EXCEL™ Billet Casting

Meeting the Needs of the Aerospace Industry and Beyond

At Almex, we understand that a versatile billet casting system is key to the success of any casthouse. We have used our comprehensive understanding of the DC casting process, metallurgical properties, mechanical design and modern manufacturing methods to develop a casting system that offers exceptional safety, productivity and value. Unlike other casting systems, the Almex Excel Billet Casting System was designed to effectively handle both hard alloy, large-diameter billets required by the aerospace industry, as well as conventional alloys and sizes for more traditional alloy applications. Almex systems are simpler, cleaner, more flexible, and more cost-effective to own and operate than any other casting system in the world. We partner with you to configure a billet system that will meet your exact specifications.

Our commitment doesn’t end once your equipment is commissioned.
Almex provides the technical know-how for effective billet production. We focus on the entire melting and casting process, and guarantee the results of the billet.

Primary System Components

• Mold Tooling — Using level-pour (hot-top) technology, molten aluminum flows from a distribution launder into water-chilled molds, solidifying the metal into the desired billet shape. Almex uses relatively short molds, resulting in rapid cooling that enhances billet metallurgical properties.

• Mold Table — Almex billet mold tables are fabricated from structural steel plate and stainless steel rectangular tubing. The internal passages are painted with an epoxy coating to prevent corrosion resulting from the continual presence of water.

• Molten Metal Distribution Launder — Sized for the specific molten metal flow rate, the Almex distribution launder allows varying launder cross sections, minimizing heat loss, and maintaining uniform metal temperature and fill rate for all molds.

• Starting Head Base — The starting head base is fabricated from heavy structural steel plates and wall pipes for maximum strength and rigidity. The assembly is stress-relieved prior to machining, and after fabrication is thoroughly cleaned, sandblasted and painted to provide the best in durability, corrosion protection and molten metal contact protection.

• Starting Heads — Almex starting heads are designed using state-of-the-art 3-D modeling software and are machined with accurate cavities and external dimensions on computer-controlled machining centers. This guarantees concentric casting of the billets. A specialized starting head is available for hard alloy and large-diameter billet casting.

Almex Optima™ Billet Molds — Designed for High Productivity and Effective Operation

Almex Optima Billet Molds are specially configured for casting hard alloys with long freezing range and common alloys — a major step ahead of traditional hot-top DC casting systems. The combination of mold design and casting practices results in high recovery of hard alloy billet in sizes up to 42 inches (1042 mm) in diameter.

Our systems are simpler, cleaner, more flexible and more cost-effective to own and operate than any other leading casting system in the world.
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