Metal casting is crucial for the production of custom metal parts.
Of the many casting methods used today, two of the most popular are squeeze casting and high-pressure die casting.
For businesses that require custom metal parts, understanding the differences between these two techniques is essential for making an informed decision about which process to use.
Both processes produce high-quality metal parts efficiently and cost-effectively. However, there are significant differences between them that can impact their suitability for specific applications.
In the following sections, we will explore the key differences between squeeze casting and high-pressure die casting, the advantages and disadvantages of each method, and the applications and industries where each process is commonly used.
By the end of this guide, you will have a better understanding of the two processes, and have a better idea of which one would be best suited for your specific manufacturing needs.
Squeeze casting (or liquid metal forging) is a casting process that combines the benefits of both casting and forging.
It is a manufacturing process where molten metal is injected into a die cavity and then subjected to high pressure to fill the cavity completely.
The process of squeeze casting involves several steps.
They include the preparation of the mold, melting the metal, injecting the molten metal into the mold, and applying pressure to solidify the metal.
Here are the steps in more detail.
| Preparation | The mold, made of two halves with the cavity shaped to the desired part, is preheated to a specified temperature to ensure proper metal flow and solidification. |
| Melting | The metal is melted in a furnace and brought to a temperature that is slightly above the pouring temperature, which ensures good flow. |
| Pouring | The molten metal is poured into the mold, filling the cavity until it takes on its shape. |
| Squeeze | Once the mold is filled with metal, a high-pressure squeeze is applied to the molten metal to ensure the mold cavity is completely filled. eliminating any voids or porosity. During this step, the pressure is maintained until the metal solidifies. |
| Cooling/Ejection | After solidifying, the mold is cooled and the part is ejected from the mold. |
Squeeze casting offers several benefits over other casting processes, including improved mechanical properties, reduced porosity, and better surface finish.
It is particularly suitable for casting high-strength alloys and complex parts with thin walls. Because of this, it is widely used in a variety of industries.
High-pressure die casting (HPDC) is a manufacturing process used to produce complex metal parts with high accuracy and repeatability.
It is a popular manufacturing method for creating aluminum, magnesium, and zinc parts with intricate geometries and high strength-to-weight ratios.
This process involves forcing molten metal into a die cavity under high pressure and then allowing it to solidify under controlled conditions.
The entire process involves several steps, which are described below.
| Preparation | The die is prepared by being coated with a lubricant to ensure that the metal does not stick to the surface. It is then closed and clamped shut. |
| Injection | Molten metal is injected into the die cavity through a sprue or gate at high speed and pressure. The metal fills the cavity and solidifies quickly due to the cooling effect of the die. |
| Ejection | Once the metal has solidified, the die is opened and the part is ejected. Ejector pins are used to push the part out of the die. |
| Trimming/Finishing | The part is then trimmed to remove any excess metal or flash that may have formed during the casting process. Any necessary finishing work, such as grinding or polishing, is also done at this stage. |
There are many advantages to using high-pressure die casting to produce metal parts.
For one, it allows for the production of complex shapes with high accuracy and repeatability.
Secondly, it is a relatively fast process—typical cycle times range from a few seconds to a few minutes.
Finally, it is ideal for producing parts that require thin walls and tight tolerances.
Overall, high-pressure die casting is a versatile and efficient manufacturing process.
It is used to produce a wide range of metal parts for industries ranging from automotive and aerospace, to consumer electronics.
The major differences between squeeze casting and high-pressure die casting can best be explained through the advantages and disadvantages of each process.
Here’s what they are.
One of the main advantages of squeeze casting is its ability to produce parts with a high level of dimensional accuracy and surface finish.
The process is an excellent choice for manufacturing components that require complex geometries, especially in the automotive industry.
Squeeze casting also offers a high degree of control over the casting process, which allows for tighter tolerances and less material waste.
Reducing material waste during the manufacturing process helps companies save money while protecting the environment at the same time.
The higher strength-to-weight ratios that are created through squeeze casting also help produce parts that are strong enough to withstand extreme conditions.
At the same time, such parts are lightweight enough to support applications commonly found in the automotive and aerospace industries.
One of the biggest drawbacks to squeeze casting is that it requires a high initial investment in equipment and tooling.
High upfront costs are not ideal for small production runs.
Due to the very specific tooling and equipment needed, there is little to no design flexibility when using it.
Because the metal is poured into a predetermined mold shape and then compressed under pressure, there are limits to how complex or intricate the designs can be.
These two disadvantages put a strict limitation on what types of components and applications squeeze casting can be used for.
A great advantage of high-pressure die casting is its ability to produce high volumes of identical metal components with high levels of accuracy.
This is particularly important for industries that require precision parts.
Through high volume and high accuracy production runs, manufacturers can produce large quantities of components that are consistent in terms of size, shape, and quality.
