Future Foundry
Solutions • Our View: Aerospace Castings

Aerospace is Casting's New Frontier

Sarginsons ability to create accurate digital twin simulations of cast performance, alongside it's ability to negate oxide and iron contamination (even in recycled aluminium), enables it to offer structural, geometrically, complex castings for use in any Aerospace application. This is a huge breakthrough that will drive serious financial economies. 

Further, the Foundry 2030 research project, with the Aerospace Technology Institute, concluded that even a high stress and workload component, such as a wing flap roller, would offer similar performance to current designs but with a 30% reduction in mass. Physical testing of the wing flap roller confirmed simulated projections. 

The potential for lightweighting through greater use of traditional castings in aerospace, including UAVs, is absolutely colossal. And one, Sarginsons, with its specialisation in lightweight, low porosity, high ductility aluminium castings, is perfectly placed to develop.

Why No Castings

Traditional low porosity casting techniques such, as gravity or low pressure, are rarely used in aerospace and never in a non-pressurised area. As research projects, such as Foundry 2030 have shown, there is no reason for this. The aviation industry ignores the potentially massive savings of casting because of incorrect received wisdom, about the variability and mechanical performance of castings.

Drones Open Doors

Drones and UAVs could change everything. Without the structural demands of road vehicles, castings can more easily create one piece structures encompassing chassis, battery cages, rotor arms and cabins or any combination of these. A rapid, reliable low cost manufacturing solutions for an industry that is ripe for lift off.

Aviation's Perfect Partner

Sarginsons is ready for meeting the stringent requirements that aviation has imposed. It has done the research, and developed the technology needed to design, simulate and manufacture airborne components, regardless of pressure. The whole being deemed viable and safe for volume casting by the Aerospace Technology Institute.

Key Points

  • Traditional Castings Safe For Aerospace
  • Huge Economies Over Investment Castings
  • Elevated Ductility in Components Available 
  • Oxides and Iron Contamination Negated
  • Massive Lightweighting Opportunities
  • Recycled Aluminium Options Available

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Technology Drives Casting

Recent advances in casting technology will change the way airplanes are designed and made. The potential for more progressive, organic looking components that reduce mass, with no loss of mechanical performance, is enormous. And Sarginsons world leading digital twin simulation technology is a vital first step.

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