raises the cost of the operation.
• High production quantities are required to justify equipment investment due to high costs.