Introduction

Patay Bucks castings Ltd are manufacturers of aluminium gravity die castings based in Buckinghamshire. Aluminium castings are produced in medium to high volume using the permanent mould process of gravity die casting. Patay Bucks Castings are capable of producing castings up to 50 kilograms in weight with an approximate weekly capacity of 25 tonnes. 

With over 80 years of knowledge and experience we have the skills to deliver your gravity die casting project from the early stages of design to production. Send us your CAD files and we will advise you how to achieve the optimum performance in design, tooling and production. 

Our Services

Spectrographic Metalogical Testing

Spectrographic analysis is a chemical analysis used to determine the composition and grade of foundry metal. The chemical composition of aluminium alloys is critical in order for the alloys to conform to a specific grade and to achieve the required mechanical and physical properties. Patay has optical emission spectrochemical analysis on site allowing us to analysis our castings measuring element concentrations across a wide range of aluminium alloys. The process begins by casting a sample metal dab, this is then machined on a lathe prior to being placed on the arc spark optical spectrometer. The results from the test are displayed on screen to analyse, the machine automatically identifies any element’s that are outside the required boundaries. If any discrepancies arise the chemical constituents of the melted can be accordingly adjusted.

 

Tooling

Patay have significant experience in component and tooling development and modifications. For new castings projects we can work alongside the customer to evaluate any potential design improvements and cost savings in component and tooling production. Patay has a subsidiary toolroom with CNC machining, CAD modelling and pattern making facilities.

 

X – Ray 

Real time radiographic testing is a non-destructive testing method which uses x-rays to inspect the internal structure of the casting for failure investigation, casting defects, process and quality control, and research and development. The real time x-ray results allow Patay to analysis casting integrity without destroying castings and allow us to optimise our process without any downtime. 

 

Heat Treatment

Our on site heat treatment facilities allow us to use various heat treatment processes to produce several degrees of hardness required for our castings. The following heat treatment processes can be carried out inline with BSI heat treatment standards. All results can be verified using our hardness tester.

TF (Fully heat treated) – Castings are heated to between 515-535oC in a heat treatment furnace for between 4 and 12 hours before quenching in hot water. The castings are then heated in a secondary furnace at between 150oC and 160oC for a further 4 to 16 hours. A TF process will produce Brinell readings between 90-110 HB, approximately double that of a standard casting.

TB7 (Solution treated) The process begins with the same initial treatment as in TF however castings are heated to a high temperature during the secondary stage (240-275oC) for between 2 and 4 hours. Hardness value would typically be in the region of 75 and 85 HB.

TE (age hardening) – The casting is heated to a temperature of 150-170oC for between 4 and 12 hours. This process can be used to accelerate the natural age hardening of the casting.

 

Shot Blasting

Shot blasting is a metal finishing process primarily for surface preparation. The shot blasting process has many benefits for aluminium castings;

  • Increased surface area due to raising of the surface roughness.
  • Elimination of surface dirt 
  • Improved adhesion 
  • Enhanced fatigue strength 
  • Enhanced surface hardness
  • Improved cosmetic appearance

The inhouse shot blasting facilities at Patay includes an enclosed cabinet with a rotating belt, the rotation of parts during the process ensures all areas of the casting achieve an even finish. 

 

Machining

Patay can offer a comprehensive one stop CNC machining service. Our machining has benefitted from investment in both 4 and 5 axis CNC machines offering precision turning, milling, and drilling. The facilities also include lathes, radial drills, and pillar drills. 

 

Quality

Patay Bucks Castings Ltd operates an ISO 9001:2015 quality management system, audited by a UKAS accredited authority, Socotec.

 

Our Processes

At the first stages of contact with our customer, the design brief and operating conditions of the final product are discussed. We are then able advise our customer on the required quality standards and procedures needed to ensure the correct quality and functionality at a commercially acceptable price.

 

Additional quality assurance options

Spectrographic analysis of material

Radiography (X-ray)

Hardness testing

Tensile testing

Crack detection

We will advise our customers which additional quality specification to choose to meet required standards for the project.