A20X High Value Large Structure Casting

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The essence of this proposal is to introduce innovative aluminium casting alloys and related processing know-how for the manufacture of advanced highly stressed large structures as found in aerospace, automotive and similar sectors. This innovation is expected to bring about a step improvement from current manufacturing methods and fully aligns with the TSB’s High Value Manufacturing strategy. A resource efficient, cost effective approach will displace expensive machine from solid methods ensuring the UK builds a strong competitive and sustainable position in these important global markets. The approach has been enabled by a patented new aluminium alloy –A20X – which has been developed and characterised by Aeromet International plc, the lead partner in this project. A20X has demonstrated characteristics which are far in excess of today’s commonly used high performance alloys; namely, high isotropic strength, double the fatigue life and properties that ensure levels of integrity not possible to achieve using current generation alloys. Application of this high value manufacturing technology is strongly supported by leading companies in the aerospace and automotive sectors seeking weight and cost reductions. The project sets out to develop and derisk the manufacture of large structures by developing and evaluating innovative casting and post casting processes using a range of virtual toolsets validated by test pieces based on real applications. Practical work will be underpinned by fundamental metallurgical characterisation and development and validation of models to optimise liquid metal and solidification behaviours.