Squeeze Casting vs Die Casting - Similarities and Differences

squeeze casting vs die casting

Squeeze Casting vs Die Casting - Similarities, Differences, and Selection Recommendations

In metal part manufacturing, choosing the right casting process often directly determines product performance and cost. Squeeze casting and die casting, as two common forming methods, not only play an important role in industrial applications but are often a key consideration during the project planning phase.

They share many similarities in process and results, such as achieving high-precision forming and mass production. However, they differ significantly in details, such as porosity, mechanical properties, and applicable scenarios. This article will provide an in-depth analysis of the similarities and differences between these two processes, helping you quickly understand their characteristics and better match them to your project needs.

1. What is Squeeze Casting?

Squeeze casting, also known as liquid die forging, is a process that combines the characteristics of casting and forging. Molten metal is poured into a heated mold, and then high pressure is applied to the metal as it solidifies after the mold is closed. The close contact between pressure and the metal and mold surface enables faster heat transfer, more efficient shrinkage compensation, and finer metal structure, effectively reducing porosity and significantly improving part strength, toughness, and fatigue performance. This process offers near-net-shape advantages and can be used for a variety of metals, including aluminum, copper, zinc, and magnesium, and is commonly used in the manufacture of automotive and aerospace components. Depending on the operation method, it can be divided into direct squeeze casting and indirect squeeze casting.

2. What is Die Casting?

Die casting is a manufacturing method that uses high pressure to force molten metal into a high-precision mold. It is suitable for producing complex and durable metal parts. The process generally involves preparing a hardened steel mold, injecting and compacting the molten metal, cooling and solidifying it, and then ejecting the finished part. The method's key advantages include achieving high dimensional accuracy and smooth surfaces, the ability to process complex geometries, and high production efficiency, making it suitable for high-volume production. The resulting parts also possess high strength and durability.

3. Squeeze casting vs die casting - similarities

(1) The basic principle is the same:

Both processes use liquid metal to fill a metal mold and solidify under controlled conditions. The core manufacturing process is "liquid metal → mold → solidification".

(2) Both use permanent metal molds:

Squeeze casting and die casting are not sand casting, but use metal molds (permanent molds) to ensure the repeatability and high dimensional accuracy of parts.

(3) Both are suitable for large-scale production:

Both processes can achieve medium to large-scale production, and production capacity can be further improved through automation, mold reuse and process optimization.

(4) Both can produce fine/complex shapes (within their respective advantages):

Die casting performs particularly well in thin walls and complex details, while squeeze casting can also meet various structural requirements in terms of designability, but the "complexity advantage" of the two focuses on different aspects.

4. Squeeze casting vs die casting - differences

(1) Different filling speeds and flow states:

Die casting usually injects molten metal into the mold cavity at a very high speed (up to 30-60 m/s), which is one of the reasons why it can produce thin-walled and fine structures; while squeeze casting deliberately uses low-speed or laminar filling (typical speed is much lower than die casting) to reduce turbulence and air entrainment, thereby reducing internal pores. The speed difference is the direct reason for the difference in density and defect rate between the two.

(2) Different pressure application methods and timing:

The pressure in die casting is mainly reflected in the injection or ejection stage and is maintained briefly in the pressure holding stage; while squeeze casting continues to apply high pressure when the metal begins to solidify, thereby "compacting" the metal and forcing shrinkage, thereby significantly reducing porosity and shrinkage. Because of this, squeeze casting parts are usually denser than die casting parts.

squeeze casting vs die casting porosity differences

(3) Internal density and post-processing capability:

Castings produced by squeeze casting usually have low porosity and internal density, making them more suitable for subsequent heat treatment (such as T6 of aluminum alloy), which can significantly improve mechanical properties; die castings may contain pores, which are easy to deform or crack at high temperatures, so they are limited during heat treatment or welding.

(4) Different production efficiency and cost orientation:

Die casting has a short cycle, is suitable for ultra-large batches and has low unit cost; although squeeze casting can be scalable, the cycle of each piece is long, the equipment or process complexity and initial investment are usually higher, and it is more suitable for small to medium batch orders with high requirements for mechanical properties and reliability.

(5) Different types of applicable parts:

Die casting is better at thin-walled, complex details and high-volume consumer parts; squeeze casting is more suitable for key structural parts that require high density, high fatigue strength or heat treatment (such as key engine parts, landing gear accessories, hydraulic/fluid control key components, etc.). 

5. Choosing between die casting and squeeze casting

(1) Complexity:

High-pressure die casting is more suitable for manufacturing parts with complex shapes and high precision requirements. Although squeeze casting can also process complex parts, it usually requires more subsequent finishing.

(2) Output:

When the production scale is large, high-pressure die casting has more advantages due to its long mold life and fast molding speed. In medium-volume production, squeeze casting is more economical.

(3) Mechanical properties:

If the product focuses on higher strength, toughness and fatigue life, squeeze casting is a better choice. If the ductility requirements are not high, die casting can be used in exchange for higher production efficiency.

(4) Industry application:

In the automotive field, die casting is often used for large-scale parts, but key components such as engines are more suitable for squeeze casting; in the aerospace field, squeeze casting is the first choice due to its high strength and density, while die casting is suitable for certain non-load-bearing parts; in the consumer electronics field, die casting is widely used to produce thin, precise housings and components, while squeeze casting is used for specific parts with higher strength requirements.

Squeeze casting products and die casting products

squeeze casting parts dense

die casting parts complex

Xavier can meet a variety of processing needs.

Unlike standalone foundries, we offer a comprehensive, one-stop solution. In addition to a variety of casting processes, we also integrate precision machining and surface treatment into a single production system, enabling a complete turnkey solution from blank to finished product. This eliminates the need for customers to source external suppliers for post-casting processing or surface treatment, reducing communication, lead times, and overall production costs. With over 15 years of industry experience, we can flexibly adapt to diverse project needs, offering efficient, reliable, and competitive manufacturing support. This integrated service model is what differentiates us from most standalone foundries in the market.

Get More Information

For a deeper understanding of the principles and advantages of squeeze casting, please review the introductory articles on our website. Xavier also offers a detailed introduction to our blank manufacturing services on our website, as we have extensive experience in die casting. This information will help you more comprehensively evaluate which process best suits your project goals.