Finishing
Squeeze Casting
Squeeze casting, also known as liquid forging, is an efficient production process in which molten aluminium alloys are poured into a mould cavity under low pressure, after which the solidifying aluminium is subjected to extremely high-pressure using hydraulics or mechanics.
Due to this high-pressure during solidification, the material is compressed, resulting in the product having superior mechanical properties compared to conventional production processes. This leads to improved strength, toughness, and fatigue resistance.
The pressure applied during the process helps fill even the most complex moulds, reducing surface defects and resulting in smoother and more accurate surface finishes. With squeeze casting, products can be produced continuously, making series sizes ranging from 1,000 to 500,000 pieces not uncommon. Due to the high volumes and the speed and efficiency of production, production costs are relatively low. However, this does require a complex mould that can withstand at least 50,000 shots.
Finishing
Advantages
The main advantages of squeeze casting are:
- Medium to large series of 1,000 to 1,000,000 pieces can be produced.
- Excellent accuracy and surface quality of products.
- Suitable for materials that are not castable in other cases.
- Improved strength, toughness, and fatigue resistance due to the applied pressure during the solidification process.
- Materials can undergo heat treatment to improve mechanical properties.
- Low unit prices compared to other, coarser casting processes.
Consequences
- Large series numbers are required to make the process costs effective; for smaller series we can offer alternative production methods and propose adjustments.
- Narrow wall thicknesses up to 2.0mm are achievable with squeeze casting. 8.0mm is the maximum wall thickness. When the walls are made thicker, the material can shrink more quickly and cause shrinkage holes.
- For product release from the mould, we recommend using a draft angle between 1.0 and 2.0°. This depends on the complexity and size of the product.
Samples
