Aluminium Die Casting
UK Casting of Aluminium
Hallam holds ISO 9001 and 14001 Quality certification, awarded and annually audited by the British Standards Institute, illustrating the company’s commitment to excellence in aluminium pressure die casting and associated manufacturing processes. Hallam also has EcoVadis certification for sustainable ESG-focused manufacturing. At every level of production, Quality, Production and Health and Safety managers work closely together to ensure that the highest possible standards are applied within the company’s aluminium casting and manufacturing processes. Lean Six Sigma, Cpk, Ppk and PPAP methodologies based on both dimensional checks and mechanical property testing are applied in production control, as required by customers.
Aluminium Die Casting Machinery and Equipment
Hallam’s manufacturing capability includes sand, gravity and high pressure die casting in aluminium and zinc alloys including bespoke specially formulated alloys to provide specific mechanical properties or other characteristics; CNC machining; fully automated powder coating; assembly of manufactured and outsourced components to create complete products and sub-assemblies.
Hallam specialises in cold chamber high-pressure aluminium die casting, guaranteeing tolerances of +/- 0.1 mm and wall thicknesses as thin as 1.5 mm. This method produces aluminium parts with fine surface finishes that can withstand harsh environmental conditions. Pressure die casting dies are designed for long-lasting, high-performance operations and careful mould design is crucial to prevent porosity in castings. Following simulation of metal flow within the casting mould Hallam’s designers strategically place vents in the casting mould to ensure elimination of trapped air.
CNC machinery is supplied and maintained by DMG MORI. Hallam uses CAMWORKS to interface Solidworks Professional CAD models with its CNC equipment.
The UK company Haviland designed and constructed Hallam’s powder coating plant specifically for the surface finishing of aluminium components and products. The plant includes a five stage pre-treatment unit and Saracen gas fired recirculating conveyerised oven and can accommodate components weighing up to 10 kg and one metre in height or diameter.
How High Pressure Aluminium Die Casting Works
Molten aluminium alloy is injected at pressures of several thousand PSI into a tool steel die during aluminium pressure die casting. When the metal has become solid, the die opens, and the casting is ejected. This technique is highly cost-effective for volume production of specially designed aluminium cast products.
Benefits of Using Hallam’s Aluminium Casting Services
Hallam utilises advanced CAD models to develop tooling that minimises porosity (air entrapment) in the castings. Hallam’s collaboration with the University of Sheffield Advanced Manufacturing Research Centre has deepened the company’s understanding of porosity prevention. Manufacturing capability is based on high-pressure die casting machinery from the world’s leading die casting machine manufacturer, Frech Germany, connected online for fault finding and efficiency monitoring. Across two shifts total casting production capacity is more than 1.5 million castings or 30,000 die casting hours per year. DMG MORI-supplied CNC machinery works seamlessly with the company’s Solidworks Professional CAD models via CAMWORKS to ensure accuracy at every stage of the production process.
Contact us to learn more about how we can assist with your Aluminium Die Casting requirements
Process methods – Lean Six Sigma
“Lean Six Sigma is a business approach to continual improvement which focuses on stripping out areas of waste from processes and minimizing product reduction. Lean refers to maximizing customer value and minimizing waste; creating more value for customers with less wasted resources. Six Sigma is the on-going effort to continually reduce process and product variation through a defined project approach” – British Standards Institute
Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects (driving toward six standard deviations between the mean and the nearest specification limit) in a manufacturing (or service) process.
The fundamental objective of the Six Sigma methodology is the implementation of a measurement-based strategy that focuses on process improvement and variation reduction through the application of Six Sigma improvement projects.
The Six Sigma DMAIC process (define, measure, analyze, improve, control) is an improvement system for existing processes looking for incremental improvement.
The Six Sigma DMADV process (define, measure, analyze, design, verify) is an improvement system used to develop new processes or products at Six Sigma quality levels.
Hallam Castings adopts Lean Six Sigma principles in all its manufacturing and administrative operations and embeds these alongside Quality and Health and Safety principles and rules in creating a fully integrated operational culture. Hallam Castings recognises that quality control, quality improvement, safety and process improvement are inextricably linked objectives.
Benefits of Aluminium Casting
Aluminium die casting enables the volume production of components with narrow tolerances and excellent surface finishes. This process offers numerous benefits for manufacturers, including the ability to produce intricate shapes quickly and cost-effectively. Hallam’s expertise and advanced aluminium die casting machines allow the company to meet the most stringent quality requirements.
Case studies
If you would like to view any of our case studies click below.
FAQ
The difference between pressure casting and sand casting is that pressure casting uses a mould to shape the metal, while sand casting uses sand to shape the metal.
We strategically design our moulds with well-planned vents and use dynamic CAD models to simulate metal flow, ensuring efficient air replacement during the die casting process.
Our aluminium die casting machines and advanced process capabilities make it possible to produce in high volume with high efficiency, which makes us a key supplier of aluminium castings in the UK. All our manufacturing and administrative operations further meet quality control, safety, sustainability, and process improvement goals by applying Lean Six Sigma methodologies. This position puts the company in a leadership spot in the UK aluminium die casting industry.
