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www.goodwinsteelcastings.com

· Accredited by ASME as a Material Organisation to ASME NCA 3800 to supply castings for nuclear applications· Certified to supply CE marked structural castings to BSEN 10340· Certified to Pressure Equipment Directive 017/23/EC & EN 764-5:2002 for the manufacture of steel castings

Reverse engineering of OEM equipment for retrofit and refurbishment

Goodwin Steel Castings LimitedIvy House Foundry, Stoke-on-Trent, ST1 3NR, United KingdomSales Director Brian Quinn Tel +44 (0)1782 220244Email [email protected] Switchboard +44 (0)1782 220000

Certified to Pressure Equipment Directive 017/23/EC & EN 764-5:2002 for the manufacture of steel castings


Castings BuyerMetal casting your engineering needs

Published by Institute of Cast Metals Engineers Spring 2014

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CASTINGS BUYER Spring 2014 1 1



· Accredited by ASME as a Material Organisation to ASME NCA 3800 to supply castings for nuclear applications· Certified to supply CE marked structural castings to BSEN 10340· Certified to Pressure Equipment Directive 017/23/EC & EN 764-5:2002 for the manufacture of steel castings

Reverse engineering of OEM equipment for retrofit and refurbishment

Goodwin Steel Castings LimitedIvy House Foundry, Stoke-on-Trent, ST1 3NR, United KingdomSales Director Brian Quinn Tel +44 (0)1782 220244Email [email protected] Switchboard +44 (0)1782 220000

Certified to Pressure Equipment Directive 017/23/EC & EN 764-5:2002 for the manufacture of steel castings


Castings BuyerMetal casting your engineering needs

Published by Institute of Cast Metals Engineers Spring 2014

castings buyer 2014 cover.indd 1 24/04/2014 14:04

EditorLynn Postle, Dip M. MCIM, FICMETel: +44(0)1544 340332email: [email protected] Sales ManagerLes Rivers, Tel: +44(0)1568 797 123email:[email protected] Sales ExecutiveTerry Fendley, Tel: +44(0)1293 776492email: [email protected] OfficesInstitute of Cast Metals Engineers,National Metalforming Centre,47 Birmingham Road, West Bromwich, West Midlands B70 6PY UK.Tel: +44 (0)121 601 6979.email: [email protected]

From the editor

The cast metals industry is a vitally important supply option for many industrial sectors offering you, the buyer, numerous alternatives for highly complex engineered components to satisfy the need for efficient, high performance, and in many cases safety critical, parts.Castings Buyer is the only global publication dedicated to providing designers and those responsible for purchasing components with the information needed when considering castings as a supply option.

Published by the Institute of Cast Metals Engineers, Castings Buyer reports on many projects involving cast components to give you a comprehensive overview of the global cast metals industry and what it can offer the wider engineering community.

In many cases castings afford solutions in terms of complexity, weight reduction and high performance and they often ‘out shine’ any other mode of manufacturing, so please read on …

Lynn Postle, FICME

Design and ProductionRivers Media Services Tel: +44 (0)1568 797 111www.rivers-media.co.uk

Casting Buyer is one of a group of titles published by The Institute of Cast Metals Engineers. Sister publication Foundry Trade Journal (published 10 times/year).

ICME is the leading UK professional organisation for those employed in the global cast metals industry.

Spring 2014

WWW.FOUNDRYTRADEJOURNAL.COM

© 2014 ICME. No portion of this journal may be reproduced without written consent. The views expressed in the articles contained in Castings Buyer are those of the respective authors of the articles and The Institute of Cast Metals Engineers does not accept responsibility for statements made and opinions expressed in papers, articles, discussions or correspondence appearing in the journal.

CONTENTSREGULARS 2 Global Castings Solution News

8 UK Cast Metals Industry Awards 2013

19 Casting Design Course – sign up now

24 Industry in Focus – news from some of your favourite metal casting companies

FEATURES10 DIE CASTING All the latest news from the international die casting

sector

14 QUALITY ENHANCEMENT Learn how vacuum impregnation is one answer to

solving the problem of porosity in castings

16 POST CASTING OPERATIONS Non-destructive testing can safeguard against

failures in materials and components – read all about it

18 HEAT TREATMENT How to double the strength in some aluminium die

cast components

20 TURKCAST 2014 Read all about the exhibition which showcases the

best of Turkish casting facilities

22 SUBCON 2014 The latest news from the UK’s premier sub-

contracting show

FOR MORE ON CASTING DESIGN AND SOURCING OF CAST COMPONENTS CONTACT ICMEwww.icme.org.uk

2 CASTINGS BUYER Spring 2014

global news ............................................................................................................................................

GLOBAL CASTING GROWTH FOR POWERHOUSESAnnual global casting production for 2012 shows continued growth, according to the 47th Census of World Casting Production produced by the American Foundry Society. Published in December, the report shows that over 100 million tons of castings were produced in 2012, a 2.3 per cent increase from 2011.

However, 20 of the 37 countries which responded reported a contraction in annual volumes, most notably Brazil with a 16.9 per cent drop in overall volume on the 2011 figures. Other double figure decreases were: Bosnia and Herzegovina, Finland, Italy, Norway, Pakistan, South Africa, Switzerland and Taiwan.

China remains as the world’s largest producer with a total volume of 42.5m tons (an increase of 1.2m tons), with the United States reclaiming the second place with 12.8m tons (up 2.8m) pushing India into third place with 9.3m tons, followed by Japan (5.3m), Germany (5.2m), Russia (4.3m, although this is the 2011 figure as no return was submitted for 2012), Brazil (2.9m), Korea (2.4m), Italy (1.9m) and France (1.8m). The UK reported 520,300t of casting production.

To view the full report visit www.moderncasting.com

One of the UK’s leading independent foundries is well positioned to enjoy new levels of growth following a £750,000 equity linked investment from Finance Yorkshire.

Doncaster based Noel Village will use the cash injection to invest in new heat treatment facilities, to ensure shorter lead times for customers.

The company is one of the UK’s leading low volume stainless and high alloy steel foundries, and its products are used by valve and pump manufacturers around the world.

A family owned business established in 1980, Noel Village has progressed from casting carbon steels for mining and engineering purposes to high specification steels for the oil, gas and nuclear industries.

The funding means that the business will no longer have to sub-contract heat treatment work and will instead be able to complete the process in-house.

The foundry has also further strengthened its management team by appointing former Sheffield Forgemasters chairman and chief executive David Fletcher as non executive chairman.

Noel Village managing director Richard Edwards said: “We believe the future belongs to businesses which understand that quick turnaround, together with great service, are priorities. Investing in heat treatment facilities means that customers will benefit from faster lead times, and we will be better positioned than ever to supply increased specification castings to the entire energy sector.”

Begbies Traynor provided corporate finance advice and legal advice was provided by hlw Keeble Hawson.

Finance Yorkshire provides seedcorn, loan and equity linked investments, ranging from £15,000 to £2m to help a range of small and medium sized businesses to meet their funding requirements for growth and development.

The project is supported financially by the European Union. It has attracted £30million investment from the European Regional Development Fund (ERDF) as part of Europe’s support for the region’s economic development through the Yorkshire and Humber ERDF Programme, £15million from UK Government and £45million match funding from the European Investment Bank. www.noelvillage.com

Contact Finance Yorkshire on Tel: 0845 649 0000, www.finance-yorkshire.com

FUTURE HOTS UP FOR FOUNDRY

Richard Edwards, Paul Gower, David Fletcher, and Anthony Village

EEF launches new REACH training and consultancy services for manufacturers

EEF, the manufacturers’ organisation, is launching a campaign to highlight business risks under the Registration, Evaluation, Authorisation and Restriction of CHemicals (REACH) Regulation and provide support to the manufacturing supply chain to enable them to manage it.

Under the Regulation substances used in either products or as part of processes may be banned and, unless manufacturers have authorisation from the EU to use it, will disappear from the EU market.

The extensive campaign will simplify the implications of REACH and provide targeted advice to manufacturers. The focus is on enabling manufacturers to effectively manage compliance internally and recognise the potential risks to their business.

The concept for the campaign is the websites ‘Where’s My Car’ and ‘Where’s My Plane’, where manufacturers can hover over part of a model car or plane to reveal which components they will no longer be able to make as a result of REACH. One example, trichloroethylene, is commonly used in cleaning or degreasing metal parts. It will be banned from use from 2016 unless approval to use it has been sought from the European Commission.

Through a series of industry training courses and expert consultancy, EEF will help manufacturers keep on top of developments, understand the risks and put in place the systems to stay ahead of competitors and safeguard product lines. In turn, this will help to foster stronger, more confident customer relationships.

EEF works closely with Defra and the HSE, the UK’s competent authority on REACH, on the Regulation and its impacts. It also feeds into the deliberations of the European Commission and the European Chemicals Agency (ECHA).

To find out if you are affected by REACH and what you need to do to make sure you can continue to do business visit: www.eef.org.uk/wheresmycar/

CASTINGS BUYER Spring 2014 3

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ONE CLICK FOR COPPER IN EUROPEThe European Copper Institute (ECI) has launched a new, comprehensive website for copper users, professionals, journalists, students and policy makers. The website contains the latest information on the uses of copper and its alloys, along with the benefits provided in the main areas of application. It also showcases the efforts of the European copper industry to strengthen the sustainability of its operations and products.

ECI represents the copper industry in Europe and is also part of an international network of industry associations, funded by the copper industry, with a common mission to defend and grow markets for copper, based on its superior technical performance and contribution to a higher quality of life. This network is unified by a common brand and visual identity - the Copper AllianceTM.

Professionals will find the technical information they need and gain easy access to various outreach campaigns.

Policy makers and regulators can access the industry’s position papers along with the scientific information needed to help them understand the role copper can play to help achieve EU and national objectives.

Across Europe, ECI works with a network of ten national associations, some of which have over 80 years’ experience in promoting and providing technical advice on the many uses of copper. “Available in ten different language chapters, the new website will broaden the visibility and strengthen the consistency of copper’s messages to audiences across Europe. Our aim is to provide relevant information, in a transparent and commercially-neutral way, that will help our target audiences make informed decisions,” says John Schonenberger, ECI’s chief executive.

Start exploring all there is to know about copper now at: www.copperalliance.eu

GRAINGER & WORRALL INVESTS £500,000 IN 3D TECHNOLOGYWorld-leading casting company, Grainger & Worrall, has enhanced its range of prototyping technologies by investing over £500,000 in an S-Print HHS sand printer. The technology enables the UK-based company to provide its customers with an additional innovative and highly advanced rapid prototyping solution.

The new addition is the first commercially available installation of its type in Europe that utilises a high heat strength (HSS) binder paired with low-expansion sand mix to create highly intricate core structures, directly from CAD data. The tool-less casting technology also provides greater design freedom by enabling the construction of previously unfeasible internal geometry, when compared with directly-milled sand moulds.

Compared to printed furan technology, the HHS sand print process produces up to 250% stronger cores that are able to maintain even greater geometric stability throughout the casting procedure. This makes it suitable for use with both iron and steel. In addition, the use of a phenol-based binder and silica synthetic blended sand offers significant advantages in the stability of aluminium castings.

Edward Grainger, director of Grainger & Worrall, said: “Our commitment to delivering market-leading programmes for our client-base means we are seeking, constantly, to improve our infrastructure and capabilities. Our latest investment will further enhance our ability to offer customers, across the automotive, motorsport and aerospace sectors, greater benefits in terms of time, cost and performance.

“The past 60 years has seen Grainger & Worrall develop and maintain a reputation for technical excellence, quality and service. The addition of the S-Print HHS sand printer will allow us to continue to deliver ground-breaking innovation for our clients, now and in the future.”

The equipment has been housed in a purpose-built production facility at G&W’s Bridgnorth site and feeds cores to the company’s six foundries. The purchase of the HHS sand printer is part of the company’s on-going commitment to invest in leading edge technologies that will keep it at the forefront of total casting solutions for the automotive, motorsport, transport and aerospace sectors.

www.gwcast.co.uk

Advancing in nuclear for leading European foundryGoodwin Steel Castings has been accredited by ASME (The American Society for Mechanical Engineers) as a Materials Organisation (MO) to ASME NCA3800 to supply castings for nuclear applications.

Working in partnership with sister machine ship – Goodwin International (GI) – the company is proficient in the supply of finished machined and pressure tested steel and nickel alloy castings. Goodwin was established in 1883 and is retained under common management by the sixth generation of the Goodwin family.

It was the first European foundry to receive accreditation to the ISO9001 quality system (then BS5750), followed by accreditation to the Environmental ISO14001 and Health and Safety OHSAS18001 standards.

The sister machine shop has one of the most comprehensive CNC machining, fabrication, assembly and inspection facilities in Europe.The group also has an established apprentice school with annual intake being 25 students for the next four-year period.Along with the ASME Nuclear Quality System Certificate, Goodwin also retains Rolls Royce Nuclear Sector Submarine approval

manufacture and machining for steel and nickel alloy castings.The company has supplied cast components for primary and secondary cooling loops in the form of pumps and valves and also supplied

critical duty class one structural components. Often working with tier one suppliers supplying components to propriety military and civil nuclear design such as the AP1000 PWR and Faslane nuclear submarine naval base.

