Low-Pressure Casting Solutions
Ozbros provides advanced low-pressure aluminium casting solutions designed to manufacture high-integrity components requiring excellent mechanical performance, structural reliability, and dimensional precision. Low-pressure die casting (LPDC) is widely recognised as one of the most reliable aluminium casting technologies for producing structural, safety-critical and pressure-tight components used in demanding engineering applications.
In the low-pressure casting process, molten aluminium is introduced into the mould through a controlled pressurised filling system. This method enables smooth and turbulence-free metal flow, significantly reducing the risk of gas entrapment and internal defects. As a result, low-pressure casting produces components with high density, improved mechanical strength, superior fatigue resistance and excellent surface quality.
This technology is particularly suitable for parts that require consistent metallurgical structure and repeatable performance, especially in applications where reliability and long-term durability are essential.
Advanced Low-Pressure Casting Technology
Our production facilities utilise modern low-pressure casting machines equipped with controlled melting systems, automated temperature management, and precision mould filling technology. These systems allow precise control of the casting process, ensuring optimal solidification conditions and uniform material properties throughout the component.
Dedicated casting cells integrate:
- Controlled furnace systems
- Automated pressure regulation
- Thermal management for mould heating and cooling
- Advanced mould design and simulation
- Automated process monitoring
This highly controlled environment ensures that each component is produced with excellent repeatability, minimal porosity and consistent metallurgical quality.
Aluminium Alloys for Low-Pressure Die Casting
Low-pressure casting is widely used with aluminium alloys designed for structural strength, fatigue resistance and heat performance.
Available aluminium casting alloys include:
- EN AC-43000 (AlSi10Mg)
- EN AC-43100
- EN AC-43200
- EN AC-42200
- EN AC-46200 (AlSi9Cu3)
- ETIAL 171
- ETIAL 177
These alloys are commonly used for structural cast components where high strength, good elongation and improved fatigue resistance are required.
Aluminium alloys such as AlSi10Mg and AlSi7Mg are particularly suitable for components that undergo heat treatment to improve mechanical properties, making them ideal for structural engineering applications.
Typical Low-Pressure Die Casting Components
Low-pressure casting enables the production of components that require high structural integrity and pressure tightness. The process is widely used for medium-to-large aluminium parts where consistent quality and reliable performance are critical.
Typical components produced using low-pressure casting include:
- Engine housings
- Structural brackets and mounting systems
- Pump housings
- Fluid management components
- Thermal management systems
- Mechanical support structures
- Pressure-tight aluminium housings
Because of the excellent material density achieved through the LPDC process, these components offer superior fatigue resistance and long service life.
Integrated Testing and Metallurgical Validation
To ensure the highest level of quality and reliability, Ozbros operates fully equipped mechanical and metallurgical testing laboratories supporting the entire casting process from material verification to final component validation.
Mechanical and metallurgical testing capabilities include:
- Fatigue testing equipment
- Radial and axial fatigue testing systems
- Tensile strength testing
- Impact testing
- Hardness testing
- Thermal analysis
- Density and porosity testing
- Metallurgical microscopy
- Spectrometer chemical analysis
- Dimensional inspection and 3D measurement
These advanced inspection and validation systems ensure that all cast components meet strict engineering and performance requirements.
Engineering and Process Development
Our experienced engineering teams support customers from the early product development stage through to serial production, including casting simulation, mould design optimisation and manufacturability analysis.
By combining advanced engineering expertise with modern casting technologies, Ozbros provides reliable aluminium casting solutions for high-performance industrial applications, ensuring optimal material performance, dimensional accuracy and production efficiency.
