MNIT Jaipur

Squeeze Casting combines the processes of Gravity Casting and Forging

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.

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 The press is then withdrawn and the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.

Casting : approx.

6000 years old, but

squeeze casting is a

relatively new

development.

Squeeze casting, also known as liquid metal forging,

is a combination of casting and forging process.

The molten metal is poured into the

bottom half of the pre-heated die.

After material goes into the mold,

the cylinder of the material tank

continues loading pressure, about

300 tons, until the end of the

casting cycle.

When the material in the mold

starts to cool down, it will begin

to shrink. The cylinder will

continue the loading pressure to

push more metal into the mold,

making the casting more solid

and with greater detail.

Bottom Die

Bottom Die

Upper die

casting

Property Attained Reason

BETTER MICROSTRUCTURE Applied pressure decreases the diffusion of the melt and the stable melt with better cooling gets a very fine grained structure

LESS CRACKS CHANCES The pressure on the melt reduces the chances of developing of crack due to loose solidification, and reduces the chances of fracture

SMOOTH FINISHING Molten metal touches the surface of the die and then the pressure applied makes the molten metal to be in contact with that of the surfaces perfectly, thus a smooth surface finishing is observed

FASTER COOLING RATE cooling rate is increased by applying high pressure during solidification, better contact between the casting and the die is improved by pressurization-results in the foundation of fine-grained structures.

POROSITY REDUCTION Because of the high pressure applied during solidification, porosities caused by both gas and shrinkage can be prevented or eliminated.

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

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.

Can be affected by premature chemical reaction, air entrapment and failure to fill the cavity resulting in reject components.

Squeeze casting is most suited to the production of light alloy components in large production quantities

Retractable and disposable cores can be used to create complex internal features

Both ferrous and non-ferrous materials can be produced using this method

Light alloy castings can be produced in complex 3D shapes which are stronger than plastic equivalents.

It has found extensive application in automotive industry in producing aluminium front steering knuckles, chassis frames,

Making of High capacity propellers for boat-engine.

PISTON, made by squeeze castingCar rim