The foundry produces high integrity castings (500-1500kg) using secondary AOD refining and has recently constructed one of the largest CNC sawing facilities (3m x 3m) and radiography facilities (9.5Mev 10 x 10 x 10m) with 70Te lifting capacity in Europe to meet customer nuclear requirements.

Goodwin is partnered with Manchester Univesity (Dalton Nuclear Institute) and Loughborough University (Materials Science) in the advancement of material and engineering practices.

Contact: Steve Birks, director and general manager, Goodwin Steel Castings Ltd, Tel: +44 (0) 1782 220292, email: [email protected] web: www.goodwin.co.uk

It is only just over a year away until NEWCAST, to be held in Düsseldorf (Germany) 16th to 20th

June 2015. The show will highlight the best in casting technology. Keep up to date with the

progress at: www.newcast.de/2330


global news ............................................................................................................................................

The global titanium market recovered rapidly from the sharp downturn in demand in 2009 and by 2011 demand for mill products had reached 165,000t, the highest level experienced by the industry. While growth stuttered in 2012, a report by Roskill Information Services is predicting growth of 4-5 per cent per year through to 2018.

In Europe and North America, aerospace applications regularly account for more than 60 per cent of demand. Production of titanium sponge and mill products in these regions is also largely orientated towards the aerospace market. The rapid growth in production of sponge and mill products in China serves the growing domestic demand in industrial applications, which accounted for more than 80 per cent of consumption in 2012.

Despite the volatility of the market and the development of other applications, aerospace remains the principle distinct market for titanium, accounting for a buy-in weight of around 60,000t of mill products in 2012. The new generation of large passenger aircraft, the A380 and A350 from Airbus and the B787 from Boeing, use greater volumes of carbon fibre reinforced polymers (CFRP) in the airframe. CFRPs are compatible with titanium, but not with aluminium, which ensures that titanium’s position as a key material in the manufacture of aircraft is assured and growing. The Russian company, VSMPO, has emerged as the leading supplier of mill products to the aerospace industry, supplying in excess of 20,000t in 2012.

The use of titanium in industrial applications is more price sensitive, as specifications are not as rigorous as they are in aerospace and there is competition from other high performance alloys. This price sensitivity is more apparent in Europe and North America than in China, which now accounts for half of all demand in industrial

TITANIUM PRODUCERS POSITIONED FOR GROWING DEMANDapplications. It appears that titanium is selected in preference to (less costly) materials for use in Chinese industrial plants.

After falling to 124,000t in 2009, global supply of titanium sponge rose by an average of 26.5 per cent per year from 2010 to 2012 to reach 241,000t - an estimated 20,000t surplus in demand. However, much of this surplus was in China and was for industrial grade material. Aerospace grade sponge is mainly produced in Japan, Russia, the USA and Kazakhstan and Roskill considers that current and forecast supply is more than adequate to meet demand as there is some unused capacity overhanging the market. US imports account for more than half the world trade in titanium sponge and US melting companies continue to rely heavily on imports from Japan and Kazakhstan, although shipments from the latter country are falling as an increasing proportion of output is processed locally.

THE SEARCH TO REDUCE PRODUCTION COSTS Titanium is recovered as sponge by the Kroll process in which titanium tetrachloride is reduced with magnesium. This is a batch process, which restricts plant capacity and speed of output, but which allows a rapid response to global demand. Research is on-going into continuous processes for direct reduction of the oxide (or other intermediate) in an attempt to cut production costs. In 2013, just one plant using the direct reduction process is operating, accounting for less than 1 per cent of supply. More significant cost reductions have been achieved in advances in melting and machining practice.

Titanium: Market Outlook to 2018 (6th edition) is available at an introductory price of £4,410 / US$7,110 / €5,580 from Roskill Information Services Ltd, 54 Russell Road, London SW19 1QL UK. Tel: +44 20 8417 0087, email: [email protected] web: www.roskill.com/titanium

International Die Casting Award for innovative Jaguar F Type componentFor the second time in its 84-year history, diecasting specialists JVM Castings has been commended in the International Die Casting Awards, sponsored by the North American Die Casters Association (NADCA).

The annual Die Casting Design Competition showcases cutting-edge developments by many of the industry’s pre-eminent companies.

The awards were in Kentucky (USA), where JVM’s design team struck gold in the structural aluminium casting category.

The team was awarded for its pioneering B Pillar castings, a heat treated body chassis part manufactured in an aluminium alloy which gives greater ductility and mechanical properties than conventional high pressure aluminium alloys, and forms one in a series of castings manufactured by JVM for the new Jaguar F Type.

The company has been making parts for Jaguar Land Rover for over 50 years, and initially began producing B Pillar structural aluminium die cast body parts for Jaguar’s popular XK model using a combination of B Post and swan neck castings – a design which became the template used by other OEM’s in their own designs.

Wayne Murcott, joint managing director at JVM, said: “When Jaguar announced plans to build its F Type model in 2010, our design team was tasked with redesigning the B Pillar structure as one single casting that would be both mass efficient and avoid the need for sub-assembly.

“The challenge facing our designers was to create a feed and runner system that would successfully make two different castings at the same time. The team spent many hours running, reviewing and enhancing design simulations using Magmasoft computers, and our finalised design reduced the total assembly weight by more than 50%.

“This new lean design meant the F Type reduced its carbon footprint, as well as eliminating the cost and weight of seven steel pressings, as well as the cost of assembly. Rather than two dies and seven stamping tools, our new B Pillar only requires one die set.

“As the largest aluminium pressure die casting company in the UK, we’re constantly looking for ways to innovate in engineering and improve our products to ensure our market remains competitive, so it means a great deal to be recognised by NADCA, the international voice of the die casting industry.”

NADCA represents the voice of the die casting industry, in an annual market worth more than $15 billion. NADCA is committed to promoting industry awareness and growth in the global market for die castings, and the association is comprised of members located throughout the world.www.jvmcastings.com

METALCASTING – an important aspect of future MANUFACTURING INITIATIVES The American Foundry Society (AFS) will play a significant role in two major US manufacturing initiatives as part of the country’s National Network for Manufacturing Innovation.

The new programs are backed by more than $300 million of public and private funds and will bring together product developers, researchers, manufacturers, universities and training institutions into regional hubs. One of the two manufacturing hubs is the American Lightweight Materials Manufacturing Innovation Institute based in Canton Township, Michigan which will focus on the manufacture of aluminium, titanium and high-strength steel.

ALMMII was awarded $70 million from the Department of Defense with matching funds from the 34 consortium partners, of which AFS is one.

Digital Labs for Manufacturing (or Digital Lab), also will receive $70 million from the Department of Defense as part of the National Network for Manufacuring Innovations. Digital Lab will bring together manufacturing and software companies to develop compatible software and hardware for supply chains to reduce manufacturing costs. AFS will work with the other partners at the new Digital Lab to solve century-old manufacturing dilemmas while utilising state-of-the-art technology.


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Sheffield Forgemasters’ specialist offshore design and engineering division, Vulcan SFM, has achieved a triple record-breaking contract win.

The contract, on behalf of Hyundai and Technip is the largest won by Vulcan SFM and will see the delivery of the largest cast steel nodes ever made, for the world’s largest floating spar gas production platform – the first of its type to operate in the Norwegian Sea.

Vulcan SFM will deliver 12 ultra-large castings for the spar, operated by Statoil ASA on behalf of the partners OMV, ConocoPhillips and Statoil, which will see service in the deep water Aasta Hansteen field off the coast of Norway.

Paul Mockford, design director at Vulcan SFM, said: “The project to develop the Aasta Hansteen gas field requires the world’s largest spar platform.”

The castings will form high strength and fatigue resistant nodal joints to connect the main leg and brace tubulars which make up the lower, truss section of the spar platform.

Mockford said: “The Aasta Hansteen Spar is the largest diameter spar which has ever been built with a diameter of 50 metres and a total hull length of 198 meters, most of which is below the surface of the sea.

“With water depths of more than 4,200 feet this is a deep water application and floating platforms are the only real option at these depths.”

Technip is acknowledged as the world leader in the manufacture of spars, and in particular, truss spars. The platform will sit vertically in the water, with its cylindrical hull providing buoyancy and stability, and tethered by mooring lines connected to piles in the sea bed.

Vulcan SFM will design and supply 12 cast nodes, the largest of which weighs 117 tonnes, seven tonnes heavier than the largest nodes made to date.

Mockford said: “The castings will be made in a specially developed and proven grade of steel offering a balance of strength, toughness and weldability. The strength is developed through heat treatment involving water quenching and these are the biggest castings we have ever quenched.

“Like all the cast nodes we have designed and supplied over the past 30 years, these castings will need to withstand immense stresses when in use. Vulcan SFM has a unique track record in the supply of this type of component.”

Total recoverable reserves for Aasta Hansteen, previously called Luva, are estimated at about 47 billion standard cubic metres (scm) of gas and 0.9 million scm of condensate.

The platform, which will be located approximately 186 miles off the Norwegian coast will be the first spar platform built with storage capacity. It will be able to store about 25,000scm of condensate, and export gas via the Polarled pipeline to Norway’s Nyhamna gas plant.

Pictured above: One of the world’s largest cast nodes undergoing heat treatment at Sheffield Forgemasters

Vulcan goes large with record breaking contract win

WORLD’S THICKEST STAINLESS STEEL SLABS PRODUCED ON CONTINUOUS CASTER

A single-strand continuous stainless steel slab caster capable of casting the world’s thickest stainless steel slabs has been brought into operation at Pohang Iron and Steel Co Ltd (Posco) in Pohang (Korea).

Siemens Metals Technologies built the machine in Posco’s stainless steel plant SSCP4. It is designed to produce 700,000 metric tons of austenitic and ferritic steel slabs with thicknesses of up to 300mm per annum. The new continuous casting plant expands Posco’s capacity for producing high-quality stainless steel.

The continuous bow-type caster from Siemens is equipped with a straight Smart Mould. It has a machine radius of 11m and a metallurgical length of 26.9m. Slabs are cast with thicknesses of 250 and 300mm in widths ranging from 800 to 1,650mm. The casting speed can reach 1.1m per minute.

Siemens was responsible for the engineering, the supply of key components and technology packages, including the LevCon mould level control, the DynaFlex mould oscillator, and DynaWidth for setting the slab width. The strand is guided by Smart Segments. DynaGap Soft Reduction 3D allows the company to determine the position of the final solidification of the strand with high precision. This enables the roll gap to be controlled precisely and high internal slab quality to be obtained. Efficient secondary cooling is also achievable, an important prerequisite for achieving slabs with a high quality surface. www.siemens.com/metals

US foundry uses NEW ALLOYGrede Foundries in St Cloud, Minnesota (US) is one of two sites using a new ductile iron alloy called SiboDur to produce durable lightweight chassis, power- and drive-train components for heavy-duty truck applications.

Grede Foundries unveiled the SiboDur components at the Mid-America Trucking Show in Louisville, in March. The metal has a unique chemistry and process that competes favourably with aluminium in weight reduction, says the company. The high-strength characteristics of SiboDur also provide cost, fatigue life and ‘manufacturability’ advantages over other materials, they claim. Heavy-duty truck manufacturers use SiboDur in parts with high stress and torque requirements including steering knuckles, differential cases, control arms, hubs, brackets, engine mounts, crankshafts and suspension links. SiboDur was developed by a Swiss company, and Grede has the exclusive license to produce the alloy in North America. In addition to St Cloud, it is being made at a Grede facility in Reedsburg, Wisconsin.

Grede has estimated annual revenues of $1 billion, is headquartered in Southfield, Michigan, and has 4,700 employees at 14 foundries and three machining operations in North America. www.grede.com Source: sctimes.com


HEAT TREATMENT SPECIALISTS CELEBRATE FIRST SOUTH KOREAN

ORDER WIN Alloy Heat Treatment Limited (AHT) has secured its first order from South Korea. The assignment came amidst a string of several export orders within the past six months, making it an exceptionally busy year for the company so far.

Heat treatment is traditionally considered to be a domestic service, with companies deterred from shipping components long distances to be treated at the final stage of the production process, but the specialised work of AHT has seen interest and orders secured from new customers in France, Germany, Italy, Poland and South Korea so far in 2013.

Having made a name for themselves as the largest subcontractor for aluminium heat treatments in the UK, the company has attracted up to 15 international clients from all over the world in the past 18 months alone, with products treated ranging from fasteners to landing gear and breaking systems.

The company’s unrivalled expertise in the heat treatment of aluminium alloys is complimented by its NADCAP Merit status, something equally responsible for the increase in overseas interest according to director of sales, Ian Perks, “We have had a NADCAP accreditation since 2004, but concentrating our efforts very strongly on maintaining it and gaining the Merit status last year has led to us increasing the potential customer base we are able to tap in to. We are also listed on approved supplier lists of prime contractors which has attracted additional clients.”

