Queen's Award for Enterprise

Motorsport Foundry

Through a co-operative understanding of our Motorsport customers unique confidentiality, high integrity casting and tooling requirements a stand-alone facility incorporating a specific process designed and developed to produce Formula One grade castings in support of the Motorsport Industry is provided at our Bridgnorth foundry.

Our unrivalled experience in racing, rally engine and transmission programs with demanding requirements for high complexity, high quality and compressed lead-times place Grainger & Worrall in a unique position whereby it can utilise its expertise and technology to achieve the highest level of casting quality in both Aluminium and CGI (compacted graphite iron).

In house computer tomography and casting simulation technology combined with the Cosworth Casting process consistently provides the race engine designer with the tools required to deliver multiple championship winning engine programs.

Grainger & Worrall are unique in the provision of a team and facility dedicated to Motorsport providing quality assured components.

There are Golden Rules that exist for making ‘the perfect casting’. Developed over recent years by many academics these focus on the avoidance of defects borne out of shortcomings in liquid melting, effects of oxide (bifilm) formation through turbulent pouring and gas bubble generation, importance of temperature gradient and adequate feeding. There are others but so far these ‘ideals’ can be summarised as the Casting Process. We operate a specialised industry leading Low Pressure Pumped system, formally known as Cosworth Rollover Casting Process. Over many years at Grainger &Worrall the roll-over casting process has been developed to meet the latest requirements in high integrity castings and Grainger & Worrall are well documented as producing the most reliable castings obtainable in the world. In qualitative terms only defect free parts get delivered to our customers. In quantitive terms the castings are achieving higher strengths and levels of durability whilst meeting the needs of engine downsizing; lighter thinner and more accurate being the key challenges.