What sizes are available?

VAEC produces billets from 5 to 10 inches in diameter and up to 6 meters in length.

Which alloys are used?

6000 series aluminium alloys are commonly used for billet casting.

Where are aluminium billets used?

They are used in construction, automotive, aerospace, and industrial sectors.

Aluminium Billet Casting | VAEC Manufacturer

Quality Begins at the Core

Precision Aluminium Billet Casting for High-Performance Extrusions

At VAEC Aluminium Extrusion Pvt Ltd, we believe the foundation of every high-performance aluminium profile is a perfectly cast billet. That’s why our billet casting process is fully integrated, quality-driven, and optimized for both strength and consistency. Our in-house billet casting facilities allow us to produce custom aluminium billets in various alloys and sizes, ready for downstream extrusion into world-class products.

Whether you require aluminium extrusion billets for architectural profiles, automotive applications, aerospace-grade alloys, or energy-sector components, our process delivers precision and reliability every time.

VAEC Billet Casting Infrastructure

4 Advanced Billet Casting Lines at VAEC

Casting Lengths: Up to 6000 mm

Our Billet Diameters: 5 inches to 12 inches (127 mm to 305 mm)

Capacity: Fully synchronized with our 35,000-ton annual extrusion throughput

Custom Alloys Available: Series 6000 (6061, 6063, 6082), 1000-series, 7000-series on request

Our billet production is optimized for vertical integration, ensuring supply consistency, alloy traceability, and tighter quality control compared to outsourced billet procurement.

Why In-House Billet Casting Matters

Material Consistency: Control over composition and cleanliness ensures predictable extrusion quality

Alloy Flexibility: Tailor-made alloys to meet specific mechanical, thermal, or corrosion-resistance requirements

Faster Lead Times: No waiting for external billet suppliers, streamlined production and dispatch

Lower Contamination Risk: Direct handling from casting to extrusion minimizes surface defects and inclusions

Cost Optimization: Efficient use of raw aluminium and recycled content for economical, eco-conscious production

VAEC Billet Casting Process

1. Alloy Selection & Preparation

Raw aluminium and master alloys are sourced based on the customer’s specifications. We offer both primary aluminium billet casting and high-quality recycled aluminium alloy billets, in line with sustainability commitments.

2. Melting & Degassing

Aluminium is melted in high-efficiency furnaces and treated to remove hydrogen, oxides, and non-metallic inclusions. Degassing and filtration are done with rotary degassers and ceramic foam filters to ensure a clean melt.

3. Alloying & Homogenization

Precise amounts of alloying elements (magnesium, silicon, manganese, zinc, etc.) are added and mixed thoroughly. Chemical composition control ensures every billet meets the required mechanical and metallurgical properties.

4. Casting

Using a direct chill (DC) vertical casting process, molten aluminium is cast into billets of the specified diameter. This method results in excellent grain structure and minimized porosity.

5. Cooling & Extraction

The billets are cooled using a water spray ring and extracted from the casting pit. Controlled cooling rates prevent internal stresses and reduce the risk of cracks or surface segregation.

6. Sawing & Scalping

Billets are cut to required lengths (typically up to 6000 mm) and may be scalped (surface layer removal) to eliminate oxide skin and ensure a clean surface for extrusion.

7. Homogenization Annealing

Billets undergo homogenization in heat treatment furnaces to dissolve segregation, equalize microstructure, and improve extrusion behavior. This ensures consistent flow during extrusion and higher surface finish quality.

8. Ultrasonic Testing

For aerospace, automotive, or other high-integrity applications, billets may be ultrasonically tested for internal defects to ensure they meet critical tolerance standards.

9. Storage & Dispatch

Finished billets are cooled, inspected, and stored in controlled conditions, ready to feed into our in-house extrusion presses or to be shipped as standalone billet supply.

Aluminium Billets for Diverse Industrial Needs

VAEC’s billet casting process supports extrusion-ready billets for a wide range of sectors:

Automotive & EV: Crash-resistant alloy billets for chassis, battery enclosures, crash rails

Building & Construction: High surface quality billets for architectural anodized profiles

Aerospace & Defence: Custom 6000- and 7000-series billets with high strength-to-weight ratios

Renewable Energy: Corrosion-resistant billets for solar mounting structures and wind power components

Electronics & Electrical: Conductive aluminium billets for heat sinks, cable trays, and control panels

Sustainability at the Core

As part of our commitment to green aluminium manufacturing, we incorporate high-purity recycled aluminium wherever possible. This significantly reduces energy consumption and carbon emissions while maintaining billet integrity. All processes are aligned with global ESG best practices and India’s net-zero targets.

We aim to offer not just aluminium extrusion billets, but sustainable, high-performance material solutions for modern industry.

Why Choose VAEC for Billet Casting?

BIS-certified billet production

Fast lead times and scalable production

Consistent alloy quality and traceability

Environmentally responsible billet manufacturing

Trusted by Indian and global OEMs across sectors

Fully integrated with extrusion, one-stop aluminium solution

Need Aluminium Billets That Perform?

Whether you’re sourcing billets for your own extrusion operations or need end-to-end profile manufacturing, VAEC Aluminium Extrusion Pvt Ltd is ready to deliver.

Connect with us today to explore our casting capabilities, place a custom billet order, or speak to a technical expert.

Frequently Asked Questions

1. What is aluminium billet casting?

Aluminium billet casting is a manufacturing process where molten aluminium is solidified into cylindrical billets, which are later used in extrusion processes to produce aluminium profiles.

2. Why is billet quality important in aluminium extrusion?

Billet quality directly affects the strength, surface finish, and dimensional accuracy of the final extrusion profile. High-quality billets ensure better performance and consistency.

3. What billet sizes does VAEC offer?

VAEC produces aluminium billets with diameters ranging from 5 inches to 10 inches and lengths up to 6 meters, suitable for various industrial applications.