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MNIT Jaipur

Casting : approx.
6000 years old, but
squeeze casting is a
relatively new
development.

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 The press is then withdrawn and the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.
Upper die

Bottom Die
casting

The molten metal is After material goes into the mold,


poured into the When the material in the mold
Bottom Die the cylinder of the material tank starts to cool down, it will begin
bottom half of the pre-
heated die. continues loading pressure, about to shrink. The cylinder will
300 tons, until the end of the continue the loading pressure to
casting cycle. push more metal into the mold,
making the casting more solid
and with greater detail.

Squeeze casting, also known as liquid metal forging,


is a combination of casting and forging process.
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
Car rim squeeze casting