Aluminium Die Casting
Brophy Castings are specialist aluminium die-casters catering to a UK
client base. The gravity die-casting process allows the production of consistent
castings incorporating complex internal structures by using a combination of
metal dies and sand cores with a flexibility in production that other processes
such as pressure die casting cannot offer. With over 30 years experience in
the aluminium gravity die-casting business there are not many problems that
we have not come across.
Die-casting
allows for extremely accurate mouldings to be created in medium
volume at a very cost effective rate. For batches of 50-5000
die-casting can often be shown to reduce costs considerably compared
to components currently machined. If you have a prototype or
a production component you are machining and want to increase
production and in turn reduce costs, then please feel free
to call us
for an informal conversation.
Our prices cannot be beaten.
Castings
Castings can be made up to 1000mm tall and approximately 700mm
wide and upto 10kg. All castings are hand poured from Half Tonne
48KVA Morgan Temperature Controlled Bale Out Resistance
Furnaces. Most of our work is in LM6 & LM25. Die cast moulds
produce an accurate component with a very good surface finish
which often does not need any secondary work. The surface finish
can also, to some extent, be modified by the type of release
agent used.
Cast-In Inserts
Pre-threaded bosses, threaded studs and high strength bearing surfaces
can be incorporated into the casting before the metal is poured.
Sand Cores
Sand cores can be used to cast awkward & complex internal shapes
including lipped cavities and internal bends.
Silica sand
cores can be made up to 300mm2 to almost any complexity.
Release Agents
We offer 4 types of release agent for varying types of finish.
- Dycote
11: General graphite based release agent for a regular surface
finish
and an easy release from the mould.
- Dycote 34:
Rougher finish.
- Dycote 140:
Finer finish.
- Dycote
39: Super fine finish.
The Dycote
permanent mould coatings promote proper mould filling and release,
improves the metallurgical properties and surface finish of aluminium
castings and protects the die, extending its life.
Medium Volume
Die-casting is ideal for medium volume work. The moulds which are machined
from cast iron are suited for a production life of 200,000+, much longer
than sand casting and with drastically lower costs than pressure
die-casting.
Depending
on the size of the component and
the mould cavities we can produce over
500 units per day from each individual furnace.
Production levels range from 50 to 50000.
Prototyping
Working closely with our clients we can help develop prototype components
and moulds working from drawings, existing parts or
design briefs.
Supply
Castings can be supplied in sacks, packaged in tissue paper or bubble
wrap, pallet stacked or crated, according to customer requirements.
Quality
Our strict quality control procedures are carried out on raw materials
as well as during the manufacturing processes to ensure that all
our customers receive only the best. Certificates of analysis & conformity
and batch traceability is offered where required. We also ensure
that all of our subcontractors provide a top grade service and
inspect all goods prior to dispatch and upon return.