Another advantage of high-pressure die casting is that it is cost-effective.
Add to this the fact that the process requires minimal finishing, and the overall production costs drop even further.
High-pressure die casting is also fast—faster than most custom casting methods.
In HPDC, the molten metal solidifies in a matter of seconds—sometimes milliseconds.
These short casting cycles offer manufacturers the ability to quickly produce large quantities of components, which helps them meet production deadlines.
Like squeeze casting, high-pressure die casting has a high initial cost of equipment and tooling.
The molds used in high-pressure die casting must also be durable enough to withstand the high pressure and temperatures the method employs.
This also adds to the overall cost.
Another major disadvantage of this casting method is that it is not suitable for all types of metals.
High-pressure die casting is typically used for metals with low melting points, such as aluminum, zinc, and magnesium.
This means that metals with high melting points cannot be used when employing HPDC.
Finally, the high pressure used in this casting process can also result in porosity, which weakens the structure of the castings.
Porosity occurs when the molten metal does not completely fill the mold, thus leaving air pockets in the castings.
In short, both squeeze casting and high-pressure die casting offer unique advantages and disadvantages depending on the specific application and desired outcome.
Ultimately, squeeze casting is better suited for producing small batches of complex and high-quality parts.
Conversely, high-pressure die casting is a more efficient and cost-effective method for producing large quantities of parts with simple geometries.
Squeeze casting is commonly utilized in the automotive industry to produce a broad range of metal components ranging from engine blocks to steering knuckles.
Of course, squeeze casting is not limited to the automotive industry. It is frequently used in the aerospace, defense, medical, and consumer goods industries as well.
A breakdown of the industries that use squeeze casting and the various applications they use it for is given below.
Squeeze casting is widely used in the automotive industry to produce engine components such as connecting rods, pistons, and cylinder heads.
The global metal casting market is projected to reach USD 39.94 billion by 2025, with squeeze casting demand within the automotive industry being one of the main drivers of this growth.
The aerospace industry uses squeeze casting to manufacture components such as turbine blades, engine housings, and structural parts.
The high strength and toughness of squeeze-cast components make them ideal for this demanding environment.
Squeeze casting is used in the defense industry to produce components for military vehicles and equipment, including armor plating, gun barrels, and missile parts.
The ability to produce complex and intricate shapes makes squeeze casting a popular choice for defense applications.
The medical industry uses squeeze casting to produce implantable medical devices like hip and knee replacements.
The high accuracy and precision of the squeeze casting process ensure that these components meet the strict quality standards required for medical applications.
Squeeze casting is used to produce high-quality, durable consumer goods such as cookware, sporting goods, and jewelry.
Moreover, the ability of squeeze casting to produce complex shapes with high accuracy and consistency makes it a popular choice for household applications.
Squeeze casting should be used for the production of high-quality, dense, and uniform custom metal parts with complex shapes and high strength-to-weight ratios.
High-pressure die casting has found many applications in industries like the automotive, aerospace, and telecommunications, among others.
A more comprehensive description of HPDC applications and the industries they serve is provided in the following sections.
High-pressure die casting is widely used in the automotive industry to produce parts such as engine blocks, transmission housings, and steering components.
According to a report by Research And Markets, the global high-pressure die-casting market is expected to experience a CAGR of 6.36% between 2020-2025.
What drives this growth is the increasing demand for lightweight vehicles.
The electrical industry uses HPDC to produce electrical components like electrical housings, connectors, and terminal blocks.
The high precision and consistent production runs of the HPDC process make it an ideal choice for the electrical industry.
High-pressure die casting is used to produce products such as kitchen appliances, furniture hardware, and lighting fixtures.
The ability of the HPDC process to produce complex shapes with high accuracy makes it a popular choice for the manufacturing of household appliances and fixtures.
The aerospace industry uses high-pressure die casting to fabricate a variety of aerospace components, including turbine blades, compressor components, and structural parts.
Since HPDC can produce high-quality parts with tight tolerances, it is an ideal choice for aerospace applications.
In the Medical Field
High-pressure die casting is used to manufacture medical devices such as orthopedic implants, dental implants, and surgical instruments.
The high precision and accuracy of the HPDC process can result in medical components with high strength and dimensional stability.
HPDC should be used when high-precision and complex metal parts with identical structures need to be manufactured quickly and cheaply on a massive scale.
Both squeeze casting and high-pressure die casting are used to produce high-quality metal parts for various industries.
Squeeze casting is best suited for applications that require high density and strength, while high-pressure die casting is better for producing parts with complex shapes and tight tolerances in large quantities.
Choosing between these two casting methods depends on the specific needs and requirements of the application.
Therefore, it is essential that you consult with a reputable metal parts manufacturer who can provide expert guidance in making this decision.
