Casting method saves energy

A novel method of casting aluminium could save the UK's light-metal foundries up to one third of their energy costs while significantly improving casting quality.

Traditional foundry methods involve melting hundreds of kilograms of aluminium and keeping it hot while ladling out what is needed into a mould, a process that is energy inefficient and can cause defects.

The CRIMSON (Constrained Rapid Induction Melting Single Shot) process ensures that the exact amount of aluminium needed for a particular casting is melted rapidly in a crucible, using induction heating. It is then squeezed upwards into a cast using a device like a toothpaste pump dispenser. The fully liquid metal is pushed up with a piston controlled by hydraulic motors linked back to computers that accurately control filling of the casting.

Developed by

researchers and local SME

, CRIMSON has received £800,000 from the EPSRC and project partners to get it to the benchmarking stage.

Dr Mark Jolly, a senior lecturer at Birmingham University's department of mechanical engineering, is leading a project to compare the energy used in traditional foundry processes against CRIMSON and develop a model of the energy used at each stage. This will allow a like-for-like comparison of the energy used to create a certain part.