The transition from aluminum machining to aluminum squeeze casting provides valuable opportunities to improve product quality, reduce production costs, and simplify the production process. Squeeze casting combines the advantages of casting and forging, producing parts with minimal porosity, high dimensional accuracy, and high strength. Traditional machining generates waste and requires more time, while squeeze casting is different as it can produce parts close to the near-net shape, reducing material loss and improving production efficiency.
Why Some Machining Applications Need to Be Replaced
For a long time, traditional machining methods such as milling and turning have been used to produce precision aluminum parts, but these methods come with limitations, making alternative methods such as squeeze casting more attractive:
Material Waste
Machining usually requires cutting off a large amount of aluminum, resulting in high material costs and increased waste.
This is particularly costly for complex parts, with material loss reaching up to 60-70%.
In contrast, squeeze casting can produce parts that are near-net shape, greatly reducing waste.
Time Consumption
Machining complex shapes takes a long time, and each cutting increases the production cycle.
Additional finishing, like polishing, will further extend production time. This slows down the delivery speed, increases costs, and makes it difficult to meet tight deadlines.
Why Squeeze Casting Can Replace Machining
Squeeze casting combines the advantages of precision casting and high-strength forging, making it a powerful alternative to traditional machining:
Material Efficiency
Squeeze casting can produce parts that are close to the near-net shape, minimizing material waste and the need for additional machining.
This makes it a more cost-effective option, especially when using expensive alloys.
Suitable for Large-Scale Production
Squeeze casting only requires one operation to quickly produce high-quality parts. This efficiency can reduce labor costs and shorten delivery times.
In addition, squeeze casting can ensure consistency of all production components and maintain a unified specification that is crucial for large-scale production.
Cost Reduction
Squeeze casting can lower production costs by reducing material waste and the need for further machining.
It also shortens production times, making it a cost-efficient choice for large-scale manufacturing.
Design Flexibility
Squeeze casting makes it easier to produce products with complex shapes that are challenging for mechanical processes.
This allows for more optimized designs in industries where reducing weight and improving strength are critical.
The following is a comparison table of commonly used materials for aluminum machining and squeeze casting, including their mechanical properties after processing:
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
|
5052
|
Machining |
230 |
195 |
10-16 |
60-80 |
6061 |
Machining |
310 |
275 |
10-17 |
85-95
|
CEX Casting Successful Cases
At CEX Casting, we have successfully helped our customers replace traditional machining with squeeze casting technology, producing complex-shaped and high-strength aluminum components.
After switching to squeeze casting technology, they exhibited similar mechanical properties and improved efficiency, resulting in significant benefits. Here is a typical example:
Part Name: Hydraulic Manifold Block
Material: A356
Heat Treatment: T6
Benefits:
1. Reducing the processing time required for internal channels and reducing material loss by 25%.
2. Maintaining mechanical strength and hardness similar to the machined version, while benefiting from the near-net shape of squeeze casting.
Conclusion
The transition from aluminum processing to aluminum extrusion casting has significant advantages in terms of strength, efficiency, and cost savings.
Squeezing casting can produce lighter and stronger components with less waste and shorter production time, making it the best choice for companies looking to improve manufacturing processes and product quality.
At CEX Casting, our expertise and advanced technology ensure high-quality customized solutions for the most demanding applications.
Whether your goal is to improve component performance or reduce costs, our team can guide you through a smooth transition to squeeze casting.
Contact us immediately to learn how we can support your next project.