Near-net-shape processes
Die Casting: Molten metal with a low melting point is forced into a mold cavity at high pressure and speed. This process offers high production efficiency and excellent surface finish, making it suitable for thin-walled, complex parts made of aluminum or zinc alloys, such as automotive engine housings and electronic device frames.
Investment Casting: A refractory slurry is applied over a wax pattern, which is subsequently melted away to create a mold shell without parting lines. This allows for the formation of high-value-added parts featuring complex curved surfaces and deep, narrow internal cavities; notably, almost all single-crystal superalloy turbine blades in the aerospace industry are produced using this method.
Squeeze Casting:This process combines the shaping capabilities of casting with the densification benefits of forging. Static pressure of several hundred megapascals is applied during the solidification of the molten metal to eliminate shrinkage cavities and porosity, resulting in mechanical properties comparable to forgings. It is commonly used for safety-critical components subjected to cyclic loads, such as automotive chassis suspension parts and pistons.
Die Forging:Parts are formed through intense plastic flow within a die cavity, preserving the continuity of metal grain flow lines and significantly enhancing fatigue resistance. It is the preferred process for high-stress, cyclic-load components such as crankshafts, connecting rods, and gears.
Stamping: Force is applied to sheet metal to induce plastic deformation. Characterized by high speed and excellent material utilization, it is ideal for the mass production of thin-walled sheet metal parts such as automotive body panels, electronic casings, and electrical contacts.
Powder Metallurgy: Metal powders are pressed into shape and then sintered. This process enables the production of porous structures, functionally graded materials, or refractory alloys, and is suitable for the mass production of small-to-medium-sized parts with simple geometries, such as gears and bearing races.
