Squeeze casting is a specialized form of metal casting that results in a superior product with increased strength and improved quality.
The numerous benefits of this process, such as optimized grain structure and improved mechanical properties, make it a popular choice for a variety of metalworking projects across several industries.
This form of casting is suitable for many different types of materials, including aluminum, magnesium, and zinc.
However, while it offers many advantages, it also has its drawbacks, which are important to know if you’re considering it for your custom-metal parts project.
In this guide, we will explore the pros and cons of squeeze casting in detail so that you can make an informed decision about whether or not it is the right choice for you.
Squeeze casting provides numerous advantages over traditional casting methods. Let’s go over the most important ones.
One of the most significant benefits of squeeze casting is its ability to produce near-net shape parts that require minimal to no machining after the casting has been completed.
Near-net shape production reduces time spent on post-casting processes and helps manufacturers and businesses save money and improve their bottom line.
By eliminating the need for additional machining work, post-casting cycle times are also reduced.
In other words, more parts can be made in less time.
Near-net shape production also improves surface finish quality. Keeping tight tolerances reduces porosity, which preserves the strength and longevity of the finished product.
To sum up, not only does near-net shape production that is the result of squeeze casting help produce high-quality components with minimal waste, but it also helps reduce post-production machining costs.
As a result, it enables companies to meet tight manufacturing deadlines.
Among the many advantages of squeeze casting, perhaps the least understood is its ability to create a fine microstructure by increasing the heat flow rate and cooling rate of the process.
A fine microstructure enhances the strength of the material
and improves the ductility of metal, so it can be formed or shaped without cracking or breaking.
The increased heat flow rate and cooling rate associated with squeeze casting result in the quick and uniform solidification of the liquid metal, creating a homogeneous microstructure.
The fine-grained structure produced by this process translates into improved mechanical properties such as strength, toughness, wear resistance, and fatigue life.
An added benefit of using squeeze casting to create a fine microstructure is the enhancement of corrosion resistance in metals.
The creation of a barrier against environmental factors such as moisture and chemicals means that the material can be used in harsh conditions that would otherwise cause rust or degradation.
Squeeze casting’s fine-microstructure capabilities provide superior strength, toughness, and fatigue resistance when compared to conventionally cast parts.
This means that this form of casting is valuable for a broad range of components used in industrial and automotive industries.
The ability of squeeze casting to reduce porosity in metal surfaces leads to higher mechanical properties in cast parts.
Porosity, or the presence of tiny holes and voids within a casting, can weaken a material’s mechanical properties and make it more susceptible to failure under stress.
By applying high pressure during the casting process, gaps are eliminated, thus producing denser and stronger castings.
Additionally, high-pressure casting helps increase fatigue failure resistance.
Fatigue failure resistance is the ability of a material to withstand repeated loading and unloading cycles without undergoing any permanent deformation or fracture.
The components produced through squeeze casting are capable of withstanding higher loads, which makes this method an attractive option for a variety of industries.
The automotive industry prizes squeeze casting for its ability to improve performance in applications such as engine blocks, pistons, and gears.
The squeeze casting process is an effective way to improve the mechanical properties of metals and alloys.
By providing these advantages, more efficient products that reduce cost and increase the efficiency of production can be achieved.
One of the most notable characteristics of squeeze casting is its ability to produce a great surface finish that requires little to no post-casting work.
Less post-casting requirements help businesses reduce their manufacturing costs.
The combination of heat and pressure used in squeeze casting creates a perfect cast with minimal porosity, allowing for an excellent surface finish that seldom needs any additional processing.
As many applications require a smooth surface finish, squeeze casting can be a useful and inexpensive tool for various industries.
It provides a perfect surface for their components, without the added costs associated with post-production machining.
One industry that requires such a finish for its applications is the aerospace industry.
Aircraft components such as engine parts, landing gear, and fuel systems require a smooth surface finish to operate efficiently with less wear and tear over time.
Another industry where a smooth and durable surface finish is critical is medical device manufacturing.
Implants, surgical instruments, and other medical components require precise dimensions and smooth surfaces to prevent infection or irritation during use.
In short, squeeze casting is ideal for manufacturers who wish to achieve a near-perfect surface in the most economical way possible.
The squeeze casting process produces little to no scrap. During the process the metal being cast is forced into every crevice of the mold, leaving very little excess material behind.
This is unlike other manufacturing processes, which leave behind significant amounts of scrap.
Of course, the more scrap that is produced, the more resources (time, money, and materials) are wasted.
By making the most of material resources, manufacturers can increase productivity, reduce waste, and ultimately boost profitability for themselves and their customers.
Additionally, by using squeeze casting instead of other manufacturing methods that produce high scrap rates, manufacturers can minimize defects and thus achieve higher yields and cost savings.
