From Concept to Launch —
Smarter Alloy & Process Development

At Secat, we help manufacturers, researchers, and product developers turn ideas into reliable, high-performing aluminum products. Our hands-on alloy and process development services provide the insights, testing, and expertise you need to optimize alloys, forming methods, and small-scale production before committing to full-scale manufacturing.

Whether you’re developing a new alloy, refining a forming process, or testing small castings, we help you reduce risk, accelerate development, and improve product performance.

What We Offer

Pilot-Scale Alloy and Casting Development

Our Nicholasville, Kentucky facility is equipped to provide small scale heats for screening different alloy compositions or pilot-scale direct chill casting of full-size billets and subscale ingots.

Product Development Support

We help evaluate new designs, identify potential manufacturing challenges, and optimize your material and process choices before full-scale production. This includes testing prototypes, assessing formability, and characterizing material properties.

Process Development & Optimization

Our team works with you to fine-tune forming, casting, or heat-treatment processes. Early testing on pilot-scale equipment can identify risks, reduce scrap, and improve overall process efficiency.

Hands-On Expertise

Our metallurgical team works closely with your engineers to provide practical, data-driven recommendations. We combine deep technical knowledge with real-world testing to ensure your product performs as expected in production and in the field.

Why Alloy & Process Development with Secat Matters:

  • Predict performance before cutting a single part

  • Optimize process parameters like temperature, speed, and pressure

  • Reduce defects and scrap by understanding root causes

  • Troubleshoot production problems through virtual testing

  • Speed up product development with fewer physical prototypes

Typical Applications

  • Alloy development and small casting trials
  • Forming process optimization for sheet, foil, or extrusions
  • Prototype and small-batch product testing
  • Process troubleshooting and refinement

Deformation Processing Specs at Secat:

HOT MILL

Maximum 5.0 in. wide

Maximum 2.5 in. thick

COLD MILL

Maximum 7.0 in. wide

Maximum 4.0 in. thick

FORGING PRESS (300T)

Upset dies

Draw forging dies

Why Secat?

Our development isn’t just theoretical—it’s built on decades of aluminum industry experience. We integrate physical data, process knowledge, and advanced simulation tools to give you clear, actionable results. Whether you’re launching a new product or improving a production line, our goal is the same: to help you succeed faster, smarter, and with less waste.

Contact Us Today