Small And Medium-Sized Business Operations
Lightweight Alloy focuses on developing lightweight alloy castings, forgings, plates, strips, foils, tubes, bars, profiles, and components—critical for weight reduction in the aerospace industry. The company employs an innovative business model of "research institute pre-research combined with corporate industrialization," meticulously following the nine-level maturity framework for new materials used in military applications. This approach spans from lab-scale validation (starting with just a few kilograms), through small-scale trials involving tens or hundreds of kilograms, to medium-scale pilot production at the ton level—and finally to full-scale, mass-production processes. Leveraging its domestic expertise in researching and developing cutting-edge aluminum and magnesium alloys, the company is uniquely positioned to create high-precision, specialized, and innovative small-batch, multi-variety, high-performance materials tailored specifically for the aerospace sector. Moreover, LightWeight Alloy boasts end-to-end development capabilities—from design blueprints to delivering finished components—including mold design and fabrication, melting and casting, non-destructive testing, heat treatment, machining, surface finishing, and rigorous quality inspections. With a comprehensive portfolio of next-generation lightweight alloys and diverse weight-reduction solutions, the company is well-equipped to significantly enhance aircraft performance. Its advanced products—including ultra-light magnesium-lithium alloys, high-strength heat-resistant magnesium-rare earth alloys, aerospace-grade high-strength aluminum-lithium alloys, and robust heat-resistant aluminum-copper alloys—as well as high-purity lithium-lead alloys, high-strength copper-silver-zirconium alloys, and state-of-the-art surface treatments for aluminum-magnesium-titanium lightweight alloys—all meet or exceed domestic industry standards.
1. Alloy Melting and Casting Tests
Melting and Casting Testing Capabilities: We conduct research on melting and casting process technologies for non-ferrous alloys such as aluminum, magnesium, copper, lead, and zinc. This includes studying alloying techniques, melting processes, modification treatments and grain refinement methods, as well as melt purification and homogenization technologies, and ingot casting and shaping techniques.
It is possible to conduct melting and casting experiments on non-ferrous metal alloys weighing between 2 and 1000 kg, under both vacuum and non-vacuum conditions.
1.1 Vacuum Melting Furnace
This includes two 25-kg, two 100-kg, and two 200-kg medium-frequency induction vacuum melting furnaces for pilot-scale testing, as well as one 1,000-kg medium-frequency induction vacuum melting furnace for semi-industrial trials.
Alloy melting and casting conducted under vacuum or in an inert protective atmosphere can minimize alloy burn-off and reduce oxide inclusions, thereby effectively enhancing the quality of the molten alloy.
Number | Device Name | Capacity | Key Features | Applicable Products |
1 | Vacuum Induction Furnace | 25kg | Aluminum, magnesium, and copper alloy melting and casting | Magnesium-lithium alloys, magnesium-rare earth alloys, aluminum-lithium alloys, copper alloy cast rods and flat ingots for aerospace and aviation applications |
2 | Vacuum Induction Furnace (Directional Solidification) | 25kg | Aluminum, magnesium, and copper alloy melting and casting, with the added capability of directional solidification. | |
3 | Vacuum Induction Furnace (American Consarc 3-Chamber) | 100kg | U.S.-made Consarc imported vacuum furnace melting unit (3 chambers), enabling the melting and casting of aluminum, magnesium, and copper alloys. | |
4 | Vacuum Induction Furnace (Water-Cooled Mold Casting) | 200kg | Aluminum, magnesium, and copper alloy melting and casting, with the added capability of water-cooled mold casting. | |
5 | Vacuum Induction Furnace | 200kg | Aluminum, magnesium, and copper alloy melting and casting | |
6 | Vacuum Induction Furnace | 1000kg | Aluminum and Copper Alloy Melting and Casting |
25kg Vacuum Induction Melting Furnace 25kg Vacuum Induction Melting Furnace (Directional Solidification)
U.S. Consarc 100kg Vacuum Melting Furnace (3 Chambers) | 200kg Vacuum Melting Furnace (Water-Cooled Mold Casting)
200kg Vacuum Induction Melting Furnace, 1000kg Vacuum Melting Furnace (for copper alloys and aluminum alloys)
1.2 Semi-Continuous Casting of Aluminum Alloys: Testing and Development
1.2.1 Characteristics of the Semi-Continuous Casting Process
The hot-top semi-continuous casting process features no metal flow drop, ensuring a smooth pouring process. The primary and secondary cooling water systems are seamlessly integrated, providing uniform cooling that promotes sequential solidification of the aluminum melt. This minimizes non-metallic oxide inclusions, porosity, and other structural defects, significantly enhancing product purity. Additionally, the upper section of the crystallizer offers excellent thermal insulation, allowing for lower casting temperatures. As a result, the resulting cast billets exhibit a fine, uniform microstructure with minimal segregation, leading to improved internal quality.
