| Two-metre-long off-road vehicle step casting for the US SUV market scoops Component of the Year at the Cast Metals Industry Awards Dinner.
Previously made as a sheet pressing and high pressure diecasting, the step casting for the US off-road SUV Ford Raptor was considered a triumph for the metal casting industry by the judges of the prestigious annual awards ceremony, held in the UK in November. The triumphant foundry is Shield Aluminium Die-Castings of Northampton (UK), which rose to the challenge of converting the part into a low pressure casting. Over 2m long and 215mm wide with a wall thickness of 3-5mm, the safety critical casting weighs only 19kg, has a high quality surface finish and minimal as-cast distortion.
Shield worked with an Australian based Ford Group design team for the supply of production castings to the USA based assembly line, to very short deadlines. Both the development team from Ford and Shield Aluminium Die-Castings, worked with HCM Engineering Ltd for the tooling and Maxima Engineering for the process methods, optimisation and robustness simulation using the tools contained in the latest MAGMASOFT® version, but the group never actually physically met. Design, process and tooling development were all completed to prove manufacturability and right-first-time sample batch castings, supplied in three months utilising regular web-based meetings. The judges were impressed not only with the casting, but also with the process control and global nature of the project.
“It is a casting that the whole team at Shield Group can be proud of, and brings a whole new area of components into the vision of the casting industry”, said Tom Smith, managing director of Shield. “As ever in this industry now, the component is the product of a team effort and it is the bringing together of organisations with key expertise from wherever they are in the world to deliver a solution that brings success.”
Previously manufactured as a pressing, this international team effort led by Shield was an impressive project from start to finish say the judges.
Shortlisted for the Component of the Year Award were Casting Technology International and Wall Colmonoy. Casting Technology International was chosen for a titanium structural aircraft wing component. Weighing 5.4kg the casting replaces a fabrication of nine machined components, is 20 per cent lighter and has validated the use of titanium castings where previously only ‘machined from solid’ had been accepted.
Wall Colmonoy was selected for its patented 316 stainless steel cable protector for the oil and gas industry. An investment casting with an aluminium insert, the cable protector is already saving significant money and time in difficult environments.
Company Achievement Award
The Company Achievement Award was won by Harrison Castings for its turnaround in sales, investment in building, plant and people and a successful move into the North American market.
Harrison Castings is an aluminium foundry employing 100 people based in a 1930s building in Leicester. Facing a decline in the large diesel market and deteriorating buildings, the company set about transforming both its location and its focus to great effect. As well as developing a strategy to build new overseas sales, particularly in North America, the management invested in a major refurbishment and capital programme creating a working environment for the future resulting in a 50 per cent growth in sales and profitability.
“The company had reached something of a crossroads with both its location and a drop in traditional markets. The successful turnaround has come from a combination of carefully implemented strategy and a confidence in the capability of the exceptional team we have here,” said Robert Harrison, chairman.
Shortlisted in the Company Achievement category was Goodwin Steel Castings for its investment in apprentices (25 per year across the Group’s UK sites) and the development of bespoke training materials and facilities including a fully equipped lecture theatre.
Also shortlisted for its apprentice training programme was Maycast-Nokes Precision Engineering, which, recognising its rural location, has supported a constant flow of apprentices into permanent employment with the company to ensure staff sustainability and expertise. The company was named one of Centrica’s Top 100 Apprentice Employers as well as winning a number of regional awards.
Wall Colmonoy was also shortlisted for its strategic approach to a full company training programme and the development of a talent development group to maximise staff potential and to provide the future leadership and succession planning
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