Process Overview
Squeeze casting occupies a unique position in the manufacturing landscape: it delivers the design freedom of casting with mechanical properties that rival forging. The process works by pouring a precise volume of molten metal into an open die, then applying 50–200 MPa of hydraulic pressure throughout the entire solidification phase. This sustained pressure eliminates gas porosity, closes shrinkage voids, and refines the grain structure — the same mechanisms that make forgings strong. The resulting microstructure is dense, uniform, and fully heat-treatable to T6, achieving yield strengths of 280–350 MPa in aluminum alloys. For brake calipers, steering knuckles, and aerospace brackets where a casting failure is not acceptable, squeeze casting is the answer. Our engineering team evaluates every squeeze casting drawing for die fill balance and pressure distribution before production.
Key Advantages
- Near-zero porosity — density and mechanical properties approach closed-die forging
- T6 heat treatment achievable — yield strength 280–350 MPa in aluminum alloys
- CT5–CT6 dimensional tolerance — tight enough to reduce or eliminate finish machining
- Complex shapes achievable that cannot be forged — eliminates assembly and welding
- Excellent surface finish Ra 1.6–3.2μm directly from die
- High material utilization — minimal flash, scrap rate typically under 1.5%
Technical Specifications
Process Flow
Step-by-step overview of our Squeeze Casting workflow — from raw material to finished casting.
Typical Applications
Compatible Materials
Full Technical Specifications
Comprehensive process parameters for Squeeze Casting — based on ISO 8062 / GB/T 6414 standards.
| Parameter | Value / Range | Notes |
|---|---|---|
| Tolerance Grade (ISO 8062) | CT5 – CT6 | Tight tolerances reduce finish machining |
| Dimensional Tolerance | ±0.2 mm – ±0.4 mm | Depends on part geometry and alloy |
| Surface Roughness (Ra) | 1.6 – 3.2 μm | Directly from die; excellent as-cast finish |
| Minimum Wall Thickness | 2.5 mm | Pressure-assisted fill enables thin sections |
| Typical Weight Range | 0.1 kg – 30 kg | Heavier parts on request |
| Typical Materials | A356, A380 Al, Magnesium alloys, Copper alloys, Steel | All heat-treatable alloys supported |
| Typical Applications | Brake calipers, steering knuckles, control arms, aerospace brackets | Safety-critical structural parts |
| Applied Pressure | 50 – 200 MPa | Sustained throughout solidification |
| Porosity Level | Near-zero (≤ 0.1%) | Density approaches closed-die forging |
| Heat Treatment | T6 (solution + artificial aging) | Yield strength 280–350 MPa in Al alloys |
| NDT / Inspection | X-ray, CMM, tensile test, hardness test | Full mechanical property report available |
| Lead Time (production) | 25 – 40 working days | After tooling approval |
* All values are indicative. Actual achievable parameters depend on part geometry, alloy, and tooling design. Contact our engineers for drawing-specific assessment.