A U.K. foundry is installing a vacuum investment casting system as part of an estimated $2.75-million (£2 million) effort focused on expanding its support for the British defense and aerospace industries. Wall Colmonoy Ltd.’s EVaCC initiative will establish vacuum pressure investment casting at the foundry in Pontardawe, Wales, significantly enhancing its ability to produce aerospace components, while strengthening the domestic manufacturing base and ensuring a secure supply chain for defense-sector customers.
Once it is operating, Wall Colmonoy’s VPIC will cast nickel-based superalloys for complex parts that are critical to most aerospace engine programs.
In addition to vacuum pressure investment casting, the plant will be introducing microstructural refinement technology to improve the mechanical performance of castings, which will allow for more design flexibility – specifically to achieve thinner airfoil sections and weight savings.
Preparations for commissioning are underway, with full operation expected in the coming months, according to Wall Colmonoy.
“This investment represents a major milestone for Wall Colmonoy Limited,” stated Dr. Chris Weirman, technical director. “It will enable us to meet needs of critical industry sectors and contribute to the advancement of the U.K.’s defense and aerospace capabilities.”
Wall Colmonoy develops and manufactures nickel and cobalt-based alloys, castings, and precision components. The organization also produces advanced metal coatings, and offers brazing, heat treatment, and welding capabilities.
Currently, the foundry’s capabilities include investment casting, centrifugal casting, sand casting, and vacuum casting, as well as hot isostatic pressing.
Wall Colmonoy is collaborating with the Rolls-Royce engineering center in Bristol, England, to retrofit and integrate the new VPIC technology. And the partnership between the two companies will address major engineering challenges, anticipating a long-term collaboration to develop engine-grade components.
“Wall Colmonoy are committed to the future of UK manufacturing and developing supply chain resilience to protect sovereign capabilities for a wide range of industrial applications on the global stage. Building upon our core competencies of producing specialist alloys, we have a unique value proposition to offer our customers,” stated Michael Shreeve, business unit manager for Precision Components.