Achieving desired TYE performance in aluminium castings is a Sarginsons speciality and a fundamental of their world leading casting services. By deploying their unique range of technologies, especially Digital Twins and Smart Cooling, Sarginsons has achieved extraordinary improvements in TYE mechanical performance, even in prototype sand castings.
The process begins by accurately simulating TYE but, as the smallest modifications matter, the real magic happens when the technology team comes together. The blended expertise of all aspects of the casting process produces remarkable results, that rarely fail to achieve targeted TYE.
Sarginsons frequently uses this technology to address TYE difficulties in existing components for other foundries as well as OEMs.
The accurate simulation of TYE data, allowing the identification of problem areas, at any point across a component's form, is a critical first step. And a unique Sarginsons ability. This allows a focussed solution to be developed that utilises any of a number of technologies.
Prototypes that don’t exhibit the same TYE attributes as the production component are of limited use. Sarginsons has developed techniques that overcome the TYE variation, generated by different casting techniques, to cast true production ready prototypes, ensuring better off-tool validation.
Sarginsons is frequently asked to improve component TYE performance after a casting fails or generates high scrap. It is usually able to do this with simple fixes, like alloy grain refinement or smart cooling, and cheaply validate those improvements through simulation. Occasionally more sophisticated fixes are required.
Casting entire sections of cars in one piece makes sound economic sense. With the development of several casting technologies, many pioneered by Sarginsons, they can also be lighter greener and cheaper.
Sarginsons five years of research into casting aerospace components has produced the technology, such as digital twin simulations, that can produce stronger, greener, and cheaper components through traditional casting techniques.
Sarginsons wanted to see if casting held any advantages over hydroformed bike frames. Particularly, whether it could be lighter. They were the same weight. The big difference is that Casting could produce shorter runs of bikes without the tooling costs, inflexible design and delays of hydroforming.
Strength is meaningless without context. Which is why Sarginsons not only looks at Tensile, Yield and Elongation characteristics but also fatigue and stress. Most importantly, Sarginsons simulates these at any point on a casting, which is a real strength.