patents,
utility models and constant
development in technology, ALUCAST, Ltd. currently manufactures 40% of castings for the aircraft industry. The management of
ALUCAST
works closely with its customers and takes their increasing requirements as a challenge for further development in the area of new technologies, new processes and new materials.
ALUCAST’s
annual investments in the company’s development are 10% of the turnover. The company is constantly focussing on the strategy of improvement, raising the level of all production phases and also the level of all inspection processes. Significant investments are also directed to the quality of the working environment, health protection and increasing personnel qualification by internal and external trainers. Based on the increasing requirements of its customers, ALUCAST also introduced the “hybrid technology” in 2014. This technology, replacing “classical” wax patterns making by 3D printing is significantly speeding up the delivery of casting prototypes and also possible first batches of castings. The 3D printing of wax patterns greatly affected the shapes of castings. Until recently, castings had to be designed relatively conservatively with regard to
the production technology. The
design of parts had to be adapted to the method of production and the method of pattern separation with regard to the pre-selected production technology. The development of 3D printing methods has shifted component shape designs to areas that in the past belonged only to artistic castings. This creates impressive and innovative shapes for which investment casting is a very suitable production technology. In this way, ALUCAST produces prototypes of castings made both Al and also Mg alloys. Today, ALUCAST, Ltd. offers its customers castings of nearly unlimited shapes with a number of cavities and minimum wall thicknesses up to 1 mm – all this with high level of dimensional tolerances and high
surface quality
(1.6–3.2 Ra). The initial production of castings at ALUCAST was focused mainly on the production of “box-
®
shaped” castings, castings for medical instruments, parts of aircraft model engines, parts of small aircraft, etc. At present, ALUCAST focuses mainly on the production of Al castings having high mechanical properties (strength and ductility) especially for aircraft and defense industries. These castings must meet the customers strictest conditions in terms of their precision, surface quality and, above all, mechanical values. Producing a casting with elongation above 3% and strength above 320 MPa requires not only highly erudite methods, but also appropriate inspection equipment. Wax patterns are produced on high-pressure presses, ceramic moulds are made at a robotic workplace with the possibility of producing castings up to 800 mm in size. High mechanical values are achieved thanks to the “JFcasting” and “ANNA” controlled cooling technology. Heat treatment is certified according to NADCAP.
Customers very often also require complete machining of castings, including fitting with HELICOIL inserts, as well as easy assembly. All this is provided by ALUCAST’s subsidiary, ALUCAST-machining. Many castings are offered to the customer not only machined with partial assembly, but also with surface treatment, all made according to ISO 9100. ALUCAST has recently started mass- producing castings from Mg alloys. The development took place in cooperation with Brno University of Technology. Castings from Mg alloys are mainly requested by aviation companies. We had to develop a system of protection against combustion during alloy melting
(the protection against combustion is a mixture of completely environmentally friendly gases) and a ceramic mould for Mg castings. Melting of Mg alloys takes place in a special electric furnace. ALUCAST supplies its customers with precision castings from a wide range alloys: • AZ 91
Rm – 240 MPa R p0.2 – 150 MPa A – 3%
• Elektron 21 Rm – 250 MPa R p0.2 - 150 MPa A – 4%
• WA 438 Rm – 230 MPa R p0.2 - 170 MPa A – 3%
The company’s business policy is open to all customers in all industries. By applying precision Al and Mg castings, ALUCAST not only saves its customers a significant portion of production costs, but also increases the usable properties of products. ALUCAST currently employs 85
workers and 15 technicians, of which 4 are foundry engineers. The volume of sales in 2019 was EUR 7.5 million. ALUCAST is certified according to
EN 9001 and AS 9100. The heat treatment of castings is
subject to NADCAP (National Aerospace and Defence Contractors Accreditation Program)
Non-destructive testing is performed
by X-ray (MU2000 X-ray) – with the option of analogue and digital output, or the creation of X-ray images according to ASTM 2033, ASTM E1742
Inspection of surface defects
– fluorescent method – procedure according to ASTM 1417.
August 2020 ❘ 21
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