Manufacturing – Casting methods - European Aluminium Association

1.11.6 Ultra Large Caster (ULC)
The VRC process was developed by Alcoa during the 1950s. PRC was added during the
1980s. The Ultra Large Caster has been built during a further development effort targeting
large castings.
Ultra Large Caster (ULC) at Alcoa Technical Center, Pittsburgh, PA
The parts produced demonstrated the potential of the process: the tailgate weights 11 kg,
replacing 11 stampings and reducing the weight by 25 % (at that time). Wall thickness was
between 2.5 mm and 6 mm. The alloy in this case was A356-T5. Mechanical properties (TYE)
were: 170 MPa, 130 MPa, 10 %.
Molds for this machine can be as big as 3400 mm x 1700 mm. This allows using a two-out die
for parts like the tailgate below.
One piece tailgate produced by ULC
Cycle time was 2 minutes: this makes ULC economically attractive
Source: Alcoa
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