What Are the Pros and Cons of Aluminum Alloy Squeeze Casting

When you inspect a casting part manufactured by CEX Casting, the precision and quality are immediately apparent.

This level of craftsmanship is achieved through our refined aluminum squeeze casting process, which we consistently apply to ensure top-tier results.

Squeeze casting, a refined form of traditional die casting, offers several advantages but also some challenges. The main advantages include excellent mechanical properties and a high-quality surface finish due to minimal gas entrapment and rapid solidification. Conversely, the process requires high initial setup costs and complex machinery, making it less economical for small production runs.

To gain a deeper understanding of squeeze casting technology, it is necessary to recognize its impressive advantages and practical limitations.

At CEX Casting, we have improved this method to avoid common defects in traditional casting, establishing new standards in the industry.

Advantages

Aluminum squeeze casting process is characterized by the following advantages which make it the first choice for producing high quality components.

Reduced Porosity

Squeeze casting can minimize gas entrapment and shrinkage during solidification.

As a result, the porosity in the castings is significantly reduced.

Lower porosity can improve the structural integrity and reliability of the components.

At CEX Casting, we conducted the pore rate testing and achieved excellent results.

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Superior Mechanical Properties

Squeeze casting is a process that applies high pressure to the molten aluminum during solidification.

This results in denser and stronger components.

The mechanical properties of the castings are significantly improved, such as tensile strength, yield strength, and hardness.

At CEX Casting, we are proud of our aluminum squeeze casting parts with excellent mechanical properties.

Check our tested values with different aluminum alloys.

High-Quality Surface Finish

The application of pressure can ensure that the molten aluminum fills the mould completely.

As a result, the parts come with smooth surfaces and fine details.

This will reduce the need for additional finishing processes and enhance the aesthetic appeal of the final product.

Production of Complex Shapes

Squeeze casting can create intricate and complex shapes that are difficult to obtain by traditional casting methods.

This capability enables the production of components with complicated geometries in a single piece, reducing assembly time and improving overall efficiency.

Improved Thermal Conductivity

The dense structure obtained from squeeze casting can enhance the thermal conductivity of aluminum parts.

This makes it particularly suitable for applications requiring efficient heat dissipation, such as in the automotive and electronic industries.

Enhanced Material Utilization

The precision of squeeze casting can reduce material waste, making it a more efficient and cost-effective method for producing aluminum components.

This leads to better utilization of raw materials and reduced production costs.

Consistency and Repeatability

Squeeze casting provides a high degree of process control.

It can ensure consistent quality and repeatability of the cast components.

This is crucial for industries that demand high product reliability and uniformity, such as the automotive industry.

Versatility in Alloy Selection

Squeeze casting can accommodate a wide range of aluminum alloys, allowing for the selection of the most appropriate material according to the specific requirements of the application.

This flexibility enhances the overall performance and suitability of the final product.

Improved Corrosion Resistance

The dense and defect-free microstructure produced by squeeze casting can provide better corrosion resistance in aluminum components.

This is particularly beneficial for applications exposed to harsh environments, such as marine and fluid control industries.

Lower Internal Stresses

The controlled solidification process in squeeze casting can lower internal stresses within the cast components.

This can reduce the likelihood of warping and distortion, leading to more stable and accurate parts.

Reduced Machining Requirements

Due to the high dimensional accuracy and superior surface finish achieved in squeeze casting, the need for extensive post-casting machining is minimized.

This not only saves time but also reduces manufacturing costs.

Reduced Scrap Rates

The precision and control in the squeeze casting process lead to lower scrap rates compared to traditional casting methods.

This improves the overall production efficiency and cost-effectiveness.

Shorter Production Cycles

Although the initial setup is complex, the actual casting cycle times can be relatively short, especially for high-volume production.

This efficiency can lead to shorter lead times for large orders.

Disadvantages

While the aluminum squeeze casting process offers various benefits, it also comes with some disadvantages that should be considered.

High Initial Investment

The equipment and tooling required for squeeze casting are complicated and expensive.

These high upfront costs can be a significant barrier for small and medium-sized enterprises to adopt the process.

At CEX Casting, thanks to our self-developed moulds, we are able to avoid intermediaries and control upfront costs as much as possible for our customers.

High Operational Costs

Ongoing operating costs, including maintenance of complex equipment and the need for skilled labour, can be higher than the cost of those simpler casting methods.

This may affect the overall cost-effectiveness of certain production volumes.

Complexity in Setup

Setting up the squeeze casting process involves precise control of various parameters, such as temperature, pressure, and mould design.

This complexity requires skilled operators and can lead to longer setup times than other casting methods.

CEX Casting has accumulated extensive manufacturing experience and has been a professional innovator in the industry, which makes us confident in keeping precise control of casting parameters.

Not Suitable for Very Thin Sections

The process is less effective for casting very thin sections, which can limit design flexibility for certain applications.

Thicker sections are required to fully benefit from the pressure applied during solidification.

At CEX Casting, thanks to our improved squeeze casting equipment, we can achieve a wall thickness range of 4mm-25mm for squeeze casting parts.

Not Suitable for Parts with Uneven Wall Thickness Variations

Parts with uneven wall thicknesses will cool at different rates, causing thermal gradients that can lead to internal shrinkage and cracks.

Inconsistent cooling will further affect the microstructure and mechanical properties of squeeze castings, which is not allowed by the casting technology.

CEX Casting has the ability of in-house mould design and making, and our patented squeeze casting technology can set special cooling methods for parts with wall thickness variations, ensuring consistent cooling rates as much as possible, thereby minimizing internal shrinkage and cracks.

Limited Size of Castings

The equipment used in squeeze casting often imposes size limitations on the parts that can be produced.

This makes it challenging to cast very large components.

At CEX Casting, by using our patented squeeze casting equipment, we can achieve a maximum casting size of 1.2m*0.8m.

Limited Material Options

CEX Casting adopts the indirect squeeze casting method, which requires the material to come with good fluidity and excellent mechanical properties, so there are not many types of materials to choose from.

Traditional ADC12 cannot be used, nor can recycled materials, as the impurity of recycled materials will affect the mechanical properties of castings.

Mould Wear and Tear

The high pressures used in squeeze casting can lead to faster wear and tear of moulds compared to lower-pressure casting methods.

This increases the frequency of mould maintenance and replacement, adding to the overall production cost.

Fortunately, at CEX Casting, customers only need to bear the initial mould cost, and we will be responsible for subsequent mould maintenance and updating, benefiting from our in-house mould design and making services.

Health and Safety Concerns

The high temperatures and pressures in squeeze casting bring much risk to health and safety.

It is very important to take proper safety measures and training to prevent accidents.

CEX Casting is an ISO 9001 and IATF 16949 certified manufacturer, which not only ensures reliable product quality but also standardizes operating procedures to ensure safe production.

Conclusion

Squeeze casting represents a significant advancement in aluminum alloy casting technology, offering various benefits to improve the quality and performance of the final product.

While this technique comes with a higher initial cost and requires a higher level of operational expertise, the advantages it offers, particularly in terms of mechanical properties and surface finish, make it a valuable process for producing high-performance aluminum castings.

At CEX Casting, we are proud to be able to improve and utilize this technology to meet the demanding needs of the global industry, contributing to the advancement of innovation in the industry.

Contact us now for more info about our squeeze casting process and cases.

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