As was mentioned earlier, the high-pressure method employed during squeeze casting ensures that the molten metal fills every cavity in the mold.
This results in fewer defects—and higher material utilization.
In other words, manufacturers can produce more usable parts per batch while minimizing their scrap rates and reducing waste.
Since there are fewer defects with squeeze cast products, they require less machining or finishing after production, further decreasing waste and costs.
Squeeze casting reduces material loss and increases material utilization, which ultimately equates to more cost savings in the long run.
All in all, squeeze casting is a smart choice for companies looking to reduce their production costs while maintaining the good quality of metal parts.
Although squeeze casting is known for the many advantages it provides manufacturers and businesses looking to produce custom metal castings, there are also some drawbacks to the process.
They should be taken into consideration before deciding on whether to use the process for a particular project or not.
The following are three of the most common disadvantages of using this particular casting method.
The high investment cost associated with squeeze casting can be a major deterrent for manufacturers and businesses looking for custom metal parts.
The equipment required for squeeze casting is expensive, making it somewhat difficult for smaller manufacturers to adopt this process.
A high upfront investment cost can lead to higher prices for customers and decreased profit margins for manufacturers.
In addition, the specialized nature of the equipment needed for squeeze casting can make it difficult to find and pay skilled workers to operate and maintain the equipment.
The demand for squeeze casting machines is on the rise, and the US Squeeze Casting Machine market is predicted to expand to $ 207.35 million by 2025.
This is due to the increased demand for lightweight and high-strength metal components in the aerospace and automotive industries.
Nevertheless, the high investment cost associated with squeeze casting remains a challenge for manufacturers and businesses in these industries.
Still, even with the cost challenges associated with squeeze casting, many manufacturers and businesses continue to invest in this process due to the superior mechanical properties and dimensional accuracy it provides.
The high-quality and precise metal parts produced by squeeze casting can help manufacturers differentiate themselves from competitors and provide added value to customers.
Therefore, although squeeze casting may require a high investment cost, the benefits of this process still outweigh the initial expense.
Businesses looking for high-quality, dense, and intricate metal parts may find that squeeze casting is still the most suitable manufacturing process for their needs, albeit a sometimes expensive one.
Yet another major limitation of squeeze casting relates to how its equipment is used.
Unlike other casting processes, such as sand casting, which can produce a wide range of part sizes and shapes, squeeze casting is limited to producing parts that fit within the confines of its equipment.
The tooling used for squeeze casting must be precisely designed and fabricated to accommodate the part being produced.
This can be time-consuming and costly.
Another limitation of squeeze-casting equipment is that it requires a high degree of precision.
This is because the process relies on a hydraulic press to apply pressure to the molten metal during the solidification period.
Any misalignment or inconsistency in the equipment can result in defects in the finished part.
Therefore, to ensure consistent quality, squeeze casting equipment must be regularly maintained and calibrated.
Additionally, the specialized nature of squeeze casting equipment means that it is typically only used for high-volume production runs of parts that require the unique properties offered by squeeze casting.
Still, there are certain applications that are well-suited for squeeze casting and the equipment it employs.
Some of these include:
The above parts require high strength, tight tolerances, and fatigue resistance that can be achieved through the squeeze casting process.
Another drawback to using squeeze casting is that it requires strict control of several variables, such as temperature, pressure, and mold design.
This level of control is necessary to ensure that the metal solidifies uniformly, and to avoid defects such as porosity, shrinkage, and cracks.
As a result of strict control, squeeze casting requires a high level of expertise and specialized equipment, both of which can be costly for manufacturers and their customers.
Moreover, strict control requirements tend to slow down the time it takes to produce a single part.
During squeeze casting, the mold must be heated to a specific temperature, the metal must be injected and solidified under pressure, and the part must cool before it can be removed from the mold.
A slower cycle time can result in longer lead times, especially for components that require large production volumes or have tight deadlines.
To sum up, while there is no doubt that squeeze casting is an excellent metalworking choice for producing high-quality metal parts, it requires lots of control measures to achieve these results.
Ultimately, this can increase costs, limit production flexibility, and slow down production rates.
Squeeze casting is an efficient and precise manufacturing process that produces well-designed metal parts with exceptional mechanical properties, good surface finishes, and low porosity rates.
However, as with all manufacturing processes, it too has some drawbacks, most notably higher equipment costs, longer cycle times, and the need for specialized equipment and skilled operators to make it work.
To better help sift through the pros and cons of this outstanding casting process, it is a good idea to contact an experienced metal parts manufacturer for valuable insights into the feasibility of squeeze casting for your particular project.
From a contract manufacturing firm, BuntyLLC evolved into a full service custom machined, forged and cast metal parts fabrication enterprise. We supply global solutions from our headquarters in Greenville, South Carolina.
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