Our Processes

High Pressure Die Casting

High Pressure Die Casting

CastAlum has ten fully-automated high pressure diecasting cells in the range of 1,000 – 1,600 tonne locking-force. Each cell has its own integral bulk-melting tower furnace to ensure that the correct quantity and quality of metal is always on hand.

Recyclable material from the trim press is fed directly back into the furnace, eliminating any possibility of contamination between differing grades of aluminium. This process is highly suited to complex thin-walled castings. Core products made from this process include Steering Gear Housings and Transmission Housings.

Squeeze Casting

In addition, CastAlum has three fully automated cells for the manufacture of indirect squeeze castings in aluminium.

Core products made from this process include Steering Knuckles and Power Take-off Covers and Housings. The process is ideally suited to the manufacturing of high-integrity castings with a requirement of thick wall sections and mechanical properties approaching those of a forged component.

High Pressure Die Casting
High Pressure Die Casting

Machining

In 2009, CastAlum built a dedicated machine shop within the existing Welshpool facility to provide a full-service to new and existing customers alike. The machining area benefits from a clean climate-controlled air supply and is supported by dedicated CMM, Pressure Testing and Gauging areas.

Learn More About OUr Machine Shop

X-Ray

CastAlum has, on-site, two X Ray machines to prove our casting integrity. In the majority of cases, this equipment is used as an internal guide to quality and for problem solving. However, for safety-critical components such as steering knuckles, Images are taken using an Auto Defect Recognition system and the results are electronically stored for life.

High Pressure Die Casting