SQUEEZE CASTING

Muhammed Labeeb
 Squeeze casting
▪ Also known as liquid-metal forging
▪ Near net shape process - the initial production of the item is very close to the
final (net) shape, reducing the need for surface finishing
▪ Combination of casting and forging
▪ Squeeze casting is simple and economical, efficient in its use of raw material
▪ The process generates the highest mechanical properties attainable in a cast
product
▪ The process was introduced in the United States in 1960 and has since gained
widespread acceptance

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 Squeeze casting
▪ The squeeze casting process uses an accurately measured or metered quantity
of molten metal which is poured into a heated mould via a launder
▪ The mould is closed to produce an internal cavity in the shape of the required
component
▪ The mould is coated with a suitable release agent and for squeeze casting it is
usually in the form of a graphite coating
▪ Pressure continues to be applied to the molten metal until it has solidified and
forms the required component
▪ The press is then withdrawn and the component is ejected

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 Squeeze casting
▪ Non ferrous alloys like aluminum, magnesium, and copper alloy components are
readily manufactured using this process
▪ The squeeze casting process, combining the advantages of the casting and
forging processes, has been widely used to produce quality castings
▪ Because of the high pressure applied during solidification, porosities caused by
both gas and shrinkage can be prevented or eliminated
▪ The cooling rate of the casting can be increased by applying high pressure during
solidification, since that contact between the casting and the die is improved by
pressurization, which results in the foundation of fine-grained structures

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 Squeeze casting process

▪ Squeeze casting consists of

entering liquid metal into a
preheated, lubricated die and
forging the metal while it
solidifies

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 Squeeze casting process

▪ The load is applied shortly after

the metal begins to freeze and
is maintained until the entire
casting has solidified

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 Casting parameters
▪ Casting temperatures depend on the alloy and the part geometry. The starting
point is normally 6 to 55°C above the liquidus temperature.
▪ Tooling temperatures ranging from 190 to 315°C are normally used
▪ Pressure levels of 50 to 140 MPa are normally used
▪ Lubrication For aluminum, magnesium, and copper alloys, a good grade of
colloidal graphite spray lubricant has proved satisfactory when sprayed on the
warm dies prior to casting

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Advantages
▪ Offers a broader range of shapes and components than other manufacturing
methods
▪ Little or no machining required post casting process
▪ Low levels of porosity
▪ Good surface texture
▪ Fine micro-structures with higher strength components
▪ No waste material, 100% utilization
Disadvantages
▪ Costs are very high due to complex tooling
▪ No flexibility as tooling is dedicated to specific components
▪ Process needs to be accurately controlled which slows the cycle time down and
increases process costs.
▪ High costs mean high production volumes are necessary to justify equipment
investment
REFERENCES
▪ ASM Metals Hand Book, 9th edn, Vol 15, Casting, ASM, Metals Park, (1983)