Alloyed collaboration results in high-strength alloy for automotive sector

December 3, 2021

Alloyed was selected to assist Grainger and Worrall in improving the performance of a complex cast-alu­minium engine block (Courtesy Alloyed)

Grainger and Worrall, Bridgnorth, Shropshire, UK, has partnered with Alloyed, Oxford, UK, to develop a new aluminium alloy, ABD®­GWA3, with improved strength, maintained ductility and good castability at production scale. The specifications for this application also aligned with a wider global push for lighter, more efficient propulsion systems.

Grainger and Worrall is a family-owned company that provides a range of manufac­turing processes, including small-series, high-integrity structural castings. Since its beginnings in 1946, the company has aimed for continuous growth in its manufacturing processes to maintain and improve the quality of its castings as new technologies emerge. As part of this, the company sought to improve the performance of a complex cast-alu­minium engine block.

The existing aluminium alloys used for this application – designated GW133® and GW116® –have been through extensive approvals and validation of the ma­terial. The aim was to improve on the specified prop­erties of these alloys within the existing validation framework.

Results illustrating the variations in strength and ductility of the new alloys (Courtesy Alloyed)

Using Alloyed’s ABD® platform – a simulation platform that provides optimisation and heat treatment options based on performance predictions – Grainger and Worrall identified three optimal alloy compositions in line with its targets. Designated ABD GWA3.4, ABD GWA3.9 and ABD ­GWA3.11, the ABD models for these compositions predicted that the strength and ductility would hit the target requirement for the en­gine block application.

Alongside developing the alloys, Alloyed also de­veloped new heat treatment cycles utilising ABD’s simulation and empirical validation capabilities to further improve strength and ductility in the alloys whilst balancing additional manufacturing costs.

These new alloy compositions were then tested under full casting produc­tion conditions, under which the proprietary alloy, ABD ­GWA3, when coupled with a unique heat treatment, provided a 30% improvement in yield strength without sacrificing ductility. This was in line with predictions made by ABD.

Since development, these new compositions have been validated to operate successfully within the approved manufacturing tolerances and are said to greatly exceed the performance of the GW133 and GW116 alloys.

Latest Industry News

Download the latest issue of PM Review

Our latest issue is now available to download in PDF format, free of charge.

As well as an extensive Powder Metallurgy industry news section, this 120-page issue includes the following exclusive articles and reports:

  • Tesla teardown: Identifying potential uses for PM in electric vehicle transmissions
  • Can European research still claim to be ‘world class’? Prof José M Torralba on the changed PM research base
  • How to make metal powders. Part 1: An introduction to atomisation, process fundamentals and powder characteristics
  • Starting out in powder production: The story of Fomas Group’s Mimete metal powder business
  • The creation of a Powder Metallurgy market leader: China’s NBTM New Materials Group Co., Ltd.
  • Tungsten heavy alloys: An exploration of how key property combinations enable better mechanical performance
  • Pharmaceuticals and PM are closer than you think: A new approach to understanding powder compaction and tablet characterisation
  • More information

Industry News


Sign up to our free e-newsletter, sent weekly to industry professionals around the world. We'll also let you know each time a new issue of PM Review magazine is available.

Subscribe for a FREE digital magazine

PM Review is the leading international magazine for the Powder Metallurgy industry.
Published four times a year, it is available as a free download or through a print subscription

Connect with us

Powder Metallurgy: The original net-shape production process

Powder Metallurgy components are relied upon by a wide variety of manufacturing industries, from automotive to power tools, household appliances, chemical engineering, filtration and more.

The main reason for the technology’s success is its cost-effectiveness at producing high volumes of net-shape components, combined with its ability to allow the manufacture of products that, because of the production processes, simply cannot be manufactured by other methods.

To discover more about how the technology has revolutionised component production, browse our Introduction to Powder Metallurgy.

Latest industry news

Copy link