What structural components are suitable for squeeze casting molds

What structural components are suitable for squeeze casting molds
Squeeze casting uses high pressure and low speed filling of 50-100MPa, which is suitable for thick walled structural parts with high density requirements, while thin-walled parts are not cost-effective.
Process characteristics
The filling speed of squeeze casting is low, and the metal liquid is filled in a laminar flow manner with less gas entrainment.
Solidification is carried out under high pressure, and shrinkage is compressed to achieve a density close to that of the forging.
The pressure is usually 50-100MPa, which is one order of magnitude higher than low-pressure casting, and the requirements for molds and equipment are higher.
Suitable part type
Thick walled and relatively simple shaped parts are most suitable, such as brake calipers, steering knuckle blanks, and load-bearing brackets.
High uniformity of wall thickness is required. The wall thickness difference is too large, and thin areas are prone to cracking under high pressure.
Not suitable for complex internal cavities. Sand cores are prone to collapse or fracture under high pressure.
Key points of mold structure
The mold should have sufficient rigidity. Under high pressure, template deformation can directly lead to wall thickness deviation.
The parting surface should be able to withstand high pressure. If the gap exceeds 0.03mm, flying edges will occur.
The top institutions must be strong. The friction between the casting and the mold cavity is high under high pressure, and the pushing force needs to be correspondingly increased.
Comparison with low-pressure casting
Density: Squeeze casting provides higher density and is suitable for safety components.
Cost: The equipment and mold investment for squeeze casting are higher, and the cost per piece is also higher.
Efficiency: The pace of squeeze casting is slow, suitable for small and medium-sized batches.
Mold maintenance for squeeze casting
Under high-pressure conditions, the fatigue crack propagation in the cavity is fast. It is recommended to conduct a surface inspection every 3000 molds and immediately grind any 0.2mm cracks found.
The wear of the ejector system is also faster than that of the low-pressure mold, and it is recommended to configure the ejector pin and guide sleeve with 1.5 times the spare parts.
Applicability verification
The first piece should undergo density testing and X-ray to confirm the shrinkage effect under high pressure.
Practical tips
The release agent for squeeze casting should be sprayed evenly. Local leakage can cause sticking to the mold and easily strain the mold cavity during cleaning.
The preheating temperature of extrusion casting molds should be higher than that of low-pressure molds, usually set at 250-300 ℃, to reduce thermal shock.
The gate design of squeeze casting should be short and thick, and a long process can cause the molten metal to solidify prematurely under high pressure.
Frequently Asked Questions
The first issue is mold cracking. The stress concentration area of the mold under high pressure is prone to cracking, and the rounded corners and transitions should be sufficient.
The second is adhesive molding. Under high pressure, the casting is tightly attached to the mold cavity, and the demolding slope needs to be larger than that of low pressure casting.
The third is dimensional accuracy. The elastic deformation of the mold under high pressure is large, and deformation compensation is needed.
The method of Xinfeng Mold
Xinfeng Mold mainly uses low pressure, gravity, and differential pressure on structural component molds, and extrusion casting projects will be evaluated according to customer equipment conditions.
The evaluation focuses on the rigidity of the mold, the ejector structure, and the cooling scheme, which determine whether stable production can be achieved.
Applicability assessment
For safety components with an annual output of less than 50000 pieces and high density requirements, extrusion casting can be evaluated.
For parts with large annual output and complex shapes, low-pressure sand cores are more suitable.
It is not recommended to use squeeze casting for thin-walled parts, as there is a high risk of mold filling and cracking.
Frequently Asked Questions
Question: What is the pressure for squeeze casting?
Answer: It is usually 50-100MPa, which is one level higher than the low pressure.
Question: What item is suitable?
Answer: Thick walled and simple shaped safety components.
Q: Can complex cavities be made?
Answer: Not suitable, the sand core is vulnerable to high pressure.
Q: Do we need to strengthen the mold specifically?
Answer: Insufficient rigidity will directly lead to wall thickness deviation.
Q: How much more expensive is it compared to low-pressure casting?
Answer: The investment in equipment and molds is higher, and the cost per unit is also higher.
Q: Can thin-walled components be used?
Answer: Not recommended, there is a high risk of filling and cracking.
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