R&D and Alloy Development
OZBROS encourages its customers to become active partners in the development process to support advanced manufacturing and improve product performance while reducing overall costs.
Our fully integrated manufacturing facility — incorporating billet casting, die production and extrusion — enables complete control over alloy composition and billet quality. This provides a significant advantage in tailoring billet properties to meet specific profile requirements.
Key R&D capabilities include:
- In-house billet casting with full alloy control
- Continuous Homogenisation process for improved microstructure uniformity
- Ultrasonic Non-Destructive Testing systems for hard alloys
- Induction billet heating for homogeneous temperature distribution
- Advanced CAD/CAM die design and simulation techniques
- MES and SAP-integrated traceability systems
By controlling alloys at source and managing the entire process from billet to finished extrusion, OZBROS delivers enhanced mechanical properties, improved yield strength and extended product lifecycle performance.
Alloy Development
The alloy development would be required for various industries, especially defense, automotive, and aerospace industries requiring high strength alloys and energy industries would require special chemical compositions for electric transmission of the aluminium alloys.
Our highly experienced R&D teams in Turkey, and our expert teams in the UK, work on your specifications and requirements in details and realize the requirements from specification to Billet and Extrusion.
Phase 1 – Customer & Engineering
- Customer Requirements
- Technical Feasibility
- Alloy Concept Design
Phase 2 – Metallurgy Development
- Laboratory Alloy Validation
- Pilot Billet Casting
- Homogenisation Development
Phase 3 – Extrusion Process Development
- Die Design
- Extrusion Trials (DOE)
- Heat Treatment Optimisation
Phase 4 – Qualification & Production
- Mechanical Testing
- Process Capability Study
- Customer Qualification
- APQP & PPAP
- Industrialisation & Serial Production
- Billet temperature
- Extrusion speed
- Ram pressure
- Die bearing length
- Quench intensity
- Cooling rate
These parameters strongly affect:
- Yield strength
- Grain structure
- Surface quality
- Profile distortion
Frequently Asked Questions
We utilise advanced 3D simulation and verification tools such as ANSYS, QForm, SolidWorks, and Pro/ENGINEER, combined with in-lab test applications to ensure performance, manufacturability, and mechanical properties.
Yes — we form long-term technical partnerships, working directly with customers to define specifications, develop tailored materials or processes, and optimise them for performance and cost.
Our processes are fully controlled via SAP-MES integrated systems, which monitor and record production parameters, heat treatment cycles, and material characteristics to ensure consistent quality, traceability and compliance.
