In 2018, MRT Castings was approached by a Tier One component supplier in need of a unique solution for a high-performance road car application. The supplier was tasked with developing a structural component that would traditionally be manufactured from steel. However, stringent weight constraints necessitated the conversion of these components to an aluminium casting, requiring the same, if not greater, strength and ductility.
Moreover, the available space within the vehicle was extremely limited, presenting a significant challenge to achieve the desired performance within a small structural envelope.
The volume requirements for this programme also meant traditional sand casting methods would not be cost-effective. Therefore, the client was seeking an efficient and reliable diecasting solution that could meet their complex specifications without compromising on quality or durability.
The Challenge
The primary challenge was to develop an aluminium casting that could replace a traditional steel component while retaining the strength and ductility. Given the limited space, the new aluminium component needed to exhibit exceptional mechanical properties within a compact form.
Additionally, achieving the required production volumes economically necessitated the use of a diecasting process rather than sand casting.
The mechanical properties required the use of a specialist primary aluminium alloy, demanding precise control during the melting and casting process. This presented a technical challenge, as the material’s unique properties needed to be carefully managed to ensure optimal performance and reliability. Ensuring consistency across production batches while maintaining tight quality standards was a key issue for this safety-critical application.
MRT’s Solution
MRT Castings leveraged its extensive expertise in gravity diecasting and utilised industry-leading Magmasoft simulation software to help the client refine the geometry of the component for optimal castability. This collaboration enabled the development of a bespoke gravity diecasting toolset, manufactured in partnership with UK-based specialist tooling suppliers.
To address the mechanical property requirements, MRT used a specialist primary aluminium alloy. This material demands rigorous control throughout the melting and casting processes. MRT’s advanced metal treatment capabilities, including automated rotary degassing and precision metal preparation, were used to ensure the highest quality melt for every production batch.
The onsite laboratory, equipped with state-of-the-art tools such as the Bruker Tasman Q4 Spectrometer and Foseco Densitec system, played a vital role in monitoring and maintaining the purity and consistency of the alloy.
During the initial development phase, extensive testing was conducted to optimise the casting process and refine the tooling. MRT’s experienced team collaborated closely with specialist heat treatment subcontractors to develop a bespoke heat treatment process tailored to the specific metallurgy and geometry of the parts.
This ensured the final components met the demanding mechanical properties required for this application.
Quality Assurance and Traceability
Given the safety-critical nature of the application, the client required stringent validation and quality assurance measures. MRT conducted tensile testing of material samples and implemented 100% radiographic inspection of all production parts.
To provide full traceability, every casting was marked with a unique serial number using dot peen technology. Production parameters, including melt and die temperatures, were recorded throughout the process using real-time data loggers. These records were then linked to the serial numbers of each casting, ensuring comprehensive traceability and quality assurance for every component produced.
Outcome
MRT Castings has successfully supplied production volumes for this high-performance automotive programme for over four years. The company’s ability to deliver advanced casting solutions, combined with its rigorous quality control and traceability measures, has established MRT as a trusted partner for this Tier One supplier.
Our approach to this project exemplifies a commitment to delivering tailored solutions for complex engineering challenges. With 75 years of diecasting experience and some of the most advanced resources in the UK foundry industry, MRT is uniquely positioned to support clients from the initial design phase through to prototyping, testing, and volume production.
Why Choose MRT?
Every project undertaken by us is approached as a unique challenge. The company’s wealth of experience, coupled with its advanced technological capabilities and collaborative approach, enables it to provide innovative solutions for even the most demanding applications. For clients seeking a true partnership, MRT’s engineering team is available to get involved from the very outset, ensuring a smooth transition from concept and design through to final production.
Get in Touch
If you have a challenging project that requires an advanced casting solution, we’re here to help. With a proven track record of delivering high-quality components for critical applications, MRT can offer the expertise and support you need to achieve your project goals.
