New foundry alloys

Original RUSAL materials to produce castings using various methods. They allow Customers to reduce costs of end products by decreasing material consumption or by using a shorter production cycle due to processability.

RUSAL created a new generation of Nikalin high-strength foundry alloys for the automotive industry. By using special eutectic-forming additives, the materials have got the fluidity typical for traditional aluminium-silicon alloys, which allows them to be used for casting parts of complex shape by various methods, including die casting technologies. The unique composition of these alloys allows achieving a strength and fatigue level exceeding the existing A356 alloys by 30-40%.

Another group of innovative materials are high-tech alloys for die casting. The use of new approaches to the design of alloys has allowed creating a line of alloys which can be applied immediately after casting without additional heat treatment. Their high processability and shorter production cycle allow decreasing the cost of finished parts by up to 30% by preventing defects during casting and subsequent deformations during heat treatment. The high plastic properties of the alloys allow applying them for elements that experience significant deformations during operation and installation.

All materials have been successfully tested for casting various parts in research centres and production companies in Russia, Europe and Asia.


Wrought aluminium alloys

A new generation of materials for various industries and the national economy. These products have been designed as a replacement for traditional aluminium alloys and steels due to an improved set of properties.

MaxiFlow is RUSAL's own brand for 6xxx alloys, which are characterised by improved processability when pressing various products, including panels with complex geometries. In terms of their strength, they fully comply with international specifications for relevant brands, but at the same time they demonstrate an increased metal flow rate when pressed without surface defects. They allow reducing the load on the press, as well as increasing productivity, while maintaining the high product quality typical of 6xxx alloys.

R-1407 is a welded material with high corrosion resistance designed for the transport of chemically dangerous cargo, including concentrated nitric acid. It has got corrosion resistance at the level of pure aluminium, with double the fatigue and endurance parameters. Calculations show that using R-1407 instead of the AD0 alloy reduces the thickness of the tank car boiler wall by 50%, and thereby increases the load capacity by 4 tonnes; and when replacing steel in tank cars for transporting oil, gasoline and aviation fuel, it reduces the boiler weight by 30%.