Squeeze casting, also referred to as liquid die forging or a low-speed, high-pressure process, is a manufacturing technique combining casting and forging. It involves alloy filling a mold, solidifying, and undergoing plastic deformation under high pressure, aiming to produce workpieces with precise internal structures, high surface finish, excellent mechanical properties, fine dimensions, clear contours, and fine grains. Primarily used to replace cast iron parts, it is widely applied in structural and load-bearing components of automobiles, especially new energy vehicles (NEVs). Its defining features are low-speed filling and high-pressure shrinkage compensation during solidification.
Die casting is a metal casting process characterized by applying high pressure via a mold cavity. This text focuses on high-pressure die casting, excluding low-pressure and counter-pressure die casting.
Both squeeze casting and high-pressure die casting offer significantly higher production efficiency than forging, enabling mass production with relatively low overall costs and the capability to produce complex components.
The rapid growth of NEVs underscores the ongoing adoption of the "aluminum-for-steel, casting-for-forging" philosophy. Steel castings, being heavy and environmentally unfriendly, are destined for phase-out. To replace these load-bearing steel components safely, aluminum castings must match the mechanical properties of steel. However, high-pressure die castings, formed via high-speed, high-pressure processes, inherently suffer from coarse grains and defects (e.g., porosity, shrinkage cavities). Forging, though mechanically superior, remains less favored due to high costs and low efficiency. Squeeze casting, merging casting’s efficiency, low cost, and scalability with forging’s mechanical performance, is a key direction for integrated, structured component development.
For high-pressure die casting, beyond squeeze casting’s application areas, its products can broadly replace steel castings. Tesla’s integrated die-casting concept has become an industry target, with super-large machines from L.K. Group, Yizumi, and Haitian continually setting records. Die casting is poised to advance toward higher performance and complexity.
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