Operations
Industry-leading technologies and processes
At EGA Leichtmetall, we use industry-leading technologies and processes to produce our metal to the highest quality. We have a track record of pioneering innovation stretching back more than 90 years.
Powered by 100 per cent renewable electricity*, we produce up to 35 thousand tonnes of aluminium billets per year, with 80 per cent secondary aluminium as input material on average.
Today, our operations are centred around a vertical continuous casting system that is designed specifically for round billets. This system is combined with two 50 tonne channel induction furnaces. This enables us to produce billets with alloy-dependent cold-forming lengths of up to 7,000 mm and diameters from 158 mm to 1,145 mm, among the largest available worldwide.
Once removed from the casting pit, billets undergo a controlled homogenisation process. This heat treatment is performed in one of our three direct gas-fired homogenisation furnaces, ensuring temperature uniformity within ± 3 °C in accordance with the key aerospace material specification AMS 2750.
Precise thermal control and multi-stage quality checks ensure metallurgical consistency essential for critical applications in aerospace, defence, and precision engineering.
*procured from renewable electricity suppliers via the public grid, verified through Guarantees of Origin that are cancelled in the German Federal Environment Agency's Registry.
We use high-quality aluminium scrap and add small amounts of primary aluminium only when required to meet specific alloying needs. Our finished billets contain 80 per cent secondary content on average. Up to 99 per cent secondary content is possible if requested.
The sorted material is melted in our inductive furnaces. This ensures precise temperature control and energy-efficient melting with minimal material loss.
Molten aluminium is cast into billets using the hot-top casting technology which allows us to produce large diameter billets with high-quality microstructure and surface quality.
All billets are heat-treated in one of our three special direct gas-fired homogenisation furnaces. With temperature precision of ±3 °C, this process ensures consistent material properties and optimises the billets for further processing in high-performance applications.
Billets can be turned to customer-specific diameters. On request, we also offer state-of-the-art ultrasonic inspection up to class AA to further verify structural integrity.
Each production batch is subject to comprehensive quality checks, including raw material and chemical analysis, hydrogen measurement, and metallographic evaluation to ensure compliance with strict specifications.
Our billets are ready for use in the fabrication of new components across the aerospace, defence, and special engineering sectors.
From standard alloys to specialised solutions
We offer a wide range of aluminium products, from standard alloys to customised solutions designed to meet specific customer requirements. Leveraging decades of expertise and process optimisation, we deliver not only reliable classics but also high-strength, application-specific hard alloy billets. With diameters ranging from 140 mm to 1,080 mm and lengths up to 3,000 mm, our turned billets set new quality benchmarks, meeting the requirements of even the most demanding applications.
