All change at NovaCast as Barry Hayward retires and new faces join the team
Following a period of sustained growth, with new business growing strongly and consolidation of existing contracts, NovaCast is looking to the future with confidence. During the past few months a transformation has occurred that has seen the re-organisation of the business, the opening of new offices at its Bowerhill site, investment in the Melksham foundry...
NovaCast team complete Tough Mudder for charity
Billed as “Probably the Toughest Event on the Planet”, Tough Mudder is a uniquely challenging obstacle course that requires endurance, fitness, determination to succeed and a love of mud! So, when Richard Phillips, Sales Director at NovaCast, was looking for events to boost the coffers of the company’s chosen charity, Wiltshire Air Ambulance, the...
The Difference Between Gravity and Pressure Die Casting
Die casting is one of the most widely used casting processes but what is the difference between Gravity Die Casting and Pressure Die Casting? Both are casting processes used by NovaCast, so we are well placed to explain the differences and discuss the selection criteria. Both forms of Die Casting employ a metal mould into...
Heat Treatment of Castings
Heat treatment of castings is primarily used to alter the physical, and sometimes chemical, properties of the cast alloy. Many of the mechanical properties of both ferrous and non-ferrous alloys are determined by their microstructure. Heat treatment Is an efficient way of manipulating the crystalline structure of the alloy to modify its mechanical behaviour in...
Elements of a Sand Casting Running System
The gating system includes all those elements which connect the pouring ladle to the mould. The various elements include: Pouring Basin or cup, Sprue, Sprue Base Well, Runner, Runner Extension, In-gate and Riser. An effective gating system should: Fill the mould cavity completely before the metal starts to solidify Control the speed that metal enters...
Focus on Metal Surface Treatments
NovaCast routinely uses a wide range of metal surface treatments on its cast products to enhance their mechanical, electrical or aesthetic properties. Surface treatments and finishes are often applied following surface preparation, usually in the form of fettling, linishing or shot blasting, and any final machining. Here, we focus on the surface treatments most commonly...
Aluminium Bronze in Metal Casting
The use of Aluminium Bronze in Metal Casting is widespread as it is a remarkably versatile alloy, conforming to the requirements of BS1400, and created when Aluminium is added to Copper as the primary alloying element with smaller amounts of Nickel and Iron to boost corrosion-resistance. Various grades of Aluminium Bronze are available with the...
What is Shell Mould Casting?
At NovaCast, we offer a wide range of casting process options as each have strengths and weaknesses that make them suited to certain applications and alloy choices. Shell Mould Casting is a metal casting process similar to sand casting, in that molten metal is poured into an expendable sand-based mould. However, in Shell Mould Casting,...
Types of shrinkage inherent in the casting process
We often say that casting molten metal is like handling a living thing. Understanding how different alloys will react to different casting processes, component geometry, running systems, temperatures, etc. is part of the art of the foundry engineer. In recent years, the wealth of experience built up at the NovaCast Foundry has been enhanced by...
Engagement with Xylem’s VA/VE Programme delivers improved castings
Xylem, one of the leading global water technology companies, is committed to an ongoing process of product improvement and cost reduction. It does this, in part, through a Value Assessment and Value Engineering (VA/VE) programme in which it challenges its international supply chain to refine and improve every aspect of what they deliver. As...
NovaCast Donates $2,000 to the Planet Water Foundation
NovaCast is committed to supporting causes that enhance quality of life in communities around the world, particularly those where interventions can save lives. Having long been a supporter of Xylem Watermark, NovaCast has recently donated $2,000 to the Planet Water Foundation, one of their partner non-profit organisations. The Planet Water Foundation is a US based,...
NovaCast Invited to Join Wiltshire Air Ambulance 100 Club
In recognition of its ongoing support for Wiltshire Air Ambulance, NovaCast has been invited to become an honorary member of the 100 Club, the elite club for businesses pledging larger sums. In addition to the monthly contribution by NovaCast, staff members, led by Sales Director Richard Phillips, have already completed sponsored events to raise money for...
Non-Destructive Testing of Cast Components
The production of high-quality castings has always been a mix of sound design, technical knowledge and the foundryman’s experience in handling and managing each stage in the casting process. More recent innovations, such as casting simulation software and 3D modelling, have helped to reduce casting defects by improving both product and gating system design. Dealing...
Casting Process Simulation Complements Traditional Foundry Expertise
Casting Process Simulation is used by NovaCast to develop comprehensive modelling of the intended production process to determine the size and shape of sprues, runners, gates, and risers. One of the main benefits of these systems is that they make it possible for us to quickly identify areas within the casting geometry that could give...
The Importance of Parting Line Design in Gravity Die Cast Components
As part of our series of articles discussing various aspects of Gravity Die Casting, we are taking a look at the importance of parting line design. The parting line is where two or more sections of the Die split to release the casting. When deciding where to place the parting line, designers will need to...
The case for Sand Casting
The Sand Casting process has been a key element in manufacturing for thousands of years and still accounts for approximately 70% of all castings. Whether Sand Casting is the best option for the production of a particular component will be dictated by considerations such as the required geometry, performance, alloy choice, production run, tolerance within...
The case for Gravity Die Casting
There are many different casting processes and each has its place. The inherent characteristics of each make them ideal for a particular component geometry, performance requirement, alloy choice, production run or tolerance within specification. Gravity die or permanent mould castings use a Cast Iron or Steel mould consisting of at least two parts. The most...
NovaCast launches new company brochure
Download the NovaCast brochure “A Single Source Solution for Precision Cast and Machined Components” for an overview of our capabilities in Sand Casting, Gravity Die Casting and Investment Casting. Optimised for viewing on digital screens, our brochure will be updated regularly as we grow into new markets and introduce new technologies to our business.
Fabrication to Casting: Steam Trap re-design creates market leading solution
As specialists in the conversion of fabrications and assemblies to single cast components, NovaCast is cutting costs and improving efficiency for its customers. One such customer is EBE Engineering; manufacturers of an innovative Venturi Orifice Steam Trap. Originally a fabrication comprising a cast stainless steel body with two welded flanges; the steam trap was slow...
NovaCast shows its support for Wiltshire Air Ambulance
As well as making a donation of £1,000 for the Wiltshire Air Ambulance’s Airbase Appeal, NovaCast has pledged ongoing support by making monthly donations. NovaCast’s Sales Director, Richard Phillips, said: “Even though NovaCast is a business that trades internationally, we feel that we are part of the local Melksham community and want to contribute wherever...
Specifying the right cast Steel alloy
Cast Steel has become an increasingly important part of NovaCast’s business over recent years. The combination of excellent design, project management and quality assurance skills at our UK foundry with the low-cost, high-quality, high-capacity capabilities of our Far Eastern partners has allowed us to compete for and win many prestigious cast Steel projects. Although we...
Brexit: Snakes and Ladders on an industrial scale
So here we are. Almost a year since Article 50 was invoked and the countdown to Brexit began. The political debate rumbles on and the media frenzy about the looming “cliff edge” if no deal is agreed is gathering pace. Against this backdrop it is easy to assume that the UK economy, and UK manufacturing...
Casting Design Considerations for Design Engineers
The design and manufacture of a metal component involves a multitude of decision points and will be influenced by considerations such as structural performance, weight, lead time, cost and aesthetics. It is understandable, therefore, that thoughts about how precisely that component is going to be manufactured are often left until the design is at a fairly...
Xylem and NovaCast join forces for Cotswold conservation project
Richard and Lauren Phillips and Richard Chandler of NovaCast recently joined employees of Godwin Pumps to support a Xylem Watermark conservation project at Abbey Grounds in Cirencester...