Alucast invests $1.2 mln to enhance aluminum casting capabilities in Wednesbury

A significant addition is the HDTD low-pressure die casting machine, which enhances production efficiency. This technology enables faster production of larger parts. Alucast has also developed ALU-HP1, a new alloy that is one-third the weight of SG Iron 420:10. Despite its reduced mass, ALU-HP1 meets critical performance criteria, including proof stress, ultimate tensile strength (UTS) and elongation.

The development of ALU-HP1 was supported by a £50,000 (USD 62,000) grant. The alloy was initially developed for casting sand military vehicle parts. Alucast adapted the alloy for low-pressure casting by optimising metal flow and refining heat treatment processes. Metallurgists have achieved a UTS of 420 MPa and aim to reach a 10 per cent elongation target.

Chairman Tony Sartorius views the new alloy as a potential breakthrough for sectors seeking weight reduction without compromising performance. CEO John Swift highlights the advantages of low-pressure die casting, including reduced porosity and improved component strength. Alucast anticipates securing over £1.5 million (USD 1.83 million) in new contracts within the next year, contributing to job creation.

Alucast distinguishes itself by offering all four major casting processes, sand, gravity, high-pressure and low-pressure, at a single site. This comprehensive capability positions the company to meet diverse client needs in the evolving manufacturing landscape.