The specialist in Aluminium casting, Alucast’s delivery of single-source manufacturing solution is supporting itself to bounce back from the pandemic.
The Wednesbury factory of Alucast that employs around 100 people has secured new wins with major carmakers and accredits its ability to provide simulation, casting, machining and the latest testing facilities.
The investment of more than £200,000 for creating a specialist Dye Penetrant offer has strengthened the business even further. This is a form of non-destructive testing used to assess structural vehicle components and other parts for cracks.
The fully trained five-member staff have been operating the new line successfully for several months.
Tony Sartorius, Chairman of Alucast, said: “The automotive sector is always looking for faster production times and ‘right first-time’ quality and this is what our latest investment is delivering.”
“Cast and machined parts are cleaned and treated with a special, coloured penetrant liquid, which searches out minute cracks in the surface of the components. The parts are then left for some time so that the penetrant can soak into any cracked areas, after which they are washed clean, which removes the liquid from the surface.”
“A developer is then used on the part and essentially draws out the penetrant from the crack to reveal a coloured line if a fault exists. If cracks are evident, the part is scrapped.”
He added: “What this means to the customer is that they don’t lose time and experience additional costs that arise when a faulty part is sent out for secondary processes.”
Alucast offers sand, gravity and high and low pressure casting to a client base that spans automotive, construction products, electrification and hydraulics.
The company had seen volumes dip during the pandemic at the Manufacturing Assembly Network (MAN) division, but, since lockdown was withdrawn, these have recovered through strong demand for its casting and machining capabilities.
The single-source solution is manifesting extreme popularity, with the Dye Penetrant testing joining additional compatible services, including casting simulation software, advanced laboratory facilities, X-ray, heat treatment and high-tech metrology.
This is supporting the organization to develop a strong reputation for supporting carmakers and tier 1s with structural lightweight components for use in next-generation vehicles and electric cars.
Sartorius added: “We have to offer more than just casting if we are going to be successful in the modern auto industry and we started the move to a single source solution five years ago.”
“Since that decision, we have invested nearly £3m into upgrading our core making facility and creating a new CNC machining shop with 5-axis capability, as well as the additional technology we have for testing and development.”
“Servitization is a big area of potential for us, where customers can access individual services we offer, such as casting simulation and heat treatment, to solve specific production issues or to ensure quality compliance.
“The addition of a Dye Penetrant department is a perfect example of this and we are seeing a steady increase in companies using it to double-check their parts.”
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