What is liquid forging?

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Process Introduction - What is liquid forging?

September 27, 2024

Liquid forging( Squeeze casting ) as liquid-metal forging, is a process by which molten metal solidifies under pressure within closed dies positioned between the plates of a hydraulic press.The applied pressure and instant contact of the molten metal with the die surface produce a rapid heat transfer condition that yields a pore-free fine-grain casting with mechanical properties approaching those of a wrought product. The squeeze casting process is easily automated to produce near-net to net shape high-quality components.


The material: A356; A356.2, AlSi9Mg; AlSi9Cu3, 319S, Al-Ti-Alloy; ZL104,ect.

Sizes avaliable: 3mm~10mm wall thickness;  

Weight: 100g~10kg noramlly

Largest length: 400mm. Some narrow sizes can be longer and thicker.

Note: above is for general situation and finally must be according to drawings.



>>Process Characteristic:

The liquid forging(squeeze casting) process, combining the advantages of the casting and forging processes, has been widely used to produce quality castings. Because of the high pressure applied during solidification, porosities caused by both gas and shrinkage can be prevented or eliminated. The cooling rate of the casting can be increased by applying high pressure during solidification, since that contact between the casting and the die is improved by pressurization, which results in the foundation of fine-grained structures.


>>The Advantages:

1) Good roughness like die casting & precision casting;

2) Parts with high-accuracy and tolerance like die casting & precision casting;

3) No more material costs and extra machining, much better than forging;

4) Can be T6 treatment, better than die casting, and like forging;

5) Parts with High Sealing Property as with almost no pores;

6) High mechanical property like forging, better than investment casting or sand casting;


>>Comparison between different processes: 

ItemsLiquid forging ForgingInvestment CastingHigh Pressure CastingLow Pressure Casting
SurfaceFineFineBadFineMedium
RoughnessRa3.2~1.6Ra3.2~1.6Ra6.3~3.2Ra3.2~1.6Ra6.3~3.2
InsideFine Grain & Compact microstructureFine Grain & Compact microstructureCoarse grain&Loosen microstructureInhomogeneous grain &Loosen microstructureCoarse grain&Loosen microstructure
Heat TreatmentT6T6T6Can't do T6T6
Structure LevelComplex StructureSimple StructureComplex StructureComplex StructureSimple Structure
Forming AccuracyHighMediumMediumHighLow
Extra MachiningMinorMoreMoreMinorMore
Production EfficiencyHighLowLowHighLow
Mechanical PropertiesSame or close to forgingHighestMediumLowLow


>>Mechanical property:

After T6, the mechanical property of squeeze casting parts could be very high.
Mechanical property comparison of the squeeze casting parts from different materials: 


Material
Lot#
Tensile Strength
Mpa
Yeild Strength
Mpa
Hardness
HB
Elongation
%
AlSi9Mg240160803
A356260180805
A356.2290220906
Al-Ti alloy3202601008
S3193402901108


>>Wide application:

With the current emphasis on reducing materials consumption through virtually net shape processing and the demand for higher-strength parts for weight savings, the emergence of squeeze casting as a production process has given materials and process engineers a new alternative to the traditional approaches of casting and forging. By pressurizing liquid metals while they solidify, near-net shapes can be achieved in sound, fully dense castings. 


Liquid forging(squeeze casting) is simple and economical, efficient in its use of raw material, and has excellent potential for automated operation at high rates of production. The process generates the highest mechanical properties attainable in a cast product. The microstructural refinement and integrity of squeeze cast products are desirable for many critical applications.


ApplicationParts 
Automobile Stressed PartsAutomobile Piston, Al-alloy or Almag wheel hub, Beam(cross beam), Knuckle, Lower arm, Brake caliper, Engine mounting, gearbox, Air compressor connectin rod
Pressure parts/Air tight PartsAir conditioning compressor turbine disk, Cylinder, Front and rear cover, Steering valve housing, Oil Pump, Manifold, Fuel distribution pipe, Brake block, Clutch cylinder
Wear resistance partsShift Fork, Pump Casing, Rocker arms, Caterpillar board, Air compressor piston and swashplate, Aluminum composite brake hub, 
Motorcycle Stressed partsAl-alloy or Almag wheel hub, Upper and lower connecting plate, Gearbox housing, Rear hanger, Crank, Frame body, Joint, Frame joint, Direction axis
Motorcycle pressure and wear partsAluminum piston, Shock absorber, Disc brake pump body
Electrical Parts/Power PartsDisk drive housing,Electrical spindle bushing, Electrical compression ring, Sonar shel, Hotplate, Computer parts, Rotors, Crimping clamp, Suspension Clamp, Parralle groove clamp
 New energy vehiclesElectric automobile parts, Hybrid Power automobile parts, Bumpers, Body shell, Body framing
Advanced fieldMilitary parts, Aerospace accessories, Aircraft Accessories, Optical frame shell, Medical equipments accessories, Fitness equipment accessories
OthersMarine Propellers, Pneumatic instrument housing,  Pressure cooker and cooker equipments parts, Furniture accessories, Valve body, Valve Accessories, Garden tool parts, Fan blades, ect. 




eric@slmetalparts.com

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