Development and production of aluminium casting alloys, impact extrusion semi-finished products and carbon products in Rheinfelden.
Aluminium Rheinfelden Alloys GmbH
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About Aluminium Rheinfelden
The Aluminium Rheinfelden Group, headquartered in Rheinfelden (Baden), traces its origins to Germany's first aluminium smelter, founded in 1898. Following a restructuring in October 2008, Aluminium Rheinfelden GmbH has operated as a holding company; the three business divisions are independent companies: Aluminium Rheinfelden Alloys GmbH develops and produces custom aluminium casting alloys, primarily for HPDC applications in the automotive and mechanical engineering sectors. Aluminium Rheinfelden Semis GmbH produces slugs, discs and blanks from pure aluminium and alloys with a high recycled content — feedstock for tubes, cans, containers and technical applications. Rheinfelden Carbon Products GmbH manufactures Söderberg and electrode pastes as well as cathode ramming pastes for the production of high-purity ferroalloys and silicon metal, including the patented electrode paste Limak. Electricity demand is covered 100 % by hydropower; scrap is largely recycled in the company's own process. Since 2021 the group has belonged to UC RUSAL; in 2026 Alloys and Semis filed for insolvency under self-administration.
- Site
- Rheinfelden (Baden)
- Processes
- Development and production of aluminium casting alloys (alloy development, no, Production of impact extrusion semi-finished products (slugs, discs and blanks from pure aluminium), Production of slugs/blanks from aluminium for spray cans, tubes, cans and containers as well as, Production of carbon products: Söderberg and electrode pastes (incl. environmentally friendly, Development of custom aluminium casting alloys (HPDC), Production of slugs, discs and blanks from pure aluminium, Söderberg and electrode pastes, cathode ramming pastes, furnace linings, Recycling in the company's own process
- Materials
- Aluminium casting alloys (custom, e.g. for automotive and mechanical engineering), Pure aluminium, Aluminium alloys with high recycled content (for impact-extruded end products), Castaduct®, Magsimal®, Silafont®, Anticorodal®, Castasil®
- Certificates
- ISO 14001:2015, ISO 45001:2018, ISO 50001
- Founded
- 1898
- Employees
- approx. 235 (group,
- Industries
- Automotive, Mechanical engineering, Packaging industry, Metalworking industry, Ferroalloys / silicon metal
- 01
Alloy development according to customer requirements
- 02
Production of aluminium casting alloys (Alloys)
- 03
Impact extrusion semi-finished products: slugs, discs, blanks (Semis)
- 04
Recycling in the company's own process
- 05
Production of carbon products: electrode and ramming pastes (Carbon)
Materials and Alloys
Custom aluminium casting alloys (HPDC)
Alloys tailored to process and cast part for automotive and mechanical engineering, e.g. Castaduct®, Magsimal®, Silafont®, Anticorodal®, Castasil®.
Pure aluminium
Base material for slugs, discs and blanks as feedstock for impact-extruded end products.
Aluminium alloys with a high recycled content
For impact-extruded end products in the packaging, mechanical engineering and automotive industries.
Carbon products (electrode and ramming pastes)
Söderberg and electrode pastes (incl. Limak) as well as cathode ramming pastes for ferroalloys, silicon metal and furnace linings.
Sites
Rheinfelden (Baden)
DEAluminium Rheinfelden Alloys GmbH – development and production of aluminium casting alloys
- Materials
- Aluminium casting alloys
Rheinfelden (Baden)
DEAluminium Rheinfelden Semis GmbH, Friedrichstrasse 50 – production and distribution of impact extrusion semi-finished
- Materials
- Pure aluminium, alloys with high recycled content
Rheinfelden (Baden)
DERheinfelden Carbon Products GmbH, Bukheinstrasse 2 – carbon products (electrode pastes, ramming pastes)
- Materials
- Carbon, binders
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Development and production of aluminium casting alloys (alloy development, noCasting | – | – | – | – | Aluminium casting alloys |
| Production of impact extrusion semi-finished products (slugs, discs and blanks from pure aluminium)Forming | – | – | – | – | Pure aluminium, Aluminium alloys with high recycled content |
| Production of slugs/blanks from aluminium for spray cans, tubes, cans and containers as well asForming | – | – | – | – | Pure aluminium |
| Production of carbon products: Söderberg and electrode pastes (incl. environmentally friendlyOther | – | – | – | – | Carbon, Binders |
1 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Molten-salt electrolysis furnaces | – | 10 | – | 1898 | Rheinfelden (historical, exit from electrolysis by 1991) |
Additional services
Quality and Certification
The group pursues a zero-defect strategy with robust processes. An integrated management system according to ISO 14001:2015 and ISO 45001:2018 (Reg. no. H60859, SQS) is certified for Alloys, Semis and Carbon; resource efficiency is regularly demonstrated according to ISO 50001.
| Evidence | Rheinfelden (Baden) |
|---|---|
| ISO 14001:2015 | |
| ISO 45001:2018 | |
| ISO 50001 |
History
- 1898
Founded as Germany's first aluminium smelter by AIAG (Alusuisse), powered by Europe's first hydroelectric power plant in Rheinfelden; ten electrolysis furnaces go into operation on 31 May.
- 1964
Start of construction of the slug operation (at that time LMG, Leichtmetallguß); peak capacity of up to 62,000 t/year.
- 1991
Exit from the electricity-cost-intensive electrolysis production of raw metal.
- 1993
Management buy-out from the parent company Alusuisse; slug production at that time approx. 13,000 t/year.
- 2008
From 01.10.2008, Aluminium Rheinfelden GmbH acts only as a holding company; Alloys, Semis and Carbon become independent companies.
- 2010
Slug capacity increased to around 25,000 t/year through modernisation.
- 2021
Since 16.04.2021, Alu Rheinfelden has been part of UC RUSAL, the largest producer of low-carbon aluminium.
- 2026
Alloys and Semis file for insolvency under self-administration on 16.07.; closure of the two plants with approx. 185 affected employees is planned; Carbon Products (approx. 50 employees) is not affected.