Squeeze Casting
CYCO offers precise casting services with advanced technology and superior workmanship. Whether you need complex and high-precision parts or mass production, we can meet your needs.
Overview of Squeeze Casting
Squeeze casting is a process combining casting and forging. A certain amount of liquid metal is poured directly into the cavity coated with lubricant, and continuously applied mechanical static pressure. The metal crystallizes and solidifies under pressure and is forced to eliminate shrinkage holes formed due to solidification contraction, i.e. the liquid metal is molded under high pressure in the machine and accompanied by a trace of plastic deformation. It combines the advantages of casting and forging to produce metal parts with high precision, high quality and excellent mechanical properties. It effectively reduces casting shrinkage defects and improves the organization density of the workpiece, as well as greatly improves the mechanical properties through heat treatment.
Processes of Squeeze Casting
1. Mold preparation: Design and prepare molds for extrusion, usually made of high-strength, wear-resistant materials. Spray special coatings on the inside of the die to reduce the friction between the metal and the die, improving the surface quality of the castings and the life of the die.
2. Metal material preparation: Select suitable metal or alloy materials for melting to achieve the desired liquid or semi-solid state. Degas and deslag the molten metal to improve its purity and fluidity.
3. Injection: Rapid and accurate injection of pre-treated liquid metal into preheated mold cavities. Injection methods include gravity pouring, low-pressure pouring or high-pressure injection, depending on the shape and size of the casting.
4. Extrusion: High pressure is applied to the metal inside the mold before the metal has fully solidified. The pressure range is usually 50 to 100 MPa. This can be accomplished hydraulically or mechanically by forcing the metal to flow under pressure and fill the cavity.
5. Solidification: Under high pressure, the metal is not only shaped, but solidifies and deforms plastically at the same time. This process results in castings with a fine, uniform grain structure and good densification, which improves their mechanical properties.
6. Cooling: During the cooling process of the casting, a certain high pressure is maintained to promote further metal flow and tissue refinement. The cooling rate and sequence of the castings are controlled through the cooling system of the mold to ensure uniform cooling and solidification.
7. Demolding and Cleaning: When the casting is completely cooled and has reached sufficient strength, release the mold pressure and open the mold to remove the casting. Clean up any residue and paint inside the mold.
8. Post-treatment: Depending on the needs, the castings may require some post-treatment operations, such as cutting, heat treatment, surface treatment, to meet the design requirements and performance standards.
Types of Squeeze Casting
Direct squeeze casting: After the liquid metal fills the mold, pressure is applied through a punch that acts directly on the liquid metal. The metal billet is directly extruded to form the desired cross-sectional shape. The process usually involves passing the metal billet through one or more extrusion molds to produce parts or components with the desired cross-section.
Indirect squeeze casting: Unlike direct squeeze casting, its main characteristic is that the pressure is not applied directly to the metal liquid, but is transferred to it through an intermediary (e.g., a piston or plunger). The metal billet is indirectly squeezed by rollers, rods, and other auxiliary tools to eventually form the desired cross-sectional shape. Compared to direct squeezing, indirect squeezing usually involves multiple steps in which the metal billet undergoes multiple deformations during the squeezing process to achieve the final shape through successive rolling or tumblin
Available Metals
Good plasticity and thermal conductivity, light weight, strong corrosion resistance, suitable for the production of various profiles, tubes and components. Aluminum alloy has broad range of choices to meet the requirements of different strength and corrosion resistance.
Excellent electrical and thermal conductivity, as well as corrosion resistance. Typically used in applications requiring high electrical conductivity, such as electrical components and electronics.
Very low density and good mechanical properties for applications requiring light weight, such as automotive components.
Better corrosion resistance, usually used in the production of small parts and decorative components.
Excellent corrosion resistance and favorable mechanical properties for applications requiring high strength and corrosion resistance, such as building structures and food processing equipment.
High strength, low density and good corrosion resistance for applications requiring lightweight and high temperature performance, such as aerospace and medical devices.
Typically used in applications requiring high strength and wear resistance, such as mechanical components.
good mechanical properties and wear resistance, suitable for some applications requiring high strength and wear resistance, such as automotive parts and construction machinery.
Available Machines
The metal billet is extruded through a die by hydraulic cylinders with the use of a fluid (usually hydraulic oil) to transmit the pressure. The hydraulic system can provide high precision and adjustable pressure.
High pressure is generated through a mechanical drive system to extrude the metal billet through a die. These machines are usually driven by crank mechanism and cam mechanism.