With higher turnovers, the company is now aiming for an increase in growth helped by the expansion in export orders. According to Perks, “If export activities continue the way they have been, we are looking at a very successful year for Alloy Heat Treatment. Plus, we also have a couple of big investments in the pipeline which will enable us to support our ever growing customer base.”

Pictured above: Alloy Heat Treatment’s sales director Ian Perks with a heat treated aerospace component

Contact: Ian Perks, Alloy Heat Treatment, Tel: +44 (0) 1384 456777, email: [email protected] web: www.alloyheat.co.uk

O’Fallon Casting, O’Fallon, Missouri (USA), has won the 2013 Casting Competition as run by the American Foundry Society (AFS) and its publication Metal Casting Design & Purchasing magazine. The metalcaster won with its electronics housing produced for the defence industry. The judges noted that the component’s elegant design and incredible detail exemplifies the capabilities of the investment casting process.

The customer avoided hours of fabrication and assembly by combining multiple parts and features into a single, rigid piece. It is lighter and more precise than a comparable fabrication; secondary machining also was minimised.

The customer, who asked to remain confidential, was familiar with the investment casting process and worked with O’Fallon’s engineers to pack the part with functional features and elements while keeping it light. Thin walls (0.06in) keep the weight low, while a lattice of ribbing provides rigidity. Holes and slots further remove unnecessary material. Functionally, the casting contains a card-guide slot and bosses as mounting features for electronics. Cast fins on the exterior act as heat sinks for the sealed interior, and a cylindrical clamp-half is cast integrally on the housing’s side. Two cast-in holes avoid secondary machining requirements.

“Just look at it and say ‘wow,’” said one of this year’s casting competition judges. “The fins, the holes, the need for dimensional stability - electronics housings will continue to demand more features as more electronics are jammed into smaller spaces.”

O’Fallon was recognised for its winning casting during the President’s Luncheon at CastExpo’13 in St Louis in April last year.

Ten other castings were honoured as ‘Best in Class’ and ‘Honorable Mention’ winners.

The Best in Class winners are: • Carley Foundry, Blaine, Minnisota, for a 340kg aluminium radar casting

produced using the no-bake sand casting process. Converted from machined plates welded together, the design resulted in a 67 per cent reduction in part cost and enabled the end user to realise substantial tooling cost savings.

• Dotson Iron Castings, Mankato, Minnisota, for a ductile iron planter row unit. Six iron castings replaced 30 stamped steel parts for a new planter that had double the planting speed and seed placement accuracy of 99 per cent.

• Monarch Industries Ltd, Winnipega, Manitoba (Canada), for a ductile iron Razr disc opener. Six machined castings replaced six weldments of 35 steel pieces. The casting design increased the part’s torsional rigidity through material placement and widening of cross sections.

• Signicast Investment Castings, Hartford, Wisconsin, for a steel investment cast shaft, worm gear. Converted from a machined from solid part, the single casting requires no machining and resulted in a 40 per cent cost reduction.

• Stahl Specialty Co, Warrensburg, Missouri, for an aluminium coolant collector produced as a permanent mould casting. The complex aluminium part provides significant weight savings from its predecessor. Honorable Mention winners are:

• Barron Industries, Oxford, Michigan, for a 578gm aluminium, investment cast duct for General Dynamics’ Abrams tanks.

• Joy Global Surface Mining, Milwaukee, for a 1456kg steel boom foot produced as a no-bake sand casting.

• Brillion Iron Works, Brillion, Wisconsin, for a 40kg sand cast ductile iron valve housing.

• Denison Industries, Denison, Texas, for an aluminium main housing and bulkheads used for industrial-sized variable transmissions.

• Victualic Co, Easton, Pennsylvania, for a ductile and austempered ductile iron Sym-Ply T20 clamp used as part of a gang wall forming system.

www.afsinc.org

ELECTRONIC HOUSING CASTING WINS AFS/METALCASTING DESIGN & PURCHASING CASTING COMPETITION

global news ............................................................................................................................................


SinterCast is the world’s leading supplier of process

control technology for the reliable high volume production of compacted graphite iron (CGI). With at least 75 per cent higher tensile strength, 45 per cent higher stiffness and approximately double the fatigue strength of conventional grey cast iron and aluminium, CGI allows engine designers to improve performance, fuel economy and durability while reducing engine weight, noise and emissions. The SinterCast technology is used for the production of more than 50 CGI components, ranging from 2kg to 17 tonnes, all using the same proven process control technology. The end-users of SinterCast-CGI components include Allen Diesels, Aston Martin, Audi, Cameron Compression, Caterpillar, Chrysler, DAF Trucks, Ford, Ford-Otosan, General Electric Transportation Systems, General Motors, Hyundai, Jaguar, Jeep, Kia, Lancia, Land Rover, MAN, MTU, Maserati, Navistar, Porsche, PSA Peugeot-Citroën, Renault-Nissan, Scania, Toyota, VM Motori, Volkswagen, Volvo and Waukesha Engine. www.sintercast.com

The CGI cylinder head upgrade, compared to the previous generation head, was specified to enable increased power and to ensure durability in the demanding duty cycles experienced by marine, mining, construction and stationary power generating engines. Following successful product development and pre-production support, series production of the Series 2000 CGI cylinder head has begun at the Tupy foundry in Joinville (Brazil), using the SinterCast process control technology. The engine is available worldwide in several cylinder configurations.

“The MTU order represents another important step forward for CGI and for Tupy, and further reinforces the transition toward CGI in state-of-the-art engine applications. The MTU cylinder head becomes our 18th CGI product in series production, and establishes an important reference as Tupy’s first industrial power component produced in CGI,” said Luiz Tarquínio, president and CEO of Tupy. “As the world’s leading supplier of compacted graphite iron, we have now established high volume series production and secured

CGI production commitments across the complete spectrum of passenger vehicle cylinder blocks, commercial vehicle cylinder blocks and heads, and industrial power engine components. Tupy will continue to build on its CGI expertise and series production leadership to motivate new CGI applications and to lead the on-going trend toward CGI.”

“The MTU Series 2000 cylinder head provides yet another example of the contribution provided by CGI in achieving performance, durability, refinement and emissions targets,” said Dr Steve Dawson, president and CEO of SinterCast. “At present, industrial power components and products other than automotive cylinder blocks and heads comprise approximately 10 per cent of our production volume. We are confident that the growth opportunities in the industrial power sector can allow us to maintain this balance as the core automotive block and head sector continues to ramp up.”

Contact: Luiz Tarquínio S Ferro,Tupy S A, Tel: +55 47 4009 8181,email: [email protected] andDr Steve Dawson, SinterCast AB,Tel: +46 8 660 7750,email: [email protected]

Headquartered in southern Brazil, Tupy has more than 2,500 employees and a production

capacity of 848,000 tonnes per year of cast iron components. With manufacturing facilities located in Joinville in the State of Santa Catarina and Mauá in the State of São Paulo (Brazil), and in Saltillo and Ramos Arizpe in the State of Coahuila (Mexico), Tupy is one of the world’s leading companies in the manufacturing of cast iron blocks and cylinder heads, and the global CGI leader with 18 CGI components in series production. Tupy has established sales and engineering offices located in Brazil, United States and Europe to support its main customers, including: Ford, Cummins, Caterpillar, Chrysler, Audi, Daimler, John Deere, Navistar and many other premier automotive and diesel engine manufacturers.www.tupy.com

Tupy begins series production of CGI cylinder head for MTU industrial power engine

MTU Friedrichshafen, a subsidiary of Rolls-Royce Power Systems AG and one of the world’s most advanced diesel engine technology and power systems providers, has introduced an upgrade of its class-leading Series 2000 engine with several new technology features, including a compacted graphite iron cylinder head.

............................................................................................................................................. global news


The Cosworth CA cylinder head by Grainger & Worrall won UK Component of the Year 2013 at the Cast Metals Industry Awards.

Sand cast in A354 aluminium, the 11kg casting has been developed since its re-introduction into Formula 1 in 2010, an area where the performance of components is constantly pushed within the stringent regulations. The cylinder head achieved extraordinarily consistent results with no casting ever failing on the track.

“This is a component right at the forefront of automotive casting technology,” said John Parker, chief executive of the Cast Metals Federation which organises the awards. “At every stage of the manufacturing process this component pushes the boundaries to achieve reliability, performance and lightness to help develop extra power and speed from the engine.”

Grainger & Worrall has a long tradition of producing major engine castings for F1 and motorsport across the world and its motorsport foundry is world renown.

“The CA cylinder head is typical of the highest standards expected by the demanding motorsport environment and we are grateful to Cosworth for allowing us to reveal one of our many specialist motorsport castings usually kept under tight security,” said Edward Grainger, director of Grainger & Worrall. “The component represents the pulling together of technological advances, its application, along with the desire and tenacity to make what are often very small but incremental steps to succeed. This culture to deliver excellence within race deadlines is what we are most proud of, and continues to push us forward ready for the next challenge.

“To win the UK Component of the Year Award is very satisfying for all the very dedicated team at Grainger & Worrall, especially against such excellent competition.”

NEW AEROSPACE ALLOY WINS FIRST UK CASTING INNOVATION AWARD A new ground-breaking aluminium alloy A20X won the first ever Innovation Award in the competition.

Developed by Aeromet International plc, and the product of 12 years development, this new high performance alloy offers higher strength to weight ratios, improved corrosion resistance, extended fatigue life and elevated temperature properties compared to any conventional cast alloy.

This is the first new alloy in 20 years to achieve both AMS (Aerospace Material Specifications) and MMPDS (The Metallic Materials Properties Development and Standardization) accreditations, vital for any material to be used in the global aerospace and defence industries. The new alloy is already bringing considerable new business

UK CAST METALS INDUSTRY AWARDS

A Formula 1 cylinder head wins UK Casting of the Year and a new ground-breaking aluminium alloy picked up the first ever Innovation Award in the UK Cast Metals Industry Awards 2013.

PUSHING THE BOUNDARIESto the company, especially from the aerospace industry.

Commenting on the achievement, John Parker said: “The introduction of a new alloy is a rare occasion, and particularly one that brings with it the benefits that A20X does. Aeromet’s commitment and achievement in bringing this new alloy to market has been considerable, but it is this continuous striving for innovation that takes our industry forward.”

“This recognition is the icing on the cake for what has been a long and difficult development period in bringing A20X to market,” said Neil Goddard, business development director at Aeromet International plc. “Having gained the two key industry approvals, the alloy is now gaining traction within the aerospace and defence sector for both sand and investment castings.

“And as we move forward into 2014, our strategy will broaden to include the automotive market with a number of OEM’s already participating in development activity. With high pressure and gravity die foundries within the UK already engaged, we are seeing properties almost double that of existing alloys which will provide car manufacturers with new design freedom to improve performance, and reduce weight and cost. Aeromet also sees the potential for licensing the use of A20X to other foundries worldwide. Unlike other ‘high property’ systems it is the material itself which has the enhanced properties so there is no capital investment needed. If the customers are to enjoy the benefits of the new alloy it cannot just be Aeromet that is casting in it.”

Aeromet International plc of Worcester is one of the UK’s leading producers of aluminium and magnesium castings by the sand and investment casting process. The

company was also shortlisted in the Component of the Year award category for its jet plane wingtip casting.

DIECASTER TAKES HOME COMPANY AWARD Progressive, employee owned and highly successful, PMS Diecasting scooped the Company of the Year Award.

A zinc foundry producing a wide range of diecast components, the company has, over the last 18 months, moved to much larger premises and set up two new companies to further support its customers and continued to grow as a company in both size and profitability.

“PMS Diecasting is an example of a strong, motivationally run foundry with a fully engaged and involved workforce,” said John Parker. “Their commitment to the customer, the staff and the bottom line shows a company at the top of its game.”

PMS managing director Gordon Panter said the award was recognition of the efforts of everyone at PMS. “All our employees are shareholders, we run a strong on-going investment programme in our staff, and at every stage the workforce fully share, control and are responsible for improving the company, sharing in the profits and benefitting from its mutual success.

“The development of one of the most advanced laser scanning facilities and a new tooling facility, and the evolution of these into two new standalone businesses, has really helped us to support our customers better and take the company forward.”

