Aerospace casting is not a different process from other casting. It is the same fundamentals: pattern, mould, pour, solidify, inspect. What makes it different is the framework within which every step is controlled, documented, and verified, and the consequence of getting any of it wrong.
Maybrey Precision Castings has held unbroken aerospace approval since 1936, when the Air Registration Board first approved our foundry for aviation work. That certification is now AS9100 Rev D. No other UK foundry has held a longer continuous record of aerospace approval.
What Aerospace Casting Requires
Aerospace castings must meet tight dimensional tolerances, specified mechanical properties, and full chemical traceability. At Maybrey, our aerospace work is produced on a dedicated line using only new PepSet silica sand. Aluminium only is melted on this line: cross-contamination with other alloys is not permitted.
Aerospace Alloys
We cast in the full range of aerospace specification aluminium alloys, including BS2L99, BSL169, A356, A357, and BSL119 (RR350). Every incoming ingot is tested on our calibrated Spectro MAX X spectrometer before use. No ingot enters production that has not been analysed and confirmed.
Traceability: From Ingot to Despatch
A router card follows every aerospace casting through the facility from moulding to despatch. Each processing step, the operator, date, and any non-conformances are recorded. Certification is issued from our in-house quality database system once all required processing and testing is complete.
Chemical and Mechanical Testing
Releasing a casting under AS9100 requires both chemical analysis and mechanical testing. Chemical analysis is carried out using Spectro MAX X spectrometers: at incoming inspection, as a daily foundry check, and as a final analysis for the certificate of conformity. Mechanical testing is carried out using our 0.5% resolution 100 kN WDW-100-E Tensile Tester, compliant to BS EN ISO 7500-1:2018.
NADCAP Sub-Contracted Processes
- Non-destructive testing (NDT)
- Hot isostatic pressing (HIPping): eliminates internal porosity in safety-critical castings
- X-ray inspection
- Dye penetrant testing
An Illustrative Application
One application that illustrates the capability of the process is the Ram Air Turbine (RAT) system: the emergency power generation unit deployed in the event of engine failure on certain aircraft. Safety-critical by definition. This is the standard to which our aerospace casting is held, across every component we produce for this sector.