Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials &
p; Metallurgy
Squeeze casting of aluminium alloy and composites
P. Manikandan1*, K. Sukumaran and D. Jebakani1
1
Dept. of Mechanical Engg., Government College of Engineering, Tirunelveli
2
National Institute of Interdisciplinary Science and Technology, CSIR, Trivandrum
*Email: tuticorinmani@rediffmail.com
Abstract
Squeeze casting is an advanced metal
forming process for manufacturing near net
engineering components. The process of squeeze
casing is the combination of metal casting and
forging. Enhanced mechanical properties can be
achieved because of fine grain structure caused by
rapid solidification. Very low shrinkage and gas
porosity can also be characterized. Squeeze casting
is suitable for high strength, high ductility,
lightweight structural aluminum castings needed
for advanced components. The present paper deals
with to study the effect of squeeze casting on
microstructural refinement leading the improved
mechanical properties of aluminum alloy and metal
matrix composites.
Keywords: Squeeze casting; Aluminium, Metal
matrix composites
1. INTRODUCTION
The use of light-metal components in
aerospace and automobile applications has
increased during the last decade. One advantage
is that light-metal components lead to an overall
reduced weight and, thus, to reduced energy
consumption. Another advantage, which may be
just as important from an environmental point of
view, is the fact that aluminium components may
be recycled with relative low energy demands [1-
4].
The most economical process of making
metallic components is casting. In the casing
process is pouring molten metal into a mold to
produce an object of desired shape.
The major drawback of casting such as gas
porosity, shrinkage defects, misruns, cold shuts,
inclusions, hot tears and hot spots. In order to
compensate the drawback of casting several new
casting techniques have been developed. One of
the methods to minimize the casting defect is by
solidifying the melt under pressure and the
process is termed as squeeze casting. In the
squeeze casting has got great potential to
fabricate near-net shape components having high
integrity with very low defects level [1-2].
High strength wrought alloy are generally
used in aerospace industry for making structural
components. Addition of high wear-resistant
409
ceramic particles such as SiC , B4C and A2O3 to
the alloy is expected to increase the mechanical
properties considerably [2]. Metal matrix
composites (MMCs) have an edge over polymer
matrix composites owing to their high
temperature withstanding ability, wear
resistance, lower coefficients of thermal
expansion and no out gassing. In metal matrix
composites, the matrix is a metal or an alloy and
the reinforcements are mainly ceramics in
different morphologies viz. continuous fiber,
short fiber, whisker and particulates. Amongst
the MMCs developed, discontinuously
reinforced MMCs (DMMCs) have an edge over
continuously reinforced MMCs in view of their
ease of synthesis and shaping and lower cost.
The components are generally shaped by
conventional methods such as forging/rolling
which are high energy intensive processes. But
squeeze casting is an economical, single-step
near-net shaping process and have advantages of
manipulating the microstructure within the
material thereby isotropic properties can be
achieved in the components. Squeeze casting is a
relatively new and developing casting process. A
major market is the automotive market which is
increasingly demanding lightweight components
to improve fuel efficiency. Because squeeze
casting is relatively new, much work needs to be
done to better understand the fundamentals of the
process.
2. Squeeze Casting
Squeeze casting (SC) for producing ultra
strong, metallic component from liquid metal.
Liquid alloy is injected inside the metallic die
and subjected to high pressures for a small time
in the cavity. Superior quality components are
possible [6].
Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy

investment casting, die casting and metal matrix

composite-making arts.
3.1. Processing techniques of squeeze casting
for metal matrix composites

There are two processing

method are available for metal matrix
composites by squeeze casting.

A. Squeeze Casting Infiltration.

B. Squeeze casting by stir casting method.

A. Squeeze Casting Infiltration

Squeeze Casting Infiltration is a forced

infiltration method of liquid phase fabrication of
Metal Matrix Composites, using a movable mold
part (ram) for applying pressure on the molten
metal and forcing it to penetrate into a performed
dispersed phase, placed into the lower fixed
mold part [8].

Fig. 1 : Process chart of Squeeze casting [6].

The process of squeeze casting consist of

following steps [1]:

1. A metered quantity of liquid metal is poured

into a preheated and well lubricated die cavity of
require size and shape kept on the bed of a
hydraulic press.

