Specialists in the production of zinc & aluminium sand castings & gravity die castings
Our established zinc & aluminium foundry in the West Midlands produces high quality castings in various grades, sizes and quantities using the airset and gravity die casting processes.
- 5,000m² Facility
- 50+ Materials
- 5 Cold Box Core Blowing Machines
- 3 Dressing Robots
Would you like to discuss a project?
Telephone: +44 (0) 121 557 9831
Email: sales@newbyfoundries.co.uk
High or Low Volume Runs
From tens to tens of thousands, we have the flexibility to cater for both.
Wide Range of Sizes
Our variety of furnaces allow us to cast intricate parts from 100g up to large 150kg castings.
Zinc Gravity Die Casting
We are one of the few foundries who cast zinc alloys using the gravity die process.
PROCESSES
Newby Foundries Light Alloys primarily produce castings using the airset moulding and gravity die casting processes. Gravity die casting is most suited to higher volume runs whereas airset moulding is most suited to low to medium volume production and large zinc or aluminium castings. Utilising the facilities of the Newby Foundries Group we are also able to offer 3D sand printed moulds & cores for prototypes or complex geometries. Therefore, we can provide customers with the most suitable casting solution for many applications, from 1 offs to thousands.
Find out more about the processes we offer below.
Airset Moulding
- Chemically bonded and hand rammed
- Resin tooling is available in various grades
- Low to medium volume
Cold-Box Core blowing
- Gas cured blown sand
- Used in combination with other processes
- Low to high volume
- Fast curing
- Resin tooling is available in various grades
- High tolerance
- Smooth surface finish
Gravity Die
- High volume
- Up to 25kg
- Cost effective piece price
- CT7 tolerance
- Very smooth surface finish
- Ra 3.2µm
3D Sand Printing
- Furan system
- 1,800 x 1,000 x 700mm bed size
- Layer thickness: 0.28mm
- No tooling required
- Moulds and cores produced without tooling
Materials
We produce many grades of zinc and aluminium including those requiring solution & precipitation heat treatments. Customer specific grades are also available on request. Our range of furnaces allow us to cast zinc parts up to 80kg and aluminium parts up to 150kg.
We can produce the following materials. Non-standard and customer specific grades are available on request.
Aluminium
- Al 99.5
- Al-Si5Cu3
- Al-Si12
- Al-Si12Fe
- Al-Si10Mg
- Al-Si12Cu
- Al-Si12CuFe
- Al-Si5Cu1Mg
- Al-Si12Cu
- Al-Si12CuFe
- Al-Si7Mg
- Al-Si7Cu2Mn0.5
- Al-Si17Cu4Mg
- AlSi7Mg0.3
- AlSi7Mg0.6
- AlSi9Cu1Mg
- AlSi5Cu3
- AlSi7Mg0.3
Zinc
- ZnAL4Cu1
- ZnAl11Cu1
- ZnAl27Cu2
Newby Foundries are committed to sourcing materials from companies that share our values in relation to human rights, ethics and environmental responsibility. We demand our suppliers comply with our code of conduct, and meet our sustainability expectations, including conflict free sourcing of materials. To ensure this commitment is fulfilled Newby Foundries ensures that its products are produced using only materials which can be proven to have originated from non-conflict sources.
Sectors
Newby foundries light alloys operate in the following industries:
We supply castings such as pumps, fans, brackets, and housings to a diverse range of customers. These include automotive, electric vehicle, oil & gas, power generation and pump OEMs as well as general engineering.
Automotive
EV
Oil & Gas
Street Furniture
PUMP
Rail
Engineering
MARINE
EQUIPMENT
Core Making
- 4X 20L cold box core blowing machines
- 1x 10L cold box core blowing machine
Melting
- 22x electric holding furnaces
- 3x bulk melt furnaces
- 2x plc controlled rotary degassing units
- 1x rotary degassing unit
- 2x density index verification machines
- 4x plc controlled gravity die tilt rigs
Moulding
- 3x 5 tonne per hour airset mixers
Sand Reclamation
- 3x attrition units
Blasting
- 2x rotary hanging shotblast units
- 1x directional shotblast cabinet
- 3x CNC dressing robots
Heat Treatment
- 2x heat treatment ovens
- 1x quench tank
Quality
- Spectrograph
- Brinell hardness machine
- Pressure test unit
OTHER SERVICES
Discover the services Newby Foundries Light Alloys can also assist with:
QUALITY
- Material testing laboratory
- Dimensional analysis reports
- PPAP & APQP
- MPI, DPI & X-ray
- Pressure testing
- Ultrasonic testing
Divisions
Explore the Newby Foundries Group
The Newby Foundries Group produce high quality castings in a variety of materials, sizes & finishes across our 4 sites. Our range of casting processes, combined with our ability to develop castings from prototype through to production means we can provide customers with an optimal casting solution for many applications.
contact Newby Foundries light alloys
Newby Foundries are specialists in the production of zinc & aluminium sand castings & gravity die castings.
Contact us to arrange a consultation or to chat to one of our team members today.
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Telephone: +44 (0) 121 557 9831
Email: sales@newbyfoundries.co.uk
Address:
Bagnall Street, Great Bridge, Tipton, West Midlands, DY4 7BS
Charter Castings Ltd. T/A: Newby Foundries Light Alloys.
