A large structural chassis casting weighing just 25kg developed in aluminium by Sarginsons Industries for an automotive application was a finalist at the recent Best of British Castings Awards.

With prototype castings from alternative suppliers failing during crash testing Sarginsons Industries’ client was experiencing problems with the gooseneck design.  Having evaluated alternative suppliers, they then approached Coventry based Sarginsons to collaborate on a new design for this complex structural casting.

Complete redesign of part was carried out against short lead times, resulting in the removal of one sand core and introduction of a strengthening rib. Computer aided engineering simulation studies were carried out including modelling of forced chilling, microstructure predictions and in-service stressed conditions to confirm the design.  Prototypes were produced in just 10 weeks and the castings successfully passed crash testing.

MD at Sarginsons Industries Andy Payne explains, “This has been a challenging project but many of the highly technical R&D processes and solutions are now being applied to other global client projects, leading to new business for the company worth several £ millions.”

Organised by the Cast Metals Federation, with CEO Dr Pam Murrell and comedian Geoff Norcott, as co-presenters, the UK Cast Metals Industry Awards Dinner attracted nearly 200 guests and focused on the great castings being manufactured in metal by UK foundries.

There were also major accolades for Tamworth-based Foseco (Innovation), William Cook Holdings (Company) in Sheffield and North Yorkshire based Sylatech Ltd who claimed the Component of the Year Award.

As Dr Pam Murrell explained “The evening clearly showcases the role of the sector in supplying highly complex and engineered near net shape components in metal for a wide range of sectors in the UK – we had some fabulous entries and all the finalists can be very proud of their achievements.”