Squeeze Casting for High‑Strength Structural Components
For engineering applications that demand high strength, pressure tightness, and structural integrity, traditional die casting may not always be sufficient. Porosity, gas entrapment, and lower mechanical properties can limit the use of conventional castings in safety‑critical or high‑load components.
Squeeze casting – also known as liquid forging – offers a solution.
What Is Squeeze Casting?
Squeeze casting is a hybrid manufacturing process that combines the near‑net‑shape capability of casting with the mechanical properties of forging. Molten aluminum is poured into a preheated die, and high pressure is applied during solidification and maintained until the part is fully solidified.
This process eliminates gas porosity, refines the grain structure, and produces castings with:
Minimal internal porosity (<1%)
Fine, uniform grain structure
High tensile strength and elongation
Excellent pressure tightness
Heat treatable to T5 or T6 condition
How Squeeze Casting Compares to Other Processes
Property
Conventional Die Casting
Squeeze Casting
Forging
Porosity | Moderate to high | Very low (<1%) | None |
Tensile strength | Moderate | High | Very high |
Design complexity | High | Moderate to high | Low |
Material utilization | Good | Very good | Moderate |
Tooling cost | Moderate | Moderate to high | High |
Production volume | High | Medium to high | Medium to high |
Ideal Applications for Squeeze Casting
Squeeze casting is particularly well‑suited for components that require:
High static and dynamic strength – Suspension arms, control arms, steering knuckles
Pressure tightness – Valve bodies, pump housings, hydraulic manifolds
Fatigue resistance – Structural brackets, engine mounts
Heat treatability – Components requiring T5 or T6 treatment
Industry
Typical Squeeze Cast Components
Automotive | Suspension arms, control arms, steering knuckles, engine mounts, shock absorber brackets |
Aerospace | Structural brackets, hydraulic housings, landing gear components |
Industrial | Pump housings, valve bodies, hydraulic manifold blocks |
Defense | High‑load structural components, weapon system housings |
Materials Available for Squeeze Casting
We offer squeeze casting in a range of aluminum alloys optimized for high‑strength applications:
Alloy
Characteristics
Typical Applications
A356 | Good castability, heat treatable, excellent strength | Structural brackets, suspension components |
A357 | Higher strength than A356, good fatigue resistance | Aerospace and defense components |
A206 | Very high strength, impact resistant | High‑load structural parts |
6061 | Weldable, corrosion resistant, heat treatable | General engineering components |
Our Squeeze Casting Capabilities
We operate in‑house squeeze casting equipment with the following specifications:
Clamping force: Up to [800 T / 1,000 T / your spec]
Maximum part weight: Up to [X kg]
Maximum part size: Up to [XXX x XXX mm]
Annual capacity: [X,XXX] tons
All squeeze castings are fully integrated with our in‑house CNC machining, heat treatment, and quality inspection services.
Quality Assurance for Structural Components
For structural applications, quality documentation is essential. We provide:
Mechanical property testing – Tensile strength, yield strength, elongation, hardness
Porosity inspection – X‑ray or C‑scan reports available
Dimensional inspection – CMM reports for critical features
Material certification – Mill certificates and alloy verification
Heat treatment records – Time‑temperature logs for T5/T6 processes
Why Choose Squeeze Casting for Your Project?
If your component requires:
Strength approaching that of a forging
Complex geometry that is difficult or expensive to forge
Pressure tightness for fluid or gas applications
Medium to high production volumes
Then squeeze casting may be the optimal manufacturing solution — offering near‑forged performance at a lower cost than forging.
Get a Technical Review
Engineers are invited to submit their part designs for a free squeeze casting feasibility analysis. Our team will review geometry, material requirements, and mechanical property targets to recommend the optimal process.