Liquid Metallurgy Press-Casting (CCLC) Process and Equipment Introduction
Liquid metallurgy press-casting (CCLC) is a combination of cast-in-place and cold forging processes. It is mostly used to produce highly complex and intricate shapes that are difficult or impossible to produce using traditional casting processes. The process begins by pressing a heated steel billet into a pre-shaped die by means of a hydraulic press. The heated steel is then forced into the cavity of the die to form the desired shape. The entire cycle of forming the workpiece and cooling it are done in one stroke of the press. This whole process of liquid metallurgy press casting or CCLC is normally done at a lower pressure and temperature rather than a traditional casting process.
The main advantage in using CCLC is that the process can create intricate components that are far harder to make using traditional casting processes. CCLC also allows more freedom in terms of component design as molding and machining cost is reduced significantly due to the reduced complexity of the components. Furthermore, CCLC has the advantage of producing components with improved fatigue properties and better dimensional stability.
To perform the CCLC process, an array of specialized equipment is required. The most important equipment includes the CCLC press and the dies. The CCLC press is the main component of the CCLC process. It is a powerful press with a range of up to 200 tons for making the actual components. The force of the machine is used to press the heated steel billet into the die and then to cool it at a regulated rate.
The dies are the tools used for the CCLC process. These dies are generally made of highly rigid steel and have a fabrication accuracy of 0.005“ or better. Although the dies can be made from a variety of materials, the two most common types are aluminum/stainless-steel and steel/stainless-steel alloys. The steel/stainless-steel alloy is preferred because it allows the dies to last longer and provide a better finish to the components.
Apart from the die, the other essential component is the lubricant. The lubricant provides a separation layer between the heated billet and the die, which helps to cool the metal faster and more efficiently. The lubricant also helps to reduce tool wear and tear due to the high contact pressure.
The CCLC process has been used by a variety of industries to create a range of metal components. It is commonly used in the automotive and aerospace industries to create complex, intricate parts like gearboxes, throttle bodies, and engine blocks. Additionally, it is also used to manufacture surgical instruments and medical equipment.
Liquid metallurgy press-casting or CCLC is a very useful and efficient process for the production of complicated, intricate components. It is capable of producing components with higher quality and improved performance than traditional casting processes. As the CCLC process requires specialized equipment and materials, the costs associated with it can be higher than traditional casting. However, when compared to the cost of machining and moulding, CCLC is still a more economical and practical option for producing complex components.
