Converting from Aluminum Die Casting to Aluminum Squeeze Casting

Aluminum die casting involves injecting molten aluminum into a mold cavity under high pressure. However, this method often faces challenges like porosity, lower mechanical strength, and inconsistent surface quality. In contrast, aluminum squeeze casting combines the benefits of casting and forging by applying high pressure during solidification, resulting in parts with higher density, strength, and precision.

Why Some Die Casting Applications Need to Be Replaced

However, it’s not always the best choice for applications that require superior mechanical properties, prompting many manufacturers to explore alternatives like squeeze casting. Here’s why:

Porosity Issues

During the injection process, trapped gases and rapid cooling often cause porosity in die castings, which weakens their structure.

This makes them unsuitable for applications requiring high strength and durability, such as automotive and aerospace parts, where safety and reliability are crucial.

Shrinkage Defects

Die casting’s rapid cooling can lead to shrinkage defects, creating inconsistent densities across the part.

This inconsistency can lead to weak spots, especially in applications that require high precision and dimensional accuracy.

Lower Mechanical Properties

Aluminum die casting parts may struggle to meet high tensile and yield strength standards.

For example, automotive components that endure continuous stress and strain require materials that can withstand high loads without deforming, which is a challenge for traditional die casting.

Inconsistent Surface Quality

The surfaces of die casting parts are often rough, requiring additional machining for a smooth finish. This increases production costs and time.

Squeeze casting can produce parts with smoother surfaces, reducing the need for extra processing.

Why Squeeze Casting Can Replace Die Casting

Squeeze casting, also known as liquid forging, applies direct pressure to molten aluminum as it solidifies.

Enhanced Mechanical Properties

The high pressure during squeeze casting leads to a denser microstructure, resulting in higher tensile strength, yield strength, and elongation.

This makes squeeze casting parts ideal for high-durability and wear-resistant applications.

Reduced Internal Defects

The squeeze casting process achieves excellent results by applying pressure during the metal cooling.

Castings come with fewer internal pores, higher overall density, and higher durability and reliability under mechanical stress.

The following table compares the typical materials used in aluminum die casting and aluminum squeeze casting, as well as their mechanical properties after casting:

Alloy Type	Process	Tensile Strength (MPa)	Yield Strength (MPa)	Elongation (%)	Hardness (HB)
A356	Squeeze Casting	300	175	6-10	75-90
A356.2	Squeeze Casting	320	190	7-12	80-95
A380	Squeeze Casting	330	180	2.5-4.5	90-100
A383	Squeeze Casting	320	160	2-4	85-95
AlSi9Mg	Squeeze Casting	340	200	5-8	85-100
AlSi10Mg	Squeeze Casting	350	210	4.5-7	90-105
AlSi9Cu3	Squeeze Casting	300	170	2.5-4	80-95
ADC12	Die Casting	250	150	1-3	70-90
A360	Die Casting	320	240	3-7	80-100
A413	Die Casting	270	160	2-4	70-90

CEX Casting Successful Cases

Since 1995, CEX Casting has focused on aluminum die casting.

Over time, we encountered challenges such as insufficient strength and porosity in our die-cast parts.

In response, we invested heavily in R&D, developing our patented squeeze casting technology.

This innovation has allowed us to replace traditional die casting, delivering higher-quality, better-performing aluminum squeeze casting parts. Below are some notable examples:

Part Name: Water Pump Connector
Material: A319
Heat Treatment: No Need
Benefits:
1. The product is internally free from pores, meeting high resistance and air-tightness requirements.
2. The entire surface is free from shrinkage holes, pits, dents, and scratches.

Part Name: Folding Parts
Material: A356.2
Heat Treatment: T6
Benefits:
1. The mechanical properties of castings meet customer requirements:
● Tensile Strength: 290MPa
● Yield Strength: 240MPa
● Hardness: 90Hb

Part Name: Medical Parts
Material: A356.2
Heat Treatment: T6
Benefits:
1. The mechanical properties of castings meet customer requirements:
● Tensile Strength: 300MPa
● Yield Strength: 260MPa
● Hardness: 90Hb

Part Name: Connecting Arm
Material: A356.2
Heat Treatment: T6
Benefits:
1. The mechanical properties of castings meet customer requirements:
● Tensile Strength: 290MPa
● Yield Strength: 240MPa
● Hardness: 90Hb

Part Name: Folding Parts
Material: A319S
Heat Treatment: T6
Benefits:
1. The product’s lifespan has doubled compared to the previous version.
2. The mechanical properties of castings meet customer requirements:
Tensile Strength: 310MPa
Yield Strength: 240MPa
Hardness: 95Hb

Part Name: Folding Parts
Material: A356
Heat Treatment: T6
Benefits:
1. The mechanical properties of castings meet customer requirements:
● Tensile Strength: 300MPa
● Yield Strength: 250MPa
● Hardness: 92Hb

Conclusion

Switching from aluminum die casting to aluminum squeeze casting offers numerous benefits, especially for industries that need high strength, reduced internal defects, and precision.

Squeeze casting addresses the limitations of die casting, providing denser, stronger, and more reliable aluminum parts.

With CEX Casting’s expertise, we can guide you through this transition and ensure superior quality for your products.