Comparing Metal Forming Processes: Die Casting vs Squeeze Casting vs Forging vs Stamping

Today we will briefly introduce the Die Casting, Squeeze Casting, Forging, Stamping and how to choose a suitable processing at the designing stage.

1.Die Casting

Die casting is a manufacturing process in which molten metal is forced under high pressure into the cavity of a precision metal mold. Under the pressure, the molten metal cools and solidifies to form the casting.

The molds are usually made of high strength alloys. The whole processing is similar to injection molding, or like kneading clay.

The equipment used for die casting is called a die casting machine. Depending on the die casting type, a cold chamber or hot chamber die casting machine is required. Die casting is mainly used for thick, complex shaped parts, such as the middle frame of a mobile phone.

The majority of die cast components are non-ferric, consisting of zinc, copper, aluminum, magnesium, lead, tin, lead-tin amalgams, and their metal blends.

Die Casting is an efficient and economic process for high volume production of metal parts with tight dimensional tolerances. The high pressure ensures the molten metal fills the mold cavity precisely.

The differences between die casting and traditional casting are:

• In die casting, the molten metal first enters a chamber and then it is injected into the mold under pressure, unlike regular gravity pouring. This makes the filling speed faster than regular gravity casting.
• There is an intensification and pressure maintaining process during die casting by applying pressure. This makes the internal density of the solidified metal better than traditional castings.

2.Squeeze Casting

Squeeze casting refers to a die casting method where high pressure is applied to the molten metal (or semi-solid slurry) in the die cavity to suppress dendrite growth and feed the shrinkage, in order to obtain high quality castings.

The advantages of squeeze cast products include:

• Almost no porosity or shrinkage defects
• High internal density and air tightness
• Can be heat treated (e.g. T6 solution treatment) for strengthening, improving tensile strength and elongation
• Good weldability
• Better corrosion resistance than die castings

3.Forging

Forging is a manufacturing process where pressure is applied to a metal workpiece by forging machines to cause plastic deformation in order to obtain forged parts with desired mechanical properties, shapes and dimensions. It is one of the two main components of forming (forging and stamping).

Forging can eliminate defects like porosity in castings produced during smelting, optimize the microstructure, and generally improve mechanical properties compared to castings due to preserved metal flow lines. For important parts in related machinery that experience high loads and harsh conditions, forgings are commonly used except for those with simple shapes that can be made by rolling, profiles or welding.

4.Stamping

The main equipment used for stamping is the stamping press. Stamping is a forming process where external force is applied by the press and dies to sheet metal, strips, tubes and profiles, causing plastic deformation or separation to obtain workpieces with desired shapes and dimensions.

Stamping can produce lightweight, high-rigidity products with consistent quality, high material utilization, good shearing and recyclability. It is suitable for mass production.

Stamping is mainly used for cutting parts with uniform thickness, such as mobile phone battery covers.

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