Products & Applications

Cast, pressed, machined, assembled.

HMW manufactures components to customer drawing and specification. Almost all are supplied fully machined and inspected; a growing proportion are delivered as complete sub-assemblies, built from our own castings and machined parts.

Materials

Materials we work in.

Aluminium, copper and copper alloys, bronze, brass and steel. Five decades of foundry and machining experience — across alloy selection, shrinkage and feeding, melt control and machinability — underpins every component we quote.

Aluminium

Aluminium alloy castings

Gravity die and sand castings from small components up to 100 kg, heat treated where the drawing requires, and to radiographic quality where the specification demands it.

Alloys  LM6 · LM9 · LM11 · LM25 · A356
Standards  IS:617 · DIN 1725
Heat treatment  Solution · Ageing · Annealing
Copper

Copper & copper alloys

High-conductivity copper castings, copper extrusions and pressed copper-alloy contacts, together with chromium copper and specialist arc-resistant contact alloys.

Grades  HC Copper Gr. 2
Also  Chromium copper · Tungsten copper
Forms  Castings · Pressings · Contacts
Bronze & brass

Bronze, brass & gunmetal

Bushes, worm gears and fittings, including gunmetal components press-fitted into aluminium housings and delivered as a finished assembly.

Gunmetal  85/5/5/5 · 87/7/3/3
Bronze  Aluminium bronze · Leaded tin bronze
Typical  Bushes · Gears · Fittings
Steel

Steel machining & treatment

We work with various grades of steel — machined and heat treated as the customer’s drawing requires — for components and assemblies including drive shafts, worms, gears, discs, forged cranks, bearing flanges, bearing pins, shims, washers and couplers.

Work  Turning · Milling · Grinding
Treatment  To customer specification
Typical  Shafts · Gears · Cranks · Flanges
Components

Representative work.

A selection of components manufactured to customer drawing and specification, supplied fully machined and inspected.

Cast aluminium ventilator rotors for traction motors
Aluminium · Radiography tested
Ventilator rotors, traction motors

Thin-section cast rotors, dynamically balanced and radiography tested.

Finned aluminium pole housings for switchgear
Aluminium
Finned pole housings

Cast and fully machined, with integral cooling fins.

Cast and machined cylindrical housings
Aluminium
Cylindrical housings

Bore-machined housings for traction equipment.

Three-arm cast aluminium spider component
Aluminium
Three-arm spider casting

Cast and machined structural component for tap changer assemblies.

Assorted cast and machined aluminium components
Aluminium
Tap changer component set

Caps, rings, flanges and linkages, supplied as a matched set.

Large cast aluminium cover
Aluminium
Cast covers & enclosures

Machined sealing faces and drilled flanges.

Cast housing and cover, powder coated
Aluminium · Powder coated
Housing & cover, coated

Machined and powder coated in-house to the customer’s colour.

Large cast aluminium drive housing cover
Aluminium
Drive housing cover

Ribbed cover with cast bosses and machined apertures.

Cast aluminium motor drive housing
Aluminium
Motor drive housing

Deep-draw cast housing with machined mounting features.

Cast aluminium tap changer head
Aluminium
Tap changer head

Machined bore, spigot and drilled mounting flange.

Cast aluminium bearing plate
Aluminium
Bearing plate

Cast plate with integral brackets and machined bores.

Cast aluminium mounting plates
Aluminium
Mounting plates

Ribbed structural plates, machined both faces.

Cast aluminium insulator flange
Aluminium
Insulator flange

Machined spigot and sealing face, drilled bolt circle.

Cast aluminium flange for insulators
Aluminium
Insulator flange, tapered

Tapered flange with machined bore and mounting holes.

Large cast aluminium ring flange
Aluminium
Large ring flange

Large-diameter ring, machined seating and drilled ports.

Machined copper pole head for VCB
Copper
Copper pole head

High-conductivity copper, finned, fully machined.

Machined copper clamp for DE locomotive
Copper
Copper clamp

Current-carrying clamp, machined from HC copper.

Copper moving shunt contact for OLTC
Copper
Moving shunt contact

Copper contact with textured current-transfer face.

Brass and gunmetal castings for locomotives
Brass & gunmetal
Locomotive castings

Bushes, brackets and fittings, cast and machined.

Brass contact block for AC EMU
Brass
Contact block

Machined brass contact block for AC EMU equipment.

Assemblies

Delivered ready to fit.

Sub-assemblies built from our own castings and machined components, with bearings, seals and hardware fitted and inspected before despatch.

Cast and machined gear assembly
Aluminium · Assembly
Gear assembly

Cast housing, machined gearing, seals and shaft fitted.

Flange-mounted bearing assembly
Machined · Assembly
Flange-mounted bearing assembly

Machined housing and shaft, bearing fitted and set.

Bearing block assembly
Machined · Assembly
Bearing block assembly

Machined block with sealed bearing and stub shaft.

RSC shell assembly for OLTC
Aluminium · Assembly
RSC shell assembly

Cast shell, machined and built up with fitted components.

Applications

Where our components are used.

HMW manufactures components and sub-assemblies. Our parts are fitted into transformers, circuit breakers and traction systems built by CPSEs and leading OEMs, and are held to the tolerances, test certification and delivery schedules those assemblies require.

Power transformer, cutaway

Transformers & tap changers

  • Cast and machined housings, covers and enclosures
  • Gear and drive assemblies for tap changer mechanisms
  • Bushing components — caps, terminals and shields
  • Grading and shielding components
  • Machined flanges and mounting components
Vacuum circuit breaker

Vacuum circuit breakers

  • Aluminium alloy pole housings, supplied fully machined
  • Pressed copper and copper-alloy contacts
  • High-conductivity copper castings for current-carrying parts
  • Contact assemblies
  • Enclosure and housing components
Traction equipment

Railways & traction

  • Contactor and master controller components
  • Air guides for traction motors
  • Traction motor ventilators — radiography tested
  • Brush holders and traction control parts
  • Cast and machined components for traction control equipment
Further end uses
<Porcelain insulators
Porcelain insulatorsAluminium alloy flanges, fully machined
on-load tap changer
On-load tap changersSelector components, moving contacts, rings and housing components
motor drive unit for on-load tap changer
OLTC motor drivesCast and machined drive housings and sub-assemblies
Supply format

Component, or complete sub-assembly.

Where a customer prefers to receive a working assembly rather than a set of parts, HMW fits the required hardware, bearings and seals to our own castings and machined components, and delivers the assembly inspected and ready to install.

  • Bearing and gear assemblies
  • Contact and switching assemblies
  • Housing and enclosure assemblies, powder coated in-house
  • Gunmetal bushes press-fitted into aluminium housings
Casting Aluminium gravity die and sand casting, up to 100 kg
Pressing 50T to 100T, copper and copper-alloy contacts and pressings
Machining CNC machining centres, CNC lathes, conventional machines
Heat treatment Solution treatment, ageing, annealing — in-house
Finishing Vibro polishing, powder coating — in-house
Testing Brinell hardness, tensile, air pressure, dynamic balancing, radiography
Tooling Dies and press tools designed and made in-house (SolidWorks / SolidCAM)
Next step

Submit a drawing for quotation.

Share a drawing and the quantity required, and we will respond with feasibility, material route and pricing. Enquiries are typically answered within two working days.

Request a quotation info@hmwmetalworks.com