Converting from Steel Casting to Aluminum Squeeze Casting

Although steel castings come with high strength, they are heavy and therefore not very suitable for industries such as automotive and aerospace that focus on weight reduction. In contrast, aluminum squeeze casting applies high pressure during the solidification process, making the components lighter with similar strength compared to the steel casting version. This makes aluminum squeeze casting a suitable alternative to the traditional steel casting process.

Why Some Steel Casting Applications Need to Be Replaced

To better understand the growing transformation of aluminum squeeze casting, it is necessary to study why steel casting, although a long-standing choice in various industries, is increasingly being reconsidered in certain applications and replaced by more modern and efficient alternatives:

Heavy Weight

Steel is known for its high strength, but it comes with a higher density and therefore weighs more.

This additional weight brings challenges as minimizing part weight is important for optimizing performance and achieving design goals, especially for the automotive and aerospace industries.

Why Squeeze Casting Can Replace Steel Casting

Although aluminum squeeze casting cannot match steel casting in terms of strength, it comes with an advantage that makes it an attractive choice for various industries and applications:

Lightweight

Although aluminum comes with lower mechanical properties than steel, its weight is about three times lighter.

This weight reduction is crucial for industries such as automotive and aerospace, as reducing the total weight of components can significantly improve fuel efficiency and performance.

For applications where strength-to-weight ratio is more important than pure strength, aluminum squeeze casting comes with significant advantages.

The following is a comparison of commonly used materials and mechanical properties of aluminum squeeze casting and steel casting after the casting process:

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
Carbon Steel	Steel Casting	500	300	15-25	120-180
Low-Alloy Steel	Steel Casting	600	350	12-20	140-200
Stainless Steel	Steel Casting	650	350	10-20	150-220
High-Alloy Steel	Steel Casting	700	450	5-15	200-300

CEX Casting Successful Cases

At CEX Casting, we have successfully helped customers transition from traditional steel casting to aluminum squeeze casting.

The following examples show how this transformation can bring significant benefits and improvements to our customers:

Part Name: Steering Knuckle
Material: A356.2
Heat Treatment: T6
Benefits:
1. The product’s weight was reduced by 54%.
2. The product strength is similar to the steel casting version, meeting customer requirements.

Part Name: Connecting Parts
Material: A356.2
Heat Treatment: T6
Benefits:
1. The product’s weight was reduced by 67%.
2. The product strength is similar to the steel casting version, meeting customer requirements.

Part Name: Bracket
Material: A356.2
Heat Treatment: T6
Benefits:
1. The product’s weight was reduced by 54%.
2. The product strength is similar to the steel casting version, meeting customer requirements.

Part Name: Connecting Parts
Material: A356.2
Heat Treatment: T6
Benefits:
1. The product’s weight was reduced by 54%.
2. The product strength is similar to the steel casting version, meeting customer requirements.

Conclusion

The transition from steel casting to aluminum squeeze casting greatly reduces the parts’ weight while maintaining strength similar to the steel casting version, making aluminum squeeze casting an ideal choice for industries seeking lightweight solutions.

At CEX Casting, we are committed to helping customers seamlessly transition and ensure they achieve the best results through our advanced aluminum squeeze casting technology.

Contact us immediately to learn how we can help you upgrade your production process and meet your specific project needs.