Benefits of Squeeze Casting
High productivity
Produce a large number of similarly shaped products in a short period of time, suitable for mass production.
High molding accuracy
Metal flows and solidifies under high pressure, which helps eliminate casting defects such as porosity, shrinkage and porosity. This usually provides highly accurate shapes and sizes, resulting in a final product with good geometric accuracy.
High material utilization
Liquid metals or alloys are better able to fill mold cavities under high pressure. The absence of risers and sprues, which are extras required in conventional casting, enables more efficient use of raw materials and reduces scrap generation.
Strong adaptability
Squeeze casting can be used to process a variety of metals, such as aluminum alloys, copper alloys, magnesium alloys, making it highly versatile. In addition, the process is also suitable for manufacturing complex shapes and large parts.
Energy saving
Since squeeze casting is able to obtain parts close to the final shape in a single molding process, subsequent machining and scrap generation are reduced.
Good surface quality
As the metal flows under high pressure, the surface finish of the casting is usually high, reducing subsequent surface treatment work.
Even internal organization
The flow of metal under pressure makes the internal organization of the castings more uniform, which improves the consistency of the overall performance.
Excellent mechanical properties
Plastic deformation occurs as the metal flows under pressure and solidifies, refining the grain structure of the casting. This results in mechanical properties close to those of forged products, such as high strength, high hardness and high toughness.
Applications
Automotive
Produce automotive components such as body structures, doors, window frames, seat tracks. Squeeze casting can provide highly accurate shapes and lightweight solutions that help improve the fuel efficiency of automobiles.
Building and structural engineering
For the production of various profiles such as aluminum window frames, door frames, beams, and columns. These products offer a high degree of corrosion resistance and strength, as well as low weight, making them ideal for building structures.
Electronic and electrical
Parts such as housings, heat sinks, and rails for electronic equipment and electrical components are manufactured. These components require excellent electrical conductivity and mechanical properties.
Aerospace
Used to manufacture various structural components such as airplane wings, fuselage structures, and engine parts. These components often have requirements for complex shapes, light weight and high strength.
Rail transportation
Applied to rail transportation systems, such as the manufacture of structural components, body frames, and seats for trains and subway cars. The use of lightweight materials contributes to transportation efficiency.
Energy
Manufacture of brackets for solar modules, structural components for wind power generation equipment, and heat sinks for various energy devices.
Why CYCO
Flexible Customization
We offer extensive material choices and customization services in various shapes and sizes. Whether your needs are simple or complex, we have the ability to provide you with a satisfactory solution.
Quality Assurance
We strictly follow international and domestic quality standards and certification systems, with strict quality control and inspection of every production process. Our products have been tested and verified many times to ensure that they meet the highest quality and safety standards.
Quick Response
We emphasize communication and cooperation with our customers, providing quick response and full service support. Our sales and technical team will answer your questions in time, provide professional advice and solutions to ensure your satisfaction.
Advanced Equipment and Technology
We adopt advanced squeeze casting equipment and technology, constantly updating and upgrading our production equipment to ensure the stability and efficiency of the production process. Meanwhile, we use computer simulation and optimization technology to improve the design accuracy and production quality of castings.
FAQs
1. How to solve porosity and inclusions in castings?
This may be caused by the fact that the molten metal contains gas or non-metallic inclusions that are not completely discharged.
To solve this problem, the following measures can be taken. Optimize the melting process to reduce the generation of gas and inclusions. Improve the design of the pouring system to increase the opportunity for gas and slag discharge. Appropriately increase the mold temperature and reduce the metal cooling rate.
2. What about deformation or cracking of castings during cooling and handling?
Caused by casting stress, improper heat treatment or mechanical processing.
Solutions include: reasonable design and manufacture of molds to reduce casting stress, optimize the heat treatment process, control the cooling rate and temperature to avoid internal stress and cracks.
3. How to fix the problem of unstable process parameters?
Stable process parameters are the key to ensure product quality. Through careful process planning and control, the stability of extrusion speed, temperature, pressure and other parameters is ensured. In addition, regular inspection and calibration of equipment and the use of automated control systems are also effective means of improving process stability.
4. Why does die wear occur in squeeze casting?
Die wear is usually caused by the friction between the metal and the die surface during the extrusion process and high temperatures. Selection of wear-resistant and high-temperature resistant mold materials, use of reasonable lubrication and cooling systems, and regular maintenance are all ways to slow down mold wear.