2. The liquid metal is then pressurised using a

suitable punch after a dwell time.
Fig. 2: Schematic of the Squeeze Casting Infiltration [8].
3. The pressure is maintain for a reasonable time
till the molten metal solidifies completely.
Squeeze Casting Infiltration process has the
4. The punch is then withdrawn and the casting following steps:
is ejected out.
1. A preform of dispersed phase (particles,
3. Squeeze casting of metal matrix composites fibers) is placed into the lower fixed mold
half.
A squeeze-casting method is taught for
manufacturing metal matrix composites which
require little or no finishing operations. This 2. A molten metal in a predetermined amount is
method utilizes a combination of techniques, poured into the lower mold half.
fundamentals of which are found in the

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Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy

3. The upper movable mold half (ram) moves

downwards and forces the liquid metal
to infiltrate the preform.

4. The infiltrated material solidifies under the

pressure.

5. The part is removed from the mold by means

of the ejector pin.

B. Squeeze casting by stir casting method

In the Squeeze casting by stir casting method

the metal matrix composites are fabricated by
two stage.

a. Synthesis of the composites by stir casting

method

b. Processing of composites to the required shape Fig. 3: Schematic diagram of the stir casting [9].
by squeeze casting.

a. Synthesis of the composites by stir casting b. Processing of composites to the required

method shape by squeeze casting.
There are different methods for the synthesis of
metal matrix composites, namely, powder Squeeze casting, also known as liquid metal
metallurgy, stir casting, compocasting and forging, is a combination of casting and forging
infiltration. Out of these, stir casting is the process.
simplest and the cheapest.In the stir casting
method, stirring is done by means of an impeller,
or electromagnetism.Out of these, impeller
stirring is the cheapest and simplest means [10] .
For the synthesis of Al DMMC by impeller
stirring, the reinforcement is added into the
vortex created by stirring the melt with a
mechanical device most often by a rotating
impeller which causes the dispersoids to move
along with the fluids resulting in mixing. A
schematic of the setup for the synthesis of Al
DMMCs by stir casting is shown in Fig.3.
Synthesis of Al DMMCs by liquid melt impeller
stirring has to incorporate and suspend ceramic
particles in liquid Al metal homogeneously.

Fig. 4: Schematic diagram of the Squeeze Casting [8].

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Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy

Sequence of operations in squeeze-casting:

1. Bring a ladle filled with liquid metal matrix

composite close to the dies

2. Pour liquid in the bottom die cavity

3. Close dies and apply pressure

4. Open dies and eject the solidified product

3.2. Characterized of Squeeze castings

1.Low shrinkage and gas porosity

In the squeeze casting process, the high

pressure applied during solidification can
eliminate porosity caused by both gas and
shrinkage.

Table 1: The Density measurements and porosity percent [4].

Squeeze pressure

As cast 70 MPa 100 160

MPa MPa
Total 2.783 0.698 0.659 0.490
pore
area sq-
m/g
Bulk 2.5846 2.6735 2.6753 2.6976
Density 2.6527* 2.6894* 2.6902* 2.6917*
g/ml
Porosity 2.27 0.71 0.63 0.48
%
* Archimedes measurements.

2.Fine grain structure caused by rapid

solidification
In the squeeze casting process the increased
cooling rate caused by improved thermal contact
between the casting and die results in the
formation of fine grained structures.Fig. 5 shows
the macrostructural characterization conducted
on the squeeze cast alloys at 70, 100 and 160
MPa, respectively. It revealed no evidence of Fig. 5: Macrostructure of squeeze cast alloys (a) 70 (b) 100
blowholes or macropores. The macrostructure is and (c) 160 MPa [4].
an equiaxised structure and the grain sizes
decrease with increase of squeeze pressure from
70 to 160 MPa.

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Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy

3. Increasing mechanical properties alloys are less while the values of nontreated
The improvement in the mechanical alloys are the lowest. The eutectic Si in as-cast
properties can be attributed to the refinement in alloy is present as coarse, acicular needles which
the microstructure obtained by the application of act as stress raisers, and consequently, the
pressure during solidification.The mechanical material is easy fractured. The heat treatment
properties such as ultimate tensile strength, yield modifies the morphology of the Si from acicular
strength , percentage of elongation, hardness and to spherodized shape, thereby improving the
wear. mechanicalproperties. The enhancement of
strength properties obtained during aging
a. Tensile properties treatment is primarily owing to the metastable
In the squeeze the pressure applied during phase from the supersaturated solution. When
solidification has to improve the tensile both the solution and aging treatment effects on
properties. Tensile test determine the strength of the tensile properties are considered, the
material when subjected to a simple stretching properties would show an increase in
operation strength and decrease in ductility. The increase
of strength with increasing squeeze pressure is
Table . 2: Mechanical properties (UTS, YS and El.%) of due to the increased solubility of Si and the
investigated alloys [4].
virtual elimination of shrinkage and/or gas voids
Effect of heat treatment could allcontribute towards the observed
Pressure MPa Non Solution Aging improvements in strength of the alloys. The
treated treatment elongation percent increases with increasing
UTS As 103 147 150 squeeze pressure, the values of solution-treated
MPa cast alloys are the largest ones. The improvements in
elongation values are most likely to be due to the
70 128 173 198 increased volume fraction of the primary a phase
and improved soundness of the alloys. The
100 131 185 200 eutectic Si morphology plays a vital role in
determining the mechanical properties. Particle
160 132 190 208 size, shape and spacing are factors that
characterize Si morphology. Under normal
YS As 64 114 82 cooling conditions, Si particles are present as
MPa cast coarse acicular needles. The needles act as crack
70 87 136 136 initiators and lower mechanical properties
appreciably. The Si particle characteristics can
100 103 139 165 be altered by subjecting the casting to a high
temperature heat treatment for long periods.
160 114 140 190 Therefore, for prolonged solution treatment, the
EI.% As 2.5 4 3.5 observed change in tensile properties are
cast attributed to change in Si particle characteristic
70 4 13 5 [4].

100 5.5 14 6 b. Hardness

160 6.5 15
Table 2 shows the values of ultimate tensile
strength (UTS), yield strength (YS) and
elongation percent (El%) of the non-heat-treated,
solution-treated and aged alloys at different
squeeze pressures. From the table UTS and YS
show an increasing trend with increasing of
squeeze pressure from 70 to 160 MPa for all
alloys. Aged alloys have the largest value of
UTS and YS, the values of solution-treated
The application of pressure during
8 solidification in squeeze casting minimizes
porosity and makes the metal more dense,
making the matrix to resist surfacial plastic
deformation, rendering higher hardness to the
matrix[3].
c. Wear
Ceramic particles such as SiC , B4C and
A2O3 may be attributed to hardness of the
material a dominating factor affecting the wear
resistance. The decrease in wear weight loss may
also be attributed to higher load bearing capacity
of hard reinforcing material[3].

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Proceedings of National Symposium for Post Graduate Students (NSPGS 2010), 24 25 April, 2010: Vol 4 Civil, Materials & Metallurgy

coefficient of friction compared to that of

aluminium alloy.

References

1. K. Sukumaran, R.M. Pillai, S.G.K. Pillai and

B.C. Pai , Squeeze Casting : A Novel Metal
Processing Technique INDIAN FOUNDRY
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2. K. Sukumaran , K.K. Ravikumar, S.G.K. Pillai,

T.P.D. Rajan, M. Ravi, R.M. Pillai, B.C. Pai
Studies on squeeze casting of Al 2124 alloy and
2124-10% SiCp metal matrix composite
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characterization and tensile properties of squeeze-
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Fig. 6: Comparison of wear characteristics of squeeze cast Behavior and Tensile Properties of Squeeze Cast
alloy and composite [2] AL 6061/SIC Metal Matrix Composites Scientia
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The wear properties of the composite are much 6. Gopal P. Sinha1 and Ashis K. Choudhury
better than that of the monolithic alloy. The ADVANCES IN NET SHAPE
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coefficient of friction in the composite is also 7. Kalakkath prakasan, Sambasivam seshan
observed to be very low compared to the base Microstructure and properties of squeeze cast
Cu-carbon fibre metal matrix composite
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and Technology of Advanced Materials 8 (2007)
4. Conclusions 494502

1. The Aluminium alloy and composite can be

squeeze cast to get the macrostructure and
mechanical properties.
2. In the case of composite, the squeeze casting
is found to be very effective not only in
minimizing the defect level thereby increasing
the mechanical properties but in improving
the overall distribution of the second phase
particles.
3. The squeeze cast metal matrix composite
shows improved wear resistance and lower
10. K.G. Satyanarayana, R.M. Pillai, B.C. Pai, An
analysis of impeller parameters for aluminium
metal matrixccomposites synthesis Materials
and Design 23 (2002) 553556.
11. Qiang Zhang, Gaohui Wu, Guoqin Chen,
Longtao Jiang, Bofeng Luan The thermal
expansion and mechanical properties of high
reinforcement content SiCp/Al composites
fabricated by squeeze casting technology
Composites: Part A 34 (2003) 10231027

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