Alucast invests £1m to enhance aluminium casting capabilities in Wednesbury

Alucast, a Black Country-based aluminium casting foundry, has invested  £1 million (USD 1.22 million) in new machinery and research and development. This move aims to bolster its position in the rail, aerospace and defence sectors. The company employs over 100 staff at its Wednesbury facility. The investment focuses on low-pressure die casting and the development of a new lightweight alloy. The goal is to meet increasing demand for high-strength, low-weight components.

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

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

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

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

To get a 360-degree view of the aluminium extrusion market, read "The World of Aluminium Extrusions – Industry Forecast to 2032"