How aluminium castings are transforming the automotive sector

Published - 24th Feb 2021

In the fast-paced automotive industry, performance and reliability are key. The industry is constantly looking for new ways to make vehicles faster, lighter and more fuel efficient.

In this blog, we look at the growth of cast aluminium automotive parts and how Haworth Castings is helping to give customers the competitive edge in this high-octane industry.

Lighter, faster cars

As automotive manufacturers focus on light-weighting, engine downsizing and electrification, aluminium is increasingly being used in vehicle components due to its excellent strength-to-weight ratio. This is helping to improve fuel efficiency, reduce carbon emissions, lower manufacturing costs and improve vehicle performance.

Automotive giants such as Jaguar, Land Rover, Audi and BMW recognise that well-engineered aluminium cast parts meet all the mechanical requirements while being up to 40% lighter than steel.[1] Indeed, the average aluminium content per vehicle is expected to increase by 20kg to 198.8kg by 2025, with casting being the predominant forming process[2].

In this climate, Haworth Castings is helping customers to gain the competitive advantage. We are highly experienced in producing precision engineering solutions for complex, performance-critical applications. High-performance automotive is a particular area of expertise where we add exceptional value for our customers, thanks to our deep technical knowledge and best-in-class design and production capabilities.

Metal casting experts for performance-critical applications

Our team produces fully finished components for applications in motorsport (including F1), luxury and high-performance cars, electric vehicles, motorbikes and even hobbyist vehicles. These components are employed across various automotive systems, from the transmission, oil distribution and hydraulic actuation systems in the powertrain, to the steering and fuel systems, and even bodywork.

Customers in the high-performance automotive sector trust us to deliver outstanding, consistent results. We can create geometrically complex components with high dimensional accuracy and low wall thicknesses – helping to reduce vehicle weight while retaining the mechanical properties. Our high-integrity parts are designed to withstand the kinds of forces exerted in performance-critical automotive systems.

Aluminium sand casting is the principal manufacturing method used in our high-performance automotive work and each aspect of the sand casting process is managed with expert care and attention to detail. This requires advanced metallurgical knowledge, the finest and best quality sand, an expertly designed running system, as well as precise control of the molten metal and cooling rates. If any single aspect of the process is miscalculated, the structural integrity, strength and shape of the part could be compromised. So, precision is critically important.

We can produce machined components with tolerances down to +/- 5 microns and fully finish the product to give the desired surface condition using a range of techniques.

We also offer a variety of non-destructive testing, as well as UKAS-accredited independent testing facilities.

Future innovations

Looking ahead, we have extensive investment plans to enhance our existing capabilities. Harnessing the latest developments in simulation, scanning and 3D printing technologies will be key to meeting the challenging engineering demands driven by light-weighting, downsizing and electrification in the automotive industry.

Watch this space for further developments from Haworth Castings. To find out more, contact us on 01794 512685 or email: sales@haworthcastings.co.uk

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[1] European Aluminium, Vision 2050 Report

[2] Ducker Frontier, Aluminium Content in European Passenger Cars, 10/10/19