Schematic Diagram of the Mold Structure for Semi-Continuous Casting with a Hot Top
Surface Quality of Aluminum Alloy Ingots
X-ray inspection images of aluminum alloy ingots
1.2.2 Semi-Continuous Casting Test Equipment
Our company has 5 melting units available for semi-continuous aluminum alloy casting trials, with each furnace capable of handling melt volumes ranging from 300 kg to 8,000 kg.
Major aluminum alloy semi-continuous casting equipment and mold specifications.
Serial No. | Equipment Model | Melting Temperature | Molding Pan Crystallizer Specifications |
1 | 8000kg Heat-Storing Tilting Gas-Fired Melting Furnace | Up to 900°C | 1. Round Bar Crystallizer Specifications: Φ254mm, 8-hole dense-pack disc Φ350/130mm, 6-hole close-pitch disc |
2 | 1000kg Resistance Melting Furnace | Up to 850℃ | 1. Round Bar Crystallizer Specifications: Φ88.5mm, 8-hole dense-array disc Φ178mm, Φ225mm, Φ254mm, Φ350mm, single-hole disc 2. Square billet crystallizer specifications: 80×80mm, 12-hole dense-row disc 3. Slab billet crystallizer specifications: 735×235mm, single-hole disc |
3 | 500kg Electromagnetic Induction Melting Furnace | Up to 900℃ | |
4 | 500kg Resistance Melting Furnace,2 units | Up to 850℃ |
8-ton heat-storage tilting gas melting furnace with casting machine
1000kg Medium-Frequency Resistance Furnace
500kg Aluminum Alloy Resistance Melting Furnace
1.2.3 Semi-Continuous Cast Aluminum Alloy Test Product
Trial product series: 2XXX aluminum-copper alloy
3XXX Series Aluminum-Manganese Alloy
4XXX Series Aluminum-Silicon Alloy
5XXX Series Aluminum-Magnesium Alloy
6XXX Series Aluminum-Magnesium-Silicon Alloy
7XXX Series Aluminum-Zinc Alloy
Custom aluminum alloys (non-standard), such as Al-Er alloy, Al-Sn alloy, Al-Sc, and Al-Fe alloys, among others
Test product specifications: Round bars measuring Φ88.5mm, Φ178mm, Φ225mm, Φ254mm, and Φ350mm
Square bar 80×80 mm
Large ingot, 735 × 235 mm
Φ88.5 × 700 mm Aluminum Alloy Round Cast Rod
80×80×720mm aluminum alloy square bar
Φ178 mm aluminum alloy round casting billet
Φ254 mm Aluminum Alloy Round Cast Rod
Φ350 mm Aluminum Alloy Round Cast Rod
Solid aluminum alloy round casting rods of various specifications
Aluminum alloy solid and hollow round casting rods of various specifications
Φ800/520 mm Large-Scale Hollow Aluminum Alloy Round Casting Rod
735×235mm large aluminum alloy ingot
1.3 Non-Vacuum Melting and Casting Test
Alloy melting and casting conducted under non-vacuum or inert protective atmospheres, combined with medium- or high-frequency electromagnetic induction stirring or mechanical stirring, promotes uniform alloy composition and temperature distribution in the molten metal, and is supported by an automated ingot casting machine.
For small-scale trials, we have one 3 kg and one 4 kg resistance melting furnace. For pilot-scale production, we’re equipped with two 500 kg resistance melting furnaces, one 500 kg electromagnetic melting furnace, three 750 kg medium-frequency induction melting furnaces, and one 1000 kg tilting resistance melting furnace.
| Number | Device Name | Capacity | Key Features | Applicable Products |
| 1 | Tilting Crucible Furnace – German Nabholz K4/10 | 3kg | Melting is carried out under a protective atmosphere, ensuring stable melting control conditions. The pneumatic tilting mechanism guarantees smooth pouring of the molten alloy. | Aluminum alloys and other non-ferrous metal alloys |
| 2 | Tilting Crucible Furnace – German Nabholz K4/13 | 4kg | Magnesium alloy | |
| 3 | Resistance Melting Furnace | 3kg | —— | Melting of alloys such as aluminum, lead, and zinc |
| 4 | Resistance Melting Furnace | 500kg | —— | Melting of cast aluminum alloys, zinc alloys, and lead-based alloys |
| 5 | Electromagnetic Induction Melting Furnace | 500kg | ||
| 6 | Medium-Frequency Induction Melting Furnace | 750kg | Medium-frequency electromagnetic stirring promotes compositional uniformity in alloy melts, paired with a semi-continuous ingot casting machine. | High-temperature refractory, easily oxidized, highly segregated in density, and low-in-impurities intermediate alloys of aluminum, copper, lead, and zinc—such as high-purity aluminum-based intermediate alloys for the aerospace industry, alloys used in modification treatments, and other innovative new alloys. |
| 7 | Resistance Induction Melting Furnace | 1000kg | The furnace body can automatically tilt, paired with an automatic ingot casting machine. | Casting alloys and intermediate alloys such as aluminum, magnesium, lead, and zinc |
4kg K4/10 Tilting Crucible Furnace, 250kg Aluminum Alloy Resistance Melting Furnace
750kg medium-frequency induction melting furnace, 1000kg resistance melting furnace
2. Compression and Tensile Tests
The extrusion and drawing test line is equipped with a 630-ton extrusion press and a ten-station wire-drawing machine, complemented by an annealing heat treatment furnace, a rapid induction heating furnace, a die heating furnace, a material discharge platform, a straightening machine, and other related equipment.
