Aluminum Alloy 535 / Almag 35 Aluminum Castings – Precision Sand Castings Made in the USA
For over six decades, Alcast Company has been a trusted American aluminum foundry recognized for producing high-performance sand castings using Aluminum Alloy 535 (Almag 35). Known throughout the industry as a difficult, niche alloy to pour, 535 requires exceptional process control and foundry expertise. While many foundries “no quote” these opportunities, Alcast has proven its capability to deliver consistent, high-quality castings in this challenging material.
Our experience and commitment to precision make us the preferred source for OEMs, engineers, and procurement teams in government (DoD and DoT), electrification (utility, energy, and data centers), and marine markets seeking durable, corrosion-resistant components that meet stringent performance and reliability standards.
What Is Aluminum Alloy 535 (Almag 35)?
Aluminum Alloy 535, also known as Almag 35, is a non-heat-treatable aluminum-magnesium alloy that provides an exceptional balance of strength, ductility, and corrosion resