Our Recent Work
Alcoa Portland & DHDS Pty Ltd – A Partnership for Cathode Assembly Excellence
For more than twenty years, DHDS has partnered with Alcoa Portland, delivering precision-engineered cathode assemblies and innovative manufacturing solutions that have improved smelting performance, reduced costs and achieved industry-leading quality outcomes.
The Challenge
Alcoa's aluminium smelting operations rely on cathode assemblies consisting of carbon cathode blocks, steel collector bars, expansion relief blocks and cast iron collector bar connections. Maximising the service life of these assemblies is essential for maintaining production efficiency and reducing costly pot failures.
Variations in operating conditions and external power supply fluctuations often reduced cathode life, creating a need for a supplier capable of manufacturing precision components while continually improving design, durability and production efficiency.
Our Solution
DHDS (formerly Metal Drilling) developed redesigned steel collector bars featuring precision-machined copper inserts. Through accurate deep hole drilling and strict dimensional control, these components exceeded performance expectations and quickly established DHDS as Alcoa's preferred supplier.
Our involvement expanded beyond drilling into complete cathode assembly production, including cast iron sealing of collector bars. While the industry commonly experiences thermal cracking rates between 5–8%, DHDS achieved a zero thermal cracking rate through precise control of casting temperatures and metallurgy.
We also introduced improved expansion relief block designs, invested in advanced robotic handling systems and implemented recycling processes that reduced waste and lowered production costs.
The Results
Extended Service Life
Redesigned collector bars significantly increased cathode life, improving pot performance and reducing maintenance downtime.
Zero Thermal Cracking
Industry-standard cracking rates of 5–8% were reduced to 0% through strict quality control and metallurgical expertise.
Improved Sustainability
Recycling of copper, steel and cast iron materials dramatically reduced waste while supporting Alcoa's environmental objectives.
Project Highlights
Through continuous innovation, precision machining and investment in advanced automation, DHDS has helped Alcoa improve cathode performance, reduce production costs and achieve industry-leading manufacturing quality over more than two decades of partnership.
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