Contact: John Parker, Cast Metals Federation, Tel: +44 (0)121 601 6394, email: [email protected]


Shortlisted in COMPONENT OF THE YEAR CATEGORYAeromet International plcAeromet’s submission of a single-piece winglet for the Embraer Phenom 300 bus jet (pictured left) is a single piece casting solution to a usually machined and assembled component saving weight and 50 per cent of the usual cost. A 6.9kg investment casting in F357 aluminium to AMS4289, the casting is made using the SOPHIA process.The casting’s shape and weight and the tight tolerances for dimensional stability make this a particularly technically taxing component to produce, but the customer benefits shown in this winglet casting open up considerable market opportunities for the future.www.aeromet.co.uk

Darwins Holdings LtdDarwins Holdings submitted a remarkable 1.22 tonnes inlet/outlet casting for the world’s largest high pressure (160 bar) submersible pump. The pumps will operate at a depth of 1000m and pump 1500 cubic metres of acidic rain water an hour by the Chinese mining industry. To date, for this type of pump, the suction and discharge castings would be separate but, for weight considerations, this is the first time they have been combined. At these pressures, casting integrity is fundamental and, using CA6NM steel added to the problems, so the innovative solutions to design, coring and casting within this casting are considerable. www.darwinscastings.comHarrison Castings LtdThree years ago Harrison Castings was asked by the world’s leading oncology treatment machine manufacturer to help develop a new patient couch for the next 25 years. The challenge was to design and manufacture a range of castings enabling the patient to be rotated 360 degrees, lifted and moved in any axis and held in one position for treatment. And all to meet the stringent safety factors required by American medical specifications.The pinpoint accuracy of the radiation beam treatment depended fundamentally on the positioning and static holding of the patient in position, the responsibility of the Harrison couch castings. Now in production and meeting all the operating criteria set out, the castings, and indeed the whole couch, are providing perfect alignment and playing their part in the life saving treatment process.www.harrisoncastings.com


DIE CASTING

The company’s unique approach for these smaller volume customers means they need to be much more than a traditional foundry. As these customers often have no experience of designing diecastings, and have none of the other necessary support processes within their supply chain, MRT has to offer the complete solution and so works in close partnership with customers’ engineers to optimise component designs for efficient casting manufacture. They then manage the tooling process, prior to starting casting production at the company’s foundry in Andover, where they operate pressure diecasting cells from 220t to 530t locking forces. The facility in Andover also includes a busy gravity diecasting foundry, further widening the range of components produced.

As many of MRT’s components are extremely complex, they often have high machining content, so the in-house CNC machine shop is one of the most advanced in the industry, equipped with 14 modern machining centres. The company also offers a full range of surface finishing processes. There is also a dedicated 4,000ft2 assembly facility for electro-mechanical assembly, and specialist packing services, enabling MRT to provide the complete finished product manufacturing process under one roof.

Using high pressure diecasting machines for small volume production means that the equipment needs to be extremely versatile to support the manufacture of a wide range of different components. So when MRT needed to invest in a new diecasting cell to support their continuing growth, the range of features required to support the diversity of castings created a challenging list for potential machine suppliers. The company who best rose to this challenge was the Italian manufacturer Colosio. Based in Botticino Sera, near Brescia, Colosio has been producing diecasting machines for over 40 years, and is able to offer the complete solution in their field. In partnership with sister company, Relbo, they manufacture diecasting machines, automatic ladles, die sprayers, and extractors.

CONSISTENCY OF CASTING In June, MRT installed the new Colosio PFO250 cold chamber diecasting cell. The machine delivers a locking force of 250t, making it suitable for aluminium components up to approximately 3.5kg. The PFO250 features real-time shot control, whereby process parameters, pressures, speeds and strokes are programmed, then monitored and adjusted automatically ensuring absolute consistency of casting quality.

MRT’s typical production batch sizes for high pressure diecastings range from as little as 50 shots to around 5000, so optimising set-ups is critical to making the process economically viable for small batch projects. Given that the company’s team is performing die changes virtually every shift, they get plenty of practice! In addition to good teamwork, and efficient procedures, there are a number of other tools used to optimise this exercise. Die designs

have been standardised and common components are used wherever possible. Dies are prepared in the in-house toolroom prior to any change, so that the minimum of work needs to be done during the machine down-time. World-class lean manufacturing techniques are employed throughout the company, so working areas and tools are well laid out and organised to improve efficiency. MRT employees have even visited Japan to study set-up reduction techniques in action in Japan’s leanest manufacturing sites.

QUICK DIE CHANGE – NOT A PROBLEM The new Colosio diecasting machine has also been optimised with several features to help MRT with the quick die changes required. Many of these features would normally only be included on much larger machines, but because of Colosio’s design flexibility and in-house manufacture, the features were able to be incorporated on to the PFO250 specifically to meet MRT’s unique demands. These features include automated tie-bar extraction to ensure ease of access for tool removal, motorised die-height adjustment and motorised shot height adjustment with automatic clamping. All die-specific injection and clamping parameters are stored within the Colosio machine’s

New cell helps widen the applications of HIGH PRESSURE DIECASTING

"Versatile equipment for small volume diecasting production for a range of different components"

The benefits of aluminium high pressure diecasting for high volume production, particularly for the automotive industry, are widely appreciated. However, there are very few foundries which focus on bringing the precision and versatility of this technology to industries where annual volumes are relatively small. UK-based MRT Castings specialise in exactly this area, and are proving that, with the right equipment and an innovative approach, the benefits of the process, such as excellent cosmetic finish and dimensional accuracy, can be enjoyed by customers with smaller volume demands in markets such as the medical, defence, marine and electronics industries.


DIE CASTING

digital ‘Fullcontrol’ control system, and can be quickly recalled the next time the tool is set up.

One of the greatest advantages with this cell is that all the peripheral devices were manufactured for MRT by Colosio and the cell has been completely integrated into the one control system, so recalling a programme on the machine when a die is set up for a production run will not only recall all of the die and injection parameters, but also all of the ladler, die spray, and extraction programmes, which makes significant time savings on every set-up. This single interface has also greatly simplified operator training, and dramatically reduced the initial installation time for the new machine, which was fully operational within 10 days of arriving in the UK.

The peripheral devices installed include Colosio’s Rotofast AL automatic ladler, and Relbo’s Plus 2-axis die sprayer and Arcofast 3 extractor. These devices greatly improve productivity of the cell, but also the consistency, controlling every variable automatically to optimise quality and repeatability. The Relbo Plus sprayer is a fully integrated two-axis automatic die sprayer, enabling very fast, effective and consistent lubrication of even the most complex die forms. The Relbo Arcofast extractor and integrated cooling conveyor further increases productivity and improves repeatability.

JOINED UP THINKING As Colosio’s UK agents are Ramsell-Naber, MRT’s principal supplier of furnaces for many years, MRT was able to purchase a new Ramsell gas-fired bale out furnace, with recuperative burner, as part of the turn-key package. The recuperative burner helps to reduce energy consumption and emissions, supporting MRT’s ISO 14001 accredited environmental programme.

With such a busy and diverse workload going through the machine, maximising machine utilisation is critical, so any problems need to be dealt with extremely quickly. MRT’s PF250 is equipped with Colosio’s Teleservice module, so that the manufacturer’s applications engineers in Botticino Sera can remotely access MRT’s machine control system over the internet to overcome any technical queries or apply any software enhancements.

The new diecasting cell is part of an on-going investment programme at MRT, which is gearing up to double its production capacity over the next three years. Growing export sales, and increasing demand from the company’s niché market sectors, are clearly testament to MRT’s philosophy that high pressure diecasting has benefits to a very diverse market, regardless of volume.

Contact: MRT Castings Ltd, South Way, Walworth Business Park, Andover, Hampshire SP10 5JT UK. Tel: +44 (0) 1264 324021,email: [email protected] web: www.mrt-castings.co.uk web: www.colosiopresse.it

"Optimising set-ups is critical to making the process economically viable for small batch projects" Foundry Yearbook

& Castings Buyers’ Directory 2014

Who’s who in the international industryThe Foundry Yearbook includes detailed information on the international trade organisations that represent the cast metals industry.

UK FoundriesAll UK foundries are listed in detail including: metals cast; processes used; in-house facilities; specialities; affiliates and number of employees.

A handy buyers’ guide for international foundrymen.

Cost £50.00 (plus postage)Contact: Sarah at the Institute of Cast Metals EngineersT: +44 (0)121 601 6979E: [email protected] www.icme.org.uk


LEARN MORE ABOUT GSC ON THE BACK & INSIDE BACK PAGES


published by

on behalf of the Institute of Cast Metals Engineers

TRADE JOURNAL INTERNATIONAL

foundry

yearbook & castings

buyers’ directory

2014

the


SECTOR STARTS NEW YEAR

OPTIMISTICALLYThe EUROGUSS exhibition, held in Nüremburg (Germany) in January, showed growth in three areas, say the organisers. There was an increase of trade visitors to

11,187 (2012: 8,415), there were a large number of international visitors – at least 30 per cent, and there was an increase in exhibitors to 470 (2012: 383).

The 2014 show marked the tenth anniversary of the International Trade Fair for Die Casting - Technology, Processes and Products.

To preserve existing achievements, companies must recognise, assess and utilise their opportunities in the future markets, stressed Dr Pero Mićić, president of the FutureManagementGroup AG, at the opening ceremony on the eve of the exhibition.

Dr Timo Würz, general secretary of CEMAFON, The European Foundry Equipment Suppliers Association, said he was “delighted” with the current state of the industry. “Our already positive expectations have been exceeded again! The economic upturn we noticed at the exhibition makes us confident for 2014 and beyond.” This is also confirmed by a representative survey of visitors and exhibitors by an independent institute: two-thirds of them assess the current economic situation positively and even see a rising trend.

Heike Slotta, director exhibitions at NürnbergMesse, sums up: “We are more than satisfied with this year’s EUROGUSS! The great rush of visitors and the high degree of international involvement – in terms of both exhibitors and visitors – speak for themselves. So I personally would like to say a big thank you to our exhibitors for their commitment.”

More than half of the exhibitors (51 per cent) were international. Die casting foundries and their component suppliers, equipment suppliers and service providers took part from 26 countries. The strongest exhibiting nations after Germany were Italy, Sweden, the Czech Republic, Austria and Switzerland. The international share of visitors also increased appreciably: over 30 per cent were international visitors, mainly from Italy, Austria, the Czech Republic, Turkey and Switzerland.

Around half of the visitors came from the automotive industry, i.e. car and vehicle manufacturers and their component supply industries, but machinery and plant construction, the electrical and electronics industry, mould making and die casting foundries also showed great interest in their sector’s event. The large share of decision-makers is also worthy of note: the exhibition survey revealed that 88 per cent of the visitors to EUROGUSS 2014 influence purchasing and procurement decisions in their company.

SPECIAL SHOWS EXAMINED THE PAST AND FUTURETradition, innovation and a look into the future were ideally combined at the tenth EUROGUSS, so the special anniversary also took a look back. A special show entitled Origins of the Future, organised in co-operation with exhibitors and associations, attracted great interest. Historical castings and tools showing

the innovativeness of the sector and individual companies and institutions offered a welcome look back to bygone times. But topical sector and research matters also attracted lively interest, as shown, for example, by the packed house at the 14th International German Die Casting Congress organised by VDG and BDG (Bundesverband der Deutschen Gießerei-Industrie/Federation of the German Die Casting Industry). There was also a big crowd on all three days of the exhibition at the special show Research for Knowledge, at which national and international research institutes, universities and colleges presented their services.

OTHER INTERNATIONAL DIE CASTING EVENTSCHINA DIECASTING 2014 takes place in Shanghai from 22nd to 24th July. The Chinese subsidiary of NürnbergMesse organises this trade fair and congress on die casting with a separate pavilion for German and European companies. Around 240 exhibitors and 8,000 trade visitors are expected at the show. The organiser is the Foundry Institute of China Mechanical Engineering Society (FICMES) and the sponsor is the Chinese Mechanical Engineering Society: www.diecastexpo.cn/en.

The NürnbergMesse Group sees its task as paving the way for German and European die casting foundries that would like to establish business connections in the Asian market, and is therefore not only active in China, but in India too. The Indian subsidiary of NürnbergMesse is involved in ALUCAST 2014, which takes place in Bangalore (India) from 4th to 6th December 2014. The trade fair and congress on aluminium and die casting expects over 100 exhibitors and 2,000 trade visitors. The event is organised by The Aluminium Casters’ Association of India: www.alucast.co.in

SAVE THE DATE!The next EUROGUSS takes place in the Exhibition Centre Nuremberg from 12th to 14th January 2016.

www.euroguss.de


The objective of the competition is to highlight the high quality of aluminium pressure die castings to others in the industry and to the public. The winning entries were selected by a qualified panel of judges from research and practice and the awards were presented at the EUROGUSS exhibition, held in Nuremberg (Germany) in January.

This year there were 17 entries: 11 from Germany, three from Austria, two from Italy and one from Switzerland.

Organised by Gesamtverband der Aluminiumindustrie (GDA), the German federal association of aluminium companies, and supported

by Bundesverband der Deutschen Gießerei-Industrie (BDG), the federal association of the German foundry industry, the International Aluminium

Pressure Die Casting Competition is a celebration of the quality of components produced by European diecasters.

DIE CASTING

1st PRIZECast side component for rear-axle support of BMW i3, Alloy: Al Si10MnMg BMW AG, Werk Landshut, Germany This component is being die cast despite strong competition from a welded structure. The casting utilises topology optimisation, an innovative development technique. The resulting casting is 10 per cent lighter than the best welded structure and thereby 10 per cent cheaper. Incidentally, the welded component only achieves 70 per cent of the intended level of integration. The winning entry also completely fulfils additional requirements for weldability and coatability (CDC).

