ALUYONIX Precision Die Casting
CASTING PROCESS METHODOLOGY

Squeeze Casting

Hybrid casting-forging technology delivering zero-porosity near-net-shape metallurgy.

Process Metallurgy & Overview

Squeeze casting combines the near-net-shape geometry of die casting with the metallurgical integrity of closed-die forging. Molten metal solidifies under massive, direct hydrostatic pressure (50 to 150 MPa) applied throughout the solidification window.

Working Principle & Operational Steps

1Accurate molten metal dose poured without turbulence into a heated bottom die.
2Upper hydraulic punch descends, forcing metal into every contour under slow, uniform velocity.
3Enormous pressure is held during the phase transformation from liquid to solid, forcing molten feed into dendrite gaps.
4Resulting microstructure has zero micro-porosity and grain refinement matching forged components.

Technical Parameter Specifications

Clamping Force
350T – 1,800 Tonnes (Direct Squeeze Press)
Wall Thickness
4.0 mm – 50.0 mm
As-Cast Tolerance
±0.05 mm to ±0.20 mm
Cycle Rate
12 – 25 shots/hr
Surface Finish
Ra 1.6 – 3.2 µm
Primary Alloys
Aluminium A356, Al-Cu 2024

Ideal Applications

  • Heavy-duty diesel engine pistons and connecting rods
  • Aircraft structural brackets and missile control fins
  • High-performance brake master pistons
  • Armored vehicle suspension control arms

Key Advantages

  • Completely eliminates gas and shrinkage micro-porosity (100% density)
  • Mechanical tensile and yield properties identical to hot-forged aluminium
  • Near-zero machining allowance required on complex exterior contours
  • Can incorporate ceramic fiber preforms to produce metal-matrix composites (MMC)

Engineering Trade-offs

  • Tooling geometry must allow high-pressure punch retraction
  • Higher machine tonnage requirement per projected square centimeter

Evaluate Feasibility for Your Part in Squeeze Casting

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