The extrusion cylinder of the 630-ton press has an inner diameter of Φ95 mm and operates at an extrusion temperature of 900°C. It enables the development and production of a wide range of products, including tubes, bars, profiles, wires, and sheets—such as seamless tubes made from aluminum (magnesium or copper) alloys, sacrificial anode rods crafted from magnesium (aluminum or zinc) alloys, magnesium (zinc) strips, and aluminum (magnesium) alloy welding wires, among other items.
| Device Model | Production capacity | Product Brand Name | Product Specifications |
| Extruder | Compression force: 630 tons, extrusion speed: 200 kg/h (calculated based on aluminum) | 1. Deformed Aluminum and Aluminum Alloys 1XXX–7XXX | 1. Extrusion billet ingot Φ92 × 300 mm |
| 2. Deformed magnesium and magnesium alloy series AZ, ZK, ME, and MgLi alloys | 2. Extruded round bar product specifications: Φ9.5mm, Φ13mm, Φ18mm, Φ21mm, Φ25mm, and 36mm | ||
| 3. Pure Zinc and Zinc Alloys | 3. Extruded strip product specifications: 10×20 mm, 1×29.5 mm, and 1.4×95 mm | ||
| 4. Red Copper and Copper Alloys | 4. Extruded pipe product specification: Φ30/26 mm | ||
| 5. Extruded profile products, such as Mg(Zn) sacrificial anodes | |||
| Wire drawing machine | Ten consecutive pulls, with a pulling speed of 200 kg/h (calculated based on aluminum) | 1. Deformed Aluminum and Aluminum Alloys 1XXX–7XXX | Wire diameter ranges from 1 to 4 mm, such as aluminum or magnesium alloy welding wires. |
| 2. Deformed magnesium and magnesium alloy series AZ, ZK, ME, and MgLi alloys | |||
| Annealing Heat Treatment Furnace | —— | —— | —— |
| Mold Heating Furnace | —— | —— | —— |
| Quick-Induction Heating Furnace | —— | —— | —— |
| Straightening Machine | —— | —— | —— |
630-ton extrusion press, 10-unit continuous wire-drawing machine
Ceramic molds for extrusion, magnesium strip extrusion products
Magnesium (Zinc) Alloy Extruded Profiles Magnesium Alloy Extruded Sacrificial Anode Bars (Domestic Early-Entry Product)
Aluminum alloy extruded round bars, aluminum alloy extruded straight wire for welding 3, and alloy rolling tests.
3. Alloy Rolling Test
The rolling test line is equipped with a four-high precision mill (Φ80/350 × 320), a two-high hot and cold rolling mill (Φ250 × 500), and two experimental two-high rolling mills (Φ120 × 200 and Φ80 × 200). It also features a heating furnace, coiler, coil slitting machine, and a 20-roll plate straightener. This setup allows for hot roughing, cold rolling, and precision rolling of non-ferrous alloys such as aluminum, magnesium, and copper. The line is ideal for conducting alloy-specific rolling process trials and can produce plates, strips, and foils ranging in thickness from 0.02 mm to 40 mm and widths from 50 mm to 400 mm.
| Equipment | Rolling width | Rolling thickness | Rolling force | Equipment Capabilities |
| Cold and hot rolling mill Φ250 × 500 mm | ≤400mm | 0.5–65 mm | 100T | The rolling mill can perform both cold and hot rolling, and with its integrated front-and-back coiling systems, it enables the production of rolled coils. It is equipped with a 700°C hot-air circulating carriage furnace featuring ±5°C precision, making it ideal for rolling production involving non-ferrous alloys such as magnesium, aluminum, and zinc. |
| Four-roll finishing mill Φ80/350 × 320 | ≤250mm | 0.05–2 mm | 80T | The rolling mill can perform strip precision rolling, making it ideal for producing colored alloy strips and foils such as magnesium, aluminum, and zinc. |
| Trial roughing mill Φ120 × 200mm | ≤200mm | 1–10 mm | 10T | Equipped with one 1350°C high-temperature heating furnace, featuring high furnace temperature and precision of ±5°C, ideal for rolling tests on non-ferrous alloys. |
| Trial Finishing Mill Φ80 × 200mm | ≤200mm | 0.02–1 mm | 500kg | The rolling mill can perform cold precision rolling on non-ferrous alloys such as aluminum, magnesium, and zinc, making it ideal for foil and strip rolling experiments—with the ability to achieve extremely thin rolling thicknesses as low as 0.02 mm. |
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