2nd PRIZEOil sump upper part for W12 FSI engines in the Audi A8, Alloy: Al Si9Cu3(Fe) Hengst GmbH & Co KG, Münster, GermanyThe design of this casting fully utilises the specific advantages that die casting technology has to offer; the high-grade surface helps satisfy demands with respect to service life. From a design point of view, there is an impressive integration of functions. This was achieved using complex tool and die technology. Noteworthy, too, is the large number of finished surfaces that are as-cast but only have small dimensional tolerances, thus requiring little post-processing.

3rd PRIZEBMW motorcycle crankcase for the new generation of water-cooled K5x boxer engines, Alloy: Al Si9Cu3 BMW AG, Werk Landshut, Germany An LDS coating is used here for the cylinder bore surfaces. This combines optimal wear properties with very good heat transfer in the crankcase. Compared with the crankcase’s predecessor, a permanent-mould casting, six built-in parts were replaced by an integrated die cast component. Complex machining places great demands on the microstructural homogeneity of the die casting.

SPECIAL COMMENDATIONSCasing for switch electronics of industrial joysticks, Alloy: Al Si9MnMg Georg Frank & Co GmbH, Heilbronn, Germany This component imposes exacting demands on both the tool making and the foundry technology. Casting the 74 holes spread over the six faces considerably reduces the amount of machining subsequently required. The alloy chosen ensures maximum corrosion resistance even in a marine environment.

Collector frame for a manufacturer of solar units, Alloy: Al Si9MgMn DGS Druckguss Systeme AG, St Gallen, Switzerland This frame literally redefines the limits of die casting capabilities. The jury recognised this successful extension of the boundaries of the process. It opens up many new fields of application for this type of component.

Gearshift dome – innovative gate system G A Röders GmbH & Co KG, Soltau, Germany Tremendous savings in raw materials and energy can be achieved by using a particularly innovative methodology for developing a gate system with an optimised volume and flow pattern. The jury recognised the contribution of the methodology to sustainable efficiency with regards raw materials and energy. Results from the German Resource Efficiency Programme (ProgRess) were implemented uncompromisingly in this project.

Left to right: 1st prize, 2nd prize, 3rd prize

The Special Commendations as listed below

International Aluminium-PressureDie Casting COMPETITION 2014



QUALITY ENHANCEMENT

A natural phenomenon that occurs during the casting process for a variety of reasons, porosity is hard to eliminate and can lead to problems ranging from poor surface finishes to ultimately the failure of a part.

Indeed porosity was named as the top problem when the North American Diecasting Association conducted a survey of the end users of cast metal products – 35 per cent named it as an issue, ahead of any other concerns.

Moreover NADCA experts believe that many of the difficulties described as “other problems” - cited by 32 per cent of survey respondents as an issue – can also be traced back to porosity in the casting.

TYPES OF POROSITYUnfortunately, porosity is hard to avoid altogether, no matter how skilled the diecaster. Shrink porosity, which is caused by the change in volume when the molten metal changes back to its solid state within the diecasting mould, is the most common form of porosity and the most difficult to control.

Flow porosity occurs when pressure conditions are poor and the molten metal does not flow well around the mould. Gas porosity occurs when vapours are trapped in the molten metal: these can be air, steam or residues of the die-release agents used to ensure the casting is easy to free from the mould.

Not every porosity will cause a problem. Enclosed porosities are tiny holes enclosed entirely within a cast metal part; they will only cause a problem if subsequent machining opens up the porosity to the surface, forming either a blind porosity or an open porosity.

Blind porosities are open only to one surface. As they leave a large internal surface area of the metal open to attack by chemicals or water, they are often the cause of ‘spotting out’ of paintwork, or of internal corrosion of parts. Open porosities cause the worst problems: they form leak paths that can lead to the failure of components which have to remain pressure-tight.

THE SOLUTION OF CHOICEA safe, reliable and permanent solution to the eternal problem of casting porosity is vacuum impregnation with sealants. Modern processes and sealants have taken vacuum impregnation a world away from its original image as a lightly controlled and relatively unskilled process to be used as a last resort on parts that were identified as not being leak-free.

The question now is: should vacuum impregnation still be viewed as a quality correction process for individual parts, or is it better employed as a quality enhancement process for all parts?

Practice varies around the world. In some territories, such as China and South East Asia and Europe, vacuum impregnation is generally used as a routine value-adding process on many parts in the automotive supply chain; in other territories, it is not so widespread.

Different OEMs have different approaches. Some might only impregnate leaking components whereas others would 100 per cent impregnate. Practice also varies according to the nature of the part: for parts such as automotive compressors, which have to remain leak-free under pressure, 100 per cent impregnation is commonplace.

One major consideration when deciding whether to routinely impregnate or not is the cost of scrapping a component or losing added value if porosity is discovered at a late stage of production. These costs can be quite considerable.

With automotive compressors, for example, leak testing cannot be carried out until the whole, complex part is assembled, complete with O-rings, seals, bearings, PAG oil and refrigerant gas, all of which would have to be replaced if the part was then disassembled, impregnated and re-assembled. The alternative, of scrapping the part, is equally costly.

Nor can suppliers risk sending out leaking parts: nowadays they would face onerous compensation claims, not just for the cost of the faulty part supplied but also for any added value that a manufacturer has lost by using the part to make a component that

Vacuum Impregnation: Routine Quality Enhancement or Remedial Process?

then turned out to be substandard.

THE ECONOMIC CASEStephen Hynes, marketing director of Ultraseal International, the leading pioneering company in the field of vacuum impregnation, said: “There is a clear economic case for routinely impregnating parts such as cylinder heads, engine blocks, transmission cases and compressors that have to remain pressure-tight in the finished vehicles.

“In the electrical industry, impregnation is also an effective solution to prevent moisture seeping into wiring harnesses and electrical ends. This is evidently very important in the automotive industry where electronics are increasingly being used to control more operations in a vehicle.

“While diecasters strive to achieve the ‘perfect casting’ this has yet to be achieved in mass production processes. Porosity is a natural and inherent factor in the casting process, despite diecasters’ best efforts.

“The trend is definitely towards using vacuum impregnation with sealant as a routine quality enhancement, especially in the automotive industry.”

Another consideration is that modern impregnation processes and sealants overcome many of the disadvantages of old-fashioned anaerobic sealants. These not only took up to 24 hours to cure but also produced pungent odours that were unpleasant to work with.

Modern methacrylate-based sealants cure in minutes and produce world class first-time sealing results. Vacuum impregnation is now a relatively clean process that can be easily introduced into an automated production line.

Porosity in casting is a big issue: the tiny holes which are often invisible to the naked eye can completely compromise the integrity of a finished cast metal part such as an automotive compressor, an engine block, cylinder head etc.


QUALITY ENHANCEMENT

THE ‘GREEN’ ANSWERRecycling sealants have taken vacuum impregnation to another level, offering significant advantages over conventional (non-recycling) methacrylate-based sealants: they use less sealant, less water and produce far less wastewater.

With conventional sealants, most of the chemical is simply washed away in the cold wash part of the process: in contrast up to 95 per cent of a recycling sealant is recovered and returned to the first stage of the impregnation process for immediate re-use, along with the cold wash water.

“Recycling sealants make routine impregnation as a value-adding process even more attractive, as they offer a higher level of performance than more conventional methacrylate-based sealants,” explained Hynes.

“They are continually gaining in popularity around the world, for their performance as well as for their cost and environmental benefits.

Best practice spreads and I expect to see both more routine impregnation of parts and a growing demand for recycling sealants.”

As environmental concerns grow around the world, the benefits of recycling sealants will become more critical. Recycling sealants are particularly suited to territories where water is in short supply, or where regulations governing the disposal of industrial waste water are strict.

From its base in Coventry (UK), Ultraseal International has led the field in vacuum impregnation for decades, being first with methacrylate-based sealants, first with recycling sealants and first with front-loading impregnation equipment.

Contact: Stephen Hynes, Ultraseal International, Godiva Place, Coventry, West Midlands CV1 5PN UK. Tel: +44 (024) 7625 8444, email: [email protected] web: www.ultraseal.co.uk


POST CASTING OPERATIONS

As part of its broad range of advanced metallurgical solutions, Keighley Laboratories offers a specialised NDT service for clients in the aerospace, automotive, petrochemical, nuclear, defence, mechanical engineering, construction, civil engineering and allied industries, covering both laboratory and site inspection. The company continually invests in staff training and new technology to expand its capabilities.

The Keighley Labs NDT facility covers the two most common methods of surface crack and flaw detection, liquid penetrant testing and magnetic particle testing, and the mainstream volumetric inspection technique, ultrasonic flaw detection, as well as providing radiographic testing services on a sub-contracted basis. Non-destructive testing and inspection procedures are highly operator-dependent, relying on the skills and experience of NDT technicians to obtain and evaluate results, and all members of the Keighley Labs team are certificated to a minimum of PCN Level 2, an internationally recognised symbol of competence. Senior NDT engineer, Roger Wheatley, is qualified to PCN Level 3 and able to develop NDT procedures, write instructions, audit techniques and both train and examine Level 1 and 2 candidates. “We like to think of ourselves as the best, with a high degree of technical skill and experience, able to handle the most critical components,” he said. “Although most of our work is carried out in the lab, around 20 per cent of projects are on site, checking fixtures that cannot be moved like motorway bridges, presses, silos, boilers, offshore rigs or miles of installed pipelines in paper mills and petrochemical plants.”

For the detection of surface breaking flaws on ferrous and non-ferrous materials, such as casting and forging defects, weld cracks, leaks in new components and fatigue cracking on in-service components, Keighley Labs provides liquid penetrant testing with either colour contrast or fluorescent techniques, working to national and international standards including BS EN 571:1997. LP testing can be undertaken either in the company’s laboratory or at the customer site.

Magnetic particle inspection is conducted on ferro-

ADVANCED NDT RESOURCES

Non-destructive testing (NDT) is a highly valued quality assurance and analytical technique that helps safeguard against the potential failure of engineering material, components, fastenings and structures. Since it enables in-depth evaluation of a material without causing damage, NDT often provides the final QA stage before a new product enters service, while in-service NDT can be the last line of defence against component failure in the field.

magnetic materials, by inducing a magnetic field into the test piece, and is ideal for detecting cracks, porosity, seams and other surface breaking, as well as sub-surface discontinuities down to 2mm. Imperfections are revealed using fluorescent or non-fluorescent media; on-site testing is carried out using permanent magnets or portable electro-magnetic yokes where a suitable power source is available. Suitable for welds, castings, forgings and machined parts, including engine, suspension and braking components, testing is carried out by Keighley Labs to BS EN ISO 9934-1 and BAE RO5-6103 standards.

For identifying imperfections within a test piece or any changes in material properties, ultrasonic flaw detection reveals volumetric discontinuation, utilising sound waves introduced into the component from an ultrasonic source. Undertaken by digital and analogue machines, ultrasonic detection is able to penetrate up to 10m in steel and can detect laminations, lack of fusion and any corrosion, as well as carrying out thickness and depth checks. This technique is suitable for welds, wrought iron products and castings in magnetic and non-magnetic materials, including glass, ceramics and plastics, again with tests carried out either in-house or on-site.

To enhance its ultrasonic testing facilities still further, Keighley Laboratories

employs a digital flaw detector, which incorporates current developments in amplifier and pulsar technology to deliver higher levels of near-surface resolution and penetrating power. It also uses a magnetic permeability meter, for measurement of ferro-magnetic inclusions in feebly magnetic materials against relevant specifications, particularly for critical aerospace and nuclear energy applications, and a hand-held ferrite content meter, for analysing the ferrite content in austenitic and duplex steel and testing weld seams and piping materials in the oil, gas and petrochemical industries.

The company has achieved world-class Nadcap accreditation for a materials testing laboratory and is approved by such bodies as Airbus, the UK Civil Aviation Authority, Rolls Royce and British Aerospace, enabling it to carry out sub-contract testing of aircraft and associated companies. It also meets the accreditation standards of many other customer industries.

Contact: Keighley Laboratories Limited, Croft House, South Street, Keighley BD21 1EG UK. Tel: +44 (0) 1535 664211, email: [email protected]

Ultrasonic detections can penetrate up to 10m in steel and can detect laminations, lack of fusion and any corrosion, as well as carrying out thickness and depth checks


HIGH QUALITY CASTINGS IN FERROUS ANDNON-FERROUS ALLOYS Cannop FoundryBased in Cinderford, Gloucestershire thefoundry manufactures and supplies castings for a wide range of engineering disciplines.

Capability: Ductile Iron (SG), Compacted graphite (CGI), Grey Iron, Wear resistant alloys (Ni hard), Si Mo , Austempered Ductile Irons (ADI), Full range of Aluminium alloys.

Markets served: Automotive prototyping and development, Power generation including green energy, Transport, Fluid flow & Control i.e. valves & pumps, General Engineering

Quality: ISO9001:2008

Services: Product Development, Magma, Patternmaking, Heat Treatment, NDT, Painting Coating, Machine shop

Cannop Foundry LtdCrabtree Road Cinderford Glos. GL142YQT: +44 (0) 1594 823966 F: +44 (0) 1594 824200E: [email protected]

www.cannop.co.uk

Ningbo Haibo Machinery Tool Co., Ltd

E-mail: [email protected] Tel: 86-574-86809916 Fax: 86-574-86809998 www.haibomachinery.com Address: No.26 Beihai Road, Beilun District, Ningbo P.R. China 315800

Over 20 years OEM experience More than 30 CNC machines Aluminum, Zinc Alloy, Magnesium die-casting machines Powder Painting Assembling Stamping

Ningbo Haibo is a manufacture factory in China. The company has more than 20 years OEM experience. It possess the strong R&D. and manufacture ability, now it has become the strong production ability withadvanced NC machining center, high CNC lathe, NC EDM, magnesium die-casting machine , Aluminum die-casting machine , Injection molding machine etc as basis. Through the basic product design& research method of PRO/E, UG, PROTEL and advanced design software and rich product design and manufacture experience, Haibo can engage in from overall shape to precision process ,and a series high requirement process at end treatment and surface treatment ability ,and possess design ,testing and the product ability of manufacturing any new , hard, master and be first-class line atprecision process, precision die-casting ,precision Forging , surface treatment on color metal. Ningbo Haibo entirely carry out quality technical and quality management and execute IS09001: 2000 quality certificate system. The excellent location is another advantage of Haibo, it adjacent to the port, which is convenient in exporting .


HEAT TREATMENT

Heat treatment has traditionally not been possible for aluminium high pressure diecastings (HPDCs) because they contain substantial amounts of entrapped gases that arise during the casting process. However, a process has recently been developed in Australia that provides the opportunity to gain large increases in mechanical properties.

High pressure diecasting is a highly efficient casting process whereby molten metal is injected at high pressure into a mould cavity. When diecastings are heated to elevated temperature for heat treatment, these gases expand causing blistering and dimensional instability. The inability to heat treat high pressure diecastings has been a limitation on their further utilisation. A process has recently been developed in Australia that overcomes these problems with the chance to obtain large increases in mechanical properties.

The patented process, developed over a five-year period from 2005 to 2010 by the Commonwealth Scientific and Industrial Research Organisation (CSIRO), overcomes these problems and provides significant improvements to tensile mechanical properties, fatigue resistance, fracture resistance and thermal heat transfer.

The process has been evaluated with a wide range of commercially produced components. All were independently assessed as having significantly increased strength and mechanical properties after treatment. The evaluations included trials on large HPDC parts (engine blocks) of up to 40kg weight.

The process is particularly effective in commonly used HPDC alloys, including CA313, CA605, A380, C380, A360, A383, ADC10, ADC12, and AlSi9Cu3Fe, as well as in a number of experimental alloy compositions.

IMPROVED MECHANICAL PROPERTIESHPDC aluminium alloy components treated with the process typically demonstrate the following improvements in properties.

Strength and Hardness is increased significantly. The yield stress of components may be doubled for little change in tensile ductility. Increasing the hardness improves both wear resistance and machinability.

Fatigue resistance is often as high as for some wrought aluminium products. This has major implications for many components, especially those used in automotive applications, which are often fatigue limited during the design process.

Thermal conductivity is increased up to 60 per cent above the as-cast condition, meaning that for engine or transmission applications heat can be transferred or removed more efficiently and quickly. Enhancing the thermal efficiency of the metal used in housings has special consequences for electric vehicles, where the thermal management of both the motor and inverter systems is crucial to their operation, robustness and life expectancy.

The high temperature strength and stability of the heat treated high pressure diecastings is excellent, typically showing mechanical properties similar to those at ambient temperature at temperatures up to 200°C. Extended testing at elevated temperature has also shown excellent stability of properties over long term tests at 150°C. This result has particular importance for turbocharged engine applications, where the strength at temperature needs to be higher than the levels currently achieved in HPDC engine blocks.

The procedure can be tailored to raise energy absorption during fracture. Energy absorption has been found to almost double for one common secondary alloy heat treated specifically for this purpose. This has significant implications for crash sensitive structural components made by high pressure diecasting. A range of new alloy compositions has since been developed and patented.

Heat treatment has been shown to make high pressure diecastings able to be anodised for decorative and protective (marine) finishes. This is expected to facilitate significant improvements in corrosion resistance.

HOW THE PROCESS WORKSHeat treatment of aluminium involves three steps: (1) solution treatment at elevated temperature to dissolve elements into solid solution; (2), quenching to

A Heat Treatment Process which DOUBLES STRENGTH in Aluminium Die-Cast Parts

Test Bars of A380 treated to different tempers

Plot of tensile strength versus yield stress (0.2% offset) showing the distribution of HPDC properties after heat treatment at different tempers

A comparison of the fatigue behaviour of test bars from Alloy ADC12. 10E7 values are runouts

Roger Lumley, Commonwealth Scientific and Industrial Research Organisation, Australia

retain the elements in a supersaturated solid solution, and (3) age hardening at a lower temperature to develop mechanical properties. Conventional solution treatments for permanent mould or sand castings are for longer periods at high temperatures; for example, 6-12 hours at 540°C. In the new process, HPDC components are heated to relatively low temperatures for short periods of time for solution treatment; for example, 10-15 minutes at 430-480°C.

The time that components are held within a specified temperature range is critical since the solution treatment procedure can be entirely non-isothermal. This step is sufficient to cause at least a partial solid solution of soluble alloying elements such as Si, Cu and Mg.


GREENSPEAK

Following quenching, the HPDC component is aged to a tempered condition, such as T4 (natural ageing at 22°C), T6 (artificial ageing at 150°C) or T7 (artificial over-ageing at 200°C).

IMPROVED MATERIAL PROPERTIESIn common with other age-hardening processes, the new heat treatment process depends on a precipitation hardening mechanism. Production of fine nanoscale particles within the aluminium grains provides additional strength by impeding the movement of dislocations.

Similarly, the new process improves thermal conductivity through its effects on alloy micro-structure and the distribution of alloying elements. The treatment causes silicon particles to become spheroidised, and also re-distributes the copper present in the alloy as fine precipitates within the aluminium matrix, resulting in improved thermal conductivity. In heavily overaged conditions, the thermal conductivity may be increased by as much as 60% above the as-cast condition.

The process can be tailored to optimise yield strength, or to optimise fracture resistance. In general, as yield strength increases, fracture resistance goes down. T4 tempers or underaged T6 tempers produce optimum combinations of tensile properties and fracture resistance. T4 tempers for common A360 or A380 alloys (Australian designations 605 and CA313 respectively) exhibit energy absorption during crack propagation (unit propagation energy) that is approximately doubled compared with the as-cast conditions. Underaged T6 tempers display the best combination of properties, with high strength and reasonable fracture resistance. Importantly, T4 tempers for HPDC components typically display superior fracture resistance to permanent mould cast 356 alloy, for similar levels of tensile properties.

A range of alloy compositions that display extraordinarily rapid strengthening behaviour has also been identified. These high pressure diecasting alloys can be treated with a complete heat treatment cycle time of only 30 minutes and develop properties superior to conventional heat treated aluminium alloys requiring thermal cycles of up to 24 hours. This has major cost and particularly energy usage implications in manufacturing processes. SIGNIFICANCE OF THE NEW PROCESS FOR HPDC COMPONENT APPLICATIONSThis new process significantly expands the range of applications in which HPDC components can be used, and allows HPDC components to be re-designed using lower amounts of metal to support the same levels of load. Heat-treated HPDC components (made from recycled metal) often have superior properties to sand cast and most permanent mould-cast aluminium alloys (made from primary metal), so substitution of these castings with a lower cost, heat-treated HPDC is also possible. The process also makes possible replacement of some wrought components, particularly when loaded in compression. The automotive sector is currently the biggest user of HPDC components, and the process is attractive to manufacturers of automotive components.

HPDC is considered the most cost-effective casting process for mass production. The cost of T6 heat treatment for a HPDC component has been quoted as being approximately half the cost of T6 heat treatment for a permanent mould or sand cast product. Heat-treated HPDC components are thus substantially cheaper to produce than a heat-treated permanent mould casting or sand casting.

Reducing the amount of metal used per casting also has obvious cost benefits. If the tensile yield strength of a HPDC part is increased around 100 per cent, then approximately 30 per cent of the mass could be removed from the part, (taking into account design considerations, stiffness, castability etc). This means more re-designed components can be made per tonne of metal than was possible for the original design. Designing a component with lower mass also has a substantial effect on productivity, die design and usage of consumables. As a result, the cost per part may be substantially reduced.

Contact: Roger Lumley, stream leader: light weighting, CSIRO Future Manufacturing Flagship, Private Bag 33, Clayton South MDC, Victoria, 3169, Australia. Tel:+613 95452894, email: [email protected]

HEAT TREATMENT

Outline programme• Introduction to casting metallurgy and

solidification• Casting processes – an overview• Principles of casting design • Do's and don'ts of design for casting• Global trends in the casting industry • Where to get help with sourcing castings• Using simulation in casting design• Additive manufacture – benefits and

limitations

CASTING DESIGN COURSE

Venue: Institute of Cast Metals Engineers,National Metalforming Centre, 47 Birmingham Road,

West Bromwich, West Midlands B70 6PYUnited Kingdom

To book contact: Nicci Taylor, ICME,Tel: + 44 (0) 121 601 6979,Fax: + 44 (0) 121 601 6981,email: [email protected]

Improve your knowledge of design for casting

2nd and 3rd July 2014

This two-day course is suitable for designers of castings and those involved in the specification of castings. The course assumes some basic knowledge of casting as a route to manufacture and the different casting processes.

Cost of attendance: ICME members, £380.00 per person (plus VAT); non-members, £425.00 per person (plus VAT). Price includes all refreshments. Help with fees for those from foundries or suppliers may be available from the Tor Lodge and Applecross Trust - contact ICME for details or visit: www.torlodge.org.uk

Test Bars of A380 treated to different tempers


TURKCAST

The 6th edition of the highly successful TURKCAST exhibition, with the participation of more than 60 leading Turkish foundries, will open its doors for global castings buyers from 11th to 13th September 2014. The event will be held in conjunction with the globally well-established exhibitions - ANKIROS 2014 - 12th International Iron-Steel and Foundry Technologies, Machinery and Products Trade Fair and ANNOFER 2014 - 11th International Non-Ferrous Metals Technology, Machinery and Products Trade Fair by HM ANKIROS A S at TUYAP Fair and Congress Center, Buyukcekmece, Istanbul.

Being one of the major castings suppliers to various industries, the Turkish foundry industry will once again welcome all casting buyers to TURKCAST. This cost saving event for casting buyers will enable visitors to meet both the commercial and technical managers of more than 60 leading Turkish foundries, to discuss their needs without having to spend a large amount of money and time for visiting their facilities which are located throughout Anatolia.

TURKCAST 2014 will showcase a wide range of foundries that are able to produce castings for various industries including: automotive, heavy equipment, construction, cement, heavy machinery, shipment, agricultural machinery, white good, energy, defense, glass, and ceramic.

TURKEY IS THE 4TH LARGEST FOUNDRY PRODUCER IN EUROPEThe Turkish foundry industry has doubled its existing capacity in the last ten years and became the fourth biggest

foundry industry of Europe, thanks to the its high technology and rapidly growing experience.

TURKCAST 2014 is the largest and the most competent foundry fair of Eurasia where casting buyers can follow up the Turkish foundry industry’s development and be a part of this success by visiting the fair. TURKCAST 2014 will again enable global casting buyers to meet more than 60 leading Turkish foundries under one roof.

DON’T MISS THIS CHANCE - FIND A RELIABLE, CAPABLE AND QUALIFIED CASTINGS SUPPLIER WITH JUST ONE VISIT…

As of February 2014, foundries that are already contracted to exhibit at TURKCAST 2014 are listed in the table below; more foundries are expected to join this list as it gets closer to the event.

WHY CHOOSE THE TURKISH FOUNDRY INDUSTRY AS A SUPPLIER?• New facilities with modern

technology and competitive

power• Young, educated and qualified

manpower• The ability and experience to fight

against a stage of recessions • Export enthusiasm and

knowledge• Government’s strategic objectives

for increasing foreign trade• Geographical proximity to

Europe

CONCURRENT EVENTS – ANKIROS/ANNOFER 2014 AND CONGRESSESBeing one of the major events for the iron, steel, non-ferrous and foundry industries, the ANKIROS/ANNOFER 2014 fairs are an international gathering that enables all leading technology, machinery, refractory, equipment and material suppliers to meet and demonstrate their products to global metallurgy industry buyers and professionals. Almost 900 exhibitors from 40 countries are expected to exhibit in these fairs this year.

During these exhibitions, the 7th International Ankiros Foundry Congress organised by TUDOKSAD-Turkish Foundry Association and the 17th International Metallurgy and Materials Congress organised by UCTEA Chamber of Metallurgical Engineers will also be conducted.

SUPPORTERSANKIROS/ANNOFER/TURKCAST 2014 exhibition trio is being fully supported by both international and local associations. The national supporters are TUDOKSAD, UCTEA, TCUD and KOSGEB and the international supporters are: CECOF, CEMAFON, EUnited, AMAFOND, VDMA, FESA and FUNDIGEX.

This is a great chance to discuss all your needs and requirements about castings with professional Turkish producers and we will be honoured to welcome you to TURKCAST 2014 as a visitor!

Detailed information about this event can obtained at:www.turkcast.com.tr in which visitor preregistration and online information request forms are available.

AFS Bıçak Ve Kalıp Daloğlu Döküm Makina Körfez Döküm

Akdaş Döküm Denizciler Dökümcülük Makim Makina Tek.

Akpınar Döküm Makina Dirinler Döküm Medaş Met. Dök. Mak.

Alcast Metal Dizayn Metalurji Döküm Mesa Makina Döküm

Altan Makina Ekstra Metal Döküm Ve İzabe Ortadoğu Döküm

Anadolu Döküm Elit Metalurji Özgayd Otomotiv

Ardemir Döküm Emin Yaldız Metalurji Özgümüş Döküm

Arya Metal Entil Endüstri Yat Özgüven Döküm

Atik Metal Ergin Makina Model Ve Döküm Pınar Döküm

Aydöküm Makina Ferro Döküm Samsun Makina Sanayi

Ayzer Döküm Gedik Döküm Vana Ser Döküm Makina

Boran Çelik Döküm Gür Metal Hassas Döküm Sönmezler Metal Demir Çelik

Burdöksan Döküm Madencilik

İmpro Metal Metalurji Döküm Trakya Döküm

Caner Döküm Kağan Döküm Ve Model Tümser Döküm

Çağ-Dök-San Çağlayan Döküm Makine Otomotiv

Kardemir Döküm Makina Ünimetal Hassas Dök.Mak. Ve Yedek Parça

Çemaş Döküm Kaydöksan Kayseri Döküm Ünlü Döküm Mak. Müh. Taahüt

Çetin Dişli Ve Makina Koçak Metalurji Makina Yazkan Mühendislik Döküm Makina

Çorum Teknik Çelik Döküm Konya Hassas Döküm Nano Tek.

TURKCAST 2014 – 6th Turkish Foundry Products Exhibition 11th to 13th September 2014, Istanbul (Turkey)

A ‘MUST VISIT’ EVENT FOR CASTING BUYERS

Some of the exhibiting foundries at TURKCAST 2014


SUBCON

Taking place from 3rd to 5th June at the NEC in Birmingham, Subcon is the UK’s national subcontracting, advanced manufacturing and technology exhibition. It covers every aspect of outsourced manufacturing services and technology from design and prototyping, machining, moulding, 3D printing, fabrication, composites, electronic assembly and finishing to software, testing, inspection and metrology.

This year’s event is set to be the biggest yet, with over 300 subcontractors exhibiting and a stronger than ever participation by UK exhibitors. Supporting this UK participation are partner organisations including the GTMA, BTMA, Confederation of British Metalforming, the Institute of Cast Metals Engineers, Made in Sheffield and the Engineering Industries Association.

Foundries continue to be strongly represented at Subcon, with exhibitors including: Thoni-Alutec, which has made significant investment at Cannop foundry since its acquisition last year; investment castings specialist the Dean Group, Cerdic Foundries, Derbyshire Castings, Longton Light Alloys, Carlton Diecastings, Midland Pressure Diecasting, Stone Foundries, Lucy Castings, William Cook and Vanguard Foundries.

Overseas exhibitors include the Fundigex Group of Spanish Castings Exports, French foundries Fonderie de L’Aisne and NDC as well Czech companies Unitherm, Kdynium and Kovosit.

Subcon has doubled in size in the last five years and is set to attract over 4,000 visitors in 2014. Leading decision makers from all sectors come to the show to identify potential manufacturing partners and place business.

HIGH LEVEL CONFERENCEFollowing on from the success of last year’s launch, Subcon is again hosting a high level conference focussing on big ideas and innovation in technology.

This year’s line-up of keynote speakers boasts a truly impressive cross-section of international business leaders from across industry. Keynote speakers at the event, which is organised by The Engineer, include top-level

representatives of the HS2, Rolls-Royce, Siemens and MAS.

The latest speaker to confirm is Dr Alan Epstein, Pratt & Whitney’s vice president, technology & environment who will be speaking on new technologies for today’s cutting edge jet engines. Other keynotes include: Siemens’ divisional director for industrial automation, Brian Holliday, explaining the what, why and how of Industry 4.0; David Clarke, chief executive of the Energy Technologies Institute looking at the options, challenges and prize of energy storage; Stephen Barr, head of the Manufacturing Advisory Service on Reshore UK and the technical director of HS2 Ltd, Andrew McNaughton, who will talk about the engineering challenges of one of the most controversial, and potentially transformative, infrastructure projects on the UK agenda. To finish on a particularly high note, the final keynote speaker is Hamid Mughal, head of global manufacturing at Rolls-Royce.

Alongside the keynotes, ‘show and tell sessions’ focus on inspiring and exciting engineering projects. Speakers include Peter Eyre, the designer of the RNLI’s new lifeboat, Kelvin Davies of BAE Systems on the application of high technology to performance sport and John Lawson, of Lawson Modelmakers, who will be telling the story of the recreation of a lost iconic aeroplane, the Bugatti 100p.

THE TIME IS RIGHTAnd the timing could not be better, with UK manufacturing continuing on its upward course and businesses confidently making plans for the future. The latest ONS figures show UK manufacturing rising by nearly 4 per cent year-on-year and by I per cent a month for the past three months.

A survey of visitors to last year’s Subcon showed that UK firms are set to place more work with UK contract manufacturers and have a high degree of confidence in the strength of the economy.

47.3 per cent of visitors to the 2013 show planned to increase the amount of work they placed with UK contract manufacturers in the following 12 months. The growth of this outsourced manufacturing sector reflects the advantages that come from using specialist third-party manufacturers to produce products.

Asked why they placed work with contract manufacturers rather than doing it in-house, the reasons cited included: more flexibility, staying focused on core business, cost, quality and the ability to meet delivery deadlines. As one respondent explained: “We outsource our manufacturing in order to focus on product development and service, while keeping capital costs down.”

To register for a free ticket to Subcon 2014 and to book conference sessions visit: www.subconshow.co.uk

Covering the complete spectrum from precision engineering to electronics, Subcon 2014 provides a single-source resource for anyone looking to find contract and subcontract manufacturing partners.

Single source for manufacturing partners


3 - 5 JUNE NEC BIRMINGHAM4




FREE

TO ATTEND

3 DAY EVENT!

FREE!

Hear the latest innovations, ideas and challenges from respected leaders in manufacturing and engineering

The Engineer Conference offers a compelling mix of inspiring keynote speakers, industry and supply chain insights and fascinating ‘Show and Tell’ sessions.

Discover the stories behind some of the UK’s most interesting engineering and manufacturing projects.

Co-located with Headline Partners

Supplier Network

REGISTER FREE AT WWW.SUBCONSHOW.CO.UK

UK automotive industry sustainable growth

Michael MychajlukPurchasing Risk Manager, Jaguar Land Rover

The engineering case for HS2

Andrew McNaughtonTechnical Director, HS2 Ltd

The factory of the future and the future of British manufacturingHamid MughalDirector of Global Manufacturing, Rolls-Royce plc

C A R E E R S

Sub_72815_Ads Round 3_210x297_FoundryTradeJournal_3_297x210_v1.indd 1 20/03/2014 11:15


Industry in focus

Lupton & Place LtdAthletic Street, Burnley, Lancashire, BB10 4LR, ENGLAND. Tel: +44 (0)1282 422361 Fax: +44 (0)1282 428107 Email:[email protected] http://www.lupton-place.co.uk

THE MODERN FACE OF DIECASTING

Here at Lupton & Place, we know that it can never be just about ‘the numbers’. Without the correct level of investment, high spec systems and quality control - quantity means nothing.

We have a policy of continuous development which reassures our customers we are always striving to better ourselves and continuously raise the bar. This is how we have maintained our place at the forefront of the industry for decades.

A programme of investment has seen the development of one of the industry’s best-equipped CNC foundries. We have recently invested £1.2million in securing the new Buhler Carat

130 diecasting cell in order to further increase our diecasting capacity. The first of its kind to be installed into a UK foundry.

The cell will produce structural castings for the automotive industry: parts will be produced in aluminium alloy AlMg5Si2Mn utilising multi-stage vacuum; resulting in high-strength, high-integrity components suitable for structural applications, without the need for heat treatment.

We have the machinery to provide a huge range of cost-effective manufacturing solutions: real time, closed-loop control, unbeatable repeatability and superior casting integrity.

A well-equipped, skilled workforce producing more than 1200 tonnes of castings per annum, with a level of quality few in the industry can match

Pressure Diecasting

Gravity Diecasting

Special Finishes

CNC Machining

High Definition Real-Time X-Ray

Certificate No FM 22097

Continuing investment in plant and people


•

Industry in focus

With its headquarters in Banbury - Oxfordshire and its operations in Poland Swan Shephard Ltd., has been serving the needs of the international foundry industry for 15 years. The manufacture of iron, steel and non-ferrous castings with full pattern-making, machining, NDT and pressure testing capabilities gives the casting buyer low cost, high value alternatives with outstanding logistics and typically a 3 working day delivery period.

As an integrated part of the Swan Group which incorporates Swan Foundry (Banbury) Ltd as a modern grey and ductile iron foundry in the U.K we can supply high value whilst integrating small, medium and volume casting production to the discerning and strategic casting buyer. Poland with its key economic emphasis on the manufacturing industries continues to invest heavily in its foundry production facilities and we are delighted to partner some of the most modern and competitive foundry facilities in Europe. We utilise all the key casting manufacturing processes including greensand, Shell, Resin-bonded sand and investment casting technologies. Whilst able to offer a complete package of pattern making capabilities we also have experience of using existing patterns, frequently with only modest conversion costs.

The Swan Group operates ISO9001 Quality systems with full traceability and certification if required. All of our Polish partners also employ environmentally – friendly processes and controls, this includes electric induction furnaces for precise control of metal chemistry and casting properties.

Furthermore we have experience in operating “Just In Time”, consignment stock and Kanban supply chains. All of our quotations are typically delivered to your warehouse, so no additional costs and we always quote in Sterling or Euros, so no exchange rate surprises.

Swan Shephard LtdPart of the Swan Group of Companies established in 1947.

Manufacturers and suppliers of castings and components to the engineering industries. • State of the Art manufacturing facilities based

in Poland with its sister firm Swan Foundry Ltd., based in Banbury Oxfordshire.

• Castings in all major iron, steel and non-ferrous alloys to European and International Standards.

• Sand and Investment Casting technologies.• Weekly delivery service with excellent logistics

– delivered to your warehouse.• ISO9001 Quality accreditation, with traceability

and certification options.• Ability to operate agreed inventory control

systems such as Kanban.

Contact Keith Shephard – Direct on +44 7803 210021 or [email protected] Shephard Ltd.Swan Close road,Banbury, OX16 5AL Tel: +44 1295 263134Email [email protected] visit our web site: www.swangroup.co.uk

Swan Shephard Ltd

As an integral component of our supply chain we also assist in the design of new foundry operations within Poland to ensure our casting customers have access to fully optimised state of the art production facilities. Accessing these production facilities has never been easier and we operate a full access philosophy for our customers and with regular flights from the UK being typically 2½ hours or less. Our Polish operations are located in the beautiful central southern city of Krakow and our team of fluent English speaking engineers are all fully experienced in casting and machining disciplines.

So if you are looking for a European manufacturer and supplier of castings able to meet your rigorous competitive supply chain demands give us a call or email us today.


Industry in focus

Manufacturing high quality machined castings

• Pattern Making• Aluminium & Bronze castings• Grey and SG Iron castings• CNC Machining• CMM Inspection• Painting & Sub Assemblies• Machine building• ISO 9001:2008

Made in Great Britain

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M J AllenA machine shop that casts & fabricates

Operating foundries and a welding facility alongside its machine shop in Ashford, Kent, M J Allen’s drive is to provide a quality, integrated casting, machining, fabricating and assembly service.

M J Allen supplies fully machined castings and fabrications to defence, medical, marine, OE and automotive (Ford) industries in the UK, Europe and North America and is certified to ISO9001, 14001 and 18001.

Their ferrous foundry produces high quality grey iron and SG iron castings to 3000kg with expertise in complex core assembly work.

The non-ferrous foundry produces precision sand castings in aluminium and bronze alloys to 1000kg for the most demanding applications.

In addition, an aluminium gravity die foundry enables volume casting to 50kg to the highest integrity.

The foundries have extensive in-house facilities for heat treatment, chemical and mechanical analysis, x-ray, dye penetrant and ultrasonic inspection and pressure testing.

The machine shop operates CMM inspection and jig boring in temperature controlled environments for the tightest of tolerances.

M J Allen’s recent CNC additions include a Doosan twin pallet, horizontal machining centre and Johnford bridge mill, covering machining in X-axis of 3.1m, Y-axis 1.8m and Z-axis 1.6m.

Coupled with paint and assembly facilities, all at the Ashford site, sourcing of machined and finished castings and fabrications of almost any size and volume is achieved with a single order.

MJ ALLEN GROUP OF COMPANIESHilton Road, Cobbs Wood Industrial Estate, Ashford, Kent TN23 1EW UK Tel:+44

(0)1233 622214. Fax: +44 (0)1233 643534Email: [email protected] Website: www.mjallen.co.uk

Majorfax LimitedMajorfax is a leading UK based castings specialist with over 25 years experience sourcing castings from its vast global network of foundries and offering a full supply chain management service.

Supplying fully machined and finished castings to a variety of industries, including the agricultural, architectural, engineering and renewable sector, the Midlands based company has developed a great reputation for delivering high quality in a cost effective way.

Providing solutions tailored to customers’ needs, Majorfax manufacture ferrous and non-ferrous castings and offer a wide range of services such as machining and finishing. Being ISO 9001:2008 accredited, the company always adheres to the highest integrated quality procedures and provides excellence and delivery to clients at competitive prices.

With constant investments being made in new warehouse facilities, technologies and infrastructure, Majorfax is committed to providing optimal products and services whilst offering its customers a hassle free purchasing experience supported by friendly and experienced staff.

Visit us at Subcon 2014 on stand M21

Global Reach, Local Service


Industry in focus

InnovativeManufacturing

Solutions

MRT Castings LimitedSouth Way, Walworth Business Park,

Andover, Hampshire, SP10 5JT, UK

www.mrt-castings.co.uk

T: +44 (0) 1264 324021

MRT CastingsMRT Castings Ltd are specialists in the manufacture of machined and finished aluminium diecastings for the medical, marine, defence, electronics and general engineering sectors. MRT offers the complete solution, from a collaborative approach to initial component design, all the way through to the supply of high

quality machined and finished components and assemblies. In their foundry, MRT operate four high pressure diecasting

cells with locking forces from 220 to 530 tons, and a flexible range of gravity diecasting cells. Meanwhile in their machining division, which now boasts 15 high speed CNC machining centres, MRT have an extensive range of Brother vertical machining centres and Hyundai-Kia Turning centres. ‘Having the fastest and most advanced manufacturing technology available to the industry means that we can provide solutions for our customers which are both competitive and flexible’, commented Phil Rawnson, MRT’s Managing Director.

For customers who don’t want to get their hands dirty at all, MRT also offer a complete assembly and logistics service, taking castings and machined components produced at MRT, and building them into finished products ready for distribution directly to end customers. This service is currently being applied to a diverse range of projects, from designer light fittings to shower waste pumps.

MRT is also investing in its team and business systems to ensure that they are growing with the business, implementing best practice, and optimising the benefits of the new technology being introduced. The Company is accredited to ISO 9011:2008 and ISO 14001:2004.

For further information: tel: (+44) 1264 324021; fax: (+44) 1264 333773; e-mail: [email protected]; web: www.mrt-castings.co.uk

Advertisement FeatureIndustry in focus

QUALITY IRON & S.G. CASTINGS

APPROVED TO ISO 9001:2008LLOYDS REGISTER AND GERMANISCHER LLOYD

Complete Heat T reatment Service

Extensive Patternmaking and Machining facilities

Individual Weights up to 25 tonnes in Grey Iron,

20 T onnes in S.G. Iron and up to 6 tonnes weight in alloyed irons

Coupe Castings Ltd, Higher Walton,Preston, Lancashire PR5 4DQ.

Tel: Preston 01772 338151Fax: 01772 627609

Email: [email protected] .coupefoundry .co.uk

Coupe Castings

www.coupefoundry.co.uk

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C A S T I N G S

Two companies in the north west of England have combined forces to acquire Coupe Castings in Preston. Shakespeare Foundry and Eaves Machining will own a50% share of new company Coupe Castings. Coupe Castingshas operated from its existing site in Higher Walton for overa hundred years, producing general engineering and jobbing cast iron castings for the automotive, wind, nuclear, power and offshore sectors. High integrity casting techniques combined with solidmodelling and solidification software enables Coupe Castings tosupply cast iron, ductile iron (SG iron) and ni-resist iron castingsto a large customer base, specialising in the valves, pipes and distribution industries. The move is a good fit for Shakespeare Foundry of Bolton asit sees them extend their capabilities. The company is a specialist in the manufacture of heat and wear resistant castings forthe cement manufacturing and mineral processing industries.Manchester-based Eaves Machining is a market leader in heavyCNC subcontracts and specialises in the machining of largecastings, forgings and fabrications. Michael Stanley, MD of Shakespeare Foundry said: "Coupe’sability to cast components up to 26 tonnes in weight is veryunique. Their range starts where Shakespeare’s ends and thebusinesses are a great fit." Ian Griffiths, CEO of Eaves Machining and the new CoupeCastings business said things were already looking up for thefoundry: "Coupe Castings is a great business with quality peopleand products. We are conducting a full strategic review ofactivities and have already won some significant new business."

Industry in focus

®

Cannop Foundry LtdCrabtree Road Cinderford Glos. GL142YQ

T: +44 (0) 1594 823966 F: +44 (0) 1594 824200 E: [email protected] www.cannop.co.uk

For More Information please contact:Mr Rod Meredith - Operations Director

M: +44 (0) 7899 665679 E: [email protected] Jay Kitchen - Technical Manager

M: +44 (0) 7931 343799 E: [email protected]

Thoni AlutecUnit 10A, Ironworks Business Centre

Selby, YO8 4NNNorth Yorkshire, England

Tel Direct Line: +44 (0) 1757 702010Tel Mobile: +44 (0) 7931 343799

www.thoni-alutec.com

For More Information please contact:Mr Jay Kitchen - Technical Manager E: [email protected]

Thoni-Alutec has seen significant investment over the last year which builds on its goal to be a provider of fully finished castings. 2012 saw the expansion of its machining capability with the purchase of a 25,000 sqM production facility in neighbouring Nisko. Here we ma-chine from solid materials such as titanium, superalloys, aluminium and magnesium to exacting tolerances to aerospace standards. Further operations such as assembly and processes such as joining casting to extruded parts are carried out here as well.

The Aerospace & Military business has seen significant growth with the addition of numerous new customers. The automotive and rail-way business is set to increase by 100% in 2014.

The low pressure foundry has doubled its capacity with the addi-tion of a new machine to meet the high quality demands and tech-nical specifications for today’s customers who recognise the advan-tages of this process.

The significant expansion born over the last few years is due to rec-ognition by customers of the advantages of not just having a cast-ing facility but also by encompassing further finishing process from machining assembly and painting the customer has the satisfaction that he can purchase a fully finished product ready to fall into their production plans. Thoni Alutec will continue to expand this philoso-phy and will continue to improve and innovate in the future.

It’s now been over a Year since Cannop foundry was acquired by Thoni-Alutec one of Europe’s premium casting producers. In this time Cannop has seen significant investment in infra structure equipment and personnel, as well as significant growth in its customer base. Im-provements to existing manufacturing facilities include the cleaning and refurbishment of the factory buildings including the office and laboratory facilities. The foundry has seen significant investment in moulding, melting and fettling equipment. Processes that were origi-nally subcontracted out are gradually being brought in house such as shot blasting, heat treatment and mechanical testing.

Cannop currently supply a very wide and varied product range to numerous market sectors such as automotive prototyping in engine blocks and heads, safety critical valves, heat exchangers, power generation engine components, exhaust manifolds, pumps, gear-boxes and general engineering sectors etc.

Cast components are produced from a wide range of ferrous al-loys and non ferrous alloys utilising the latest melting and casting techniques to ensure components are manufactured to the highest integrity. The Iron Foundry specialises in the manufacture of compo-nents in Grey, Ductile, (SG), CGI, SiMo, Wear resistant Alloys (Ni-Hard), Austempered ductile Irons (ADI). The Non Ferrous Foundry produces sand and gravity die castings in aluminium to BS1490 or BS EN 1706

The site currently holds approvals for the manufacture of castings to ISO9001:2008 along with several major worldwide Customer based approvals.

Cannop foundry continues the path of growth and continuous improvements with further investment in infra-structure equipment and personnel, allied with a solid and expanding customer base.

Improvements to existing manufacturing facilities include the cleaning and refurbishment of the factory buildings including the office and laboratory facilities.

The foundry has seen significant investment in moulding, melting and fettling equipment. Processes that were originally subcontracted out are now in house such as shot blasting, heat treatment and mechanical testing.

Cannop currently supply a very wide and varied product range to numerous market sectors such as automotive prototyping in engine blocks and heads, safety critical valves, heat exchangers, power generation engine components, exhaust manifolds, pumps, gearboxes and general engineering sectors etc.

Cast components are produced from a wide range of non-ferrous alloys and ferrous alloys utilising the latest melting and casting techniques to ensure components are manufactured to the highest integrity. The Non Ferrous Foundry produces sand and gravity die castings in aluminium to BS1490 or BS EN 1706.

The Iron Foundry specialises in the manufacture of components in Grey, Ductile (SG), CGI, SiMo, Wear resistant and Austempered ductile Irons (ADI).

The site currently holds approvals for the manufacture of castings to ISO9001:2008 along with several major worldwide Customer based approvals.

Thoni-Alutec has seen significant investment over the last year which builds on its goal to be a provider of fully finished castings. 2012 saw the expansion of its machining capability with the purchase of a 25,000 sqM production facility in neighbouring Nisko. Here we ma-chine from solid materials such as titanium, superalloys, aluminium and magnesium to exacting tolerances to aerospace standards. Further operations such as assembly and processes such as joining casting to extruded parts are carried out here as well.

The Aerospace & Military business has seen significant growth with the addition of numerous new customers. The automotive and railway business is set to increase by 100% in 2014.

The low pressure foundry has doubled its capacity with the addition of a new machine to meet the high quality demands and technical specifications for today’s customers who recognise the advantages of this process.

The significant expansion born over the last few years is due to recognition by customers of the advantages of not just having a casting facility but also by encompassing further finishing process from machining assembly and painting the customer has the satisfaction that he can purchase a fully finished product ready to fall into their production plans. Thoni Alutec will continue to expand this philosophy and will continue to improve and innovate in the future.

Industry in focus

Looking for a Casting Supplier?any metal, any quantity, any process

www.sarginsons.com

Want to discuss your requirements or get advice? Call us on +44 (0) 2476 466 291

Achieving the perfect casting is a complex process. There is a challenge associated with optimising the manufacturing process for your component, production run, timescale and budget.

For more than 75 years Sarginsons has been the best UK aluminium diecaster when it comes to producing high quality components that save our customers time and money.

We pride ourselves on our ability to resolve even the most complex diecasting challenges quickly and cost effectively – so you receive exactly what you need, when you need it.

And our track record speaks for itself. Our clients include some of the most respected names in the automotive, petrochemical, energy and engineering sectors, including Aston Martin, Caterpillar, JCB, Jaguar Land Rover, Rotork and Bombardier.

‘We develop practical and cost-effective solutions to manufacturing problems’

• Leadership – Extensive investment in cutting edge manufacturing processes means we boast fast lead times and reduced unit costs

• Expertise – One of the few European companies combining sandcasting, gravity and low pressure in a single foundry, so you benefit from synergies during manufacture

• Service – Large enough to deliver high volume projects but small enough to give you a true personal service

E

ST

AB

L I S H E D F O R OV

ER75years

Sarginsons Advert 128 x 185mm, no bleed.

18931 SAR_CastingsBuyer_AW.indd 1 27/03/2014 14:31

Modern Manufacturing facilities with 1200 employees based in Poland.

Aluminium and Magnesium Castings in: High Precision SandLow Pressure DieGravity Die

Capability: Design Pattern making Comprehensive inspection facilitiesCNC Machining Surface treatmentAssembly

Quality: NADCAP ISO9001 EN/AS 9100 IRIS DB ISO14001 etc

Markets: Medical Energy Railway Aerospace Defense & Marine etc

For more information contact: Mr. Jay Kitchen,Thoni-Alutec UKUnit 10A, Ironworks Business CentreSelby, YO8 4NNNorth Yorkshire, EnglandTel Direct Line: +44 (0) 1757 702010Tel Mobile: +44 (0) 7931 343799E: [email protected]

For All Your Precision Alloy Casting Needs

www.thoni-alutec.com

Comprehensive inspection facilities

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