Precision Forming Processes
Die Casting: Molten metal is injected into a precision 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 from low-melting-point materials (such as 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 then melted away to create a seamless, unitary mold shell. This allows for the casting of parts with complex curved surfaces and deep, narrow internal cavities; notably, almost all single-crystal superalloy turbine blades in the aerospace industry are manufactured using this process.
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 forged parts. It is commonly used for safety-critical components subjected to cyclic loads, such as automotive chassis suspension parts and pistons.
Die Forging: Pressure is applied to a heated metal billet using a die, preserving the continuous grain flow (fiber structure) and significantly enhancing fatigue resistance. It is the preferred process for high-stress, cyclic-load components such as crankshafts, connecting rods, and gears.
Stamping: Sheet metal undergoes plastic deformation or separation. This process is characterized by high speed, high material utilization, and excellent dimensional consistency, making it ideal for mass-producing thin-walled parts such as automotive body panels, electronic casings, and electrical contacts.
Powder Metallurgy: Metal powders are compacted into shape and then sintered at high temperatures. The resulting material exhibits virtually no segregation, allowing for the creation of porous structures, functionally graded materials, or refractory alloys; it is well-suited for the mass production of small-to-medium-sized parts with simple geometries, such as gears and bearing races.
