Doncasters at the Forefront of Investment Casting Excellence
MELBOURNE, UK: Doncasters, the leading global manufacturer of precision components and assemblies for the aerospace industry, is pioneering the development of the investment casting process at its Precision Castings facility in Bochum, Germany.
Doncasters Precision Castings - Bochum is an industry leader specialising in high volume cast superalloy blade and vane airfoils for high-temperature, tolerance-critical applications for aerospace and industrial gas turbines. Over $25m has been invested over recent years to make the site unique in its field in the manufacture of leading edge equiaxed, directionally solidified (DS) and single crystal (SX) castings.
A crucial differentiator is that Doncasters Precision Castings - Bochum possesses all the key manufacturing and supply chain processes in-house, which provides an unrivalled level of capability for the site and its customers. Bochum not only has its own manufacturing facilities for the production of superalloys and ceramic cores - capabilities also include hot isostatic pressing (HIPing), heat treatment and worldleading liquid metal cooling technology (LMC). These, along with recent technical advancements such as the implementation of advanced cooling designs and the introduction of higher temperature alloys, have helped to develop products that can better withstand the harsh environment created in gas turbines and give overall enhanced performance for its customers.
In addition to proven manufacturing performance, Bochum has developed a culture which promotes Six Sigma and Kaizen principles. The site has 16 Kaizen Green Belts and two Kaizen Black Belts. This level of commitment to continuous improvement has enabled Bochum to quickly adapt to the major challenges facing the aerospace market and aero-engine manufacturers' requirements for shorter lead times and a reduction in the number of supply chain partners.
Bochum's unique specialist technology to manufacture components of the highest specifications combined with its reputation for providing a tightly-focussed, responsive customer service, has resulted in the site becoming a vital part of the supply chain solution for leading OEMs. The site has been awarded a number of high profile contracts from aerospace industry leaders such as Rolls-Royce and Turbomeca.
Rolls-Royce has selected Bochum to produce directionally solidified low pressure blades for its Trent 1000 engine for the new Boeing 787 Dreamliner and its Trent 800 engine for the Boeing 777. Turbomeca, the leading manufacturer of small turbine engines for helicopter, ground and marine applications, has appointed Bochum to produce single crystal airfoils for the Arrius, Arriel and TM 333.
Eric J. Lewis, CEO of Doncasters, says: "Bochum is at the forefront of casting technology, proven by its track record of innovation and results for customers. Opportunities from aerospace manufacturers such as Rolls-Royce and Turbomeca are testimony to Doncasters' excellence in casting technology - a reputation which we are continually striving to improve even further."
The Doncasters Group is a leading international manufacturer that supplies precision components and assemblies to the aerospace, power generation, specialty automotive and medical orthopaedic industries. Doncasters excels in working with alloys and metals that are difficult to shape and form.
The company's unparalleled range of products and processes has been developed to offer customers a broad, vertically integrated capability. Core manufacturing processes include precision casting, forging, fabrication, machining and production of superalloys.
Key products include airfoils, structures, casings, rings, exhausts and combustion components for gas turbine applications, aerostructures and components for airframe applications, femoral knees, tibial trays, humeral stems, femoral hips and bone plates for orthopaedic applications and compressor and turbine wheels for the turbocharger market. The company offers well-developed supply chain integration solutions, delivering complex assemblies and engine-ready components to its customers.
Doncasters employs some 4,700 people at over 20 sites across Europe, the USA and Mexico. The Group has institutionalised lean manufacturing and Six Sigma principles throughout its operations.
For more information contact:
Caroline Gamble, Doncasters Group Ltd.
T: 44 (0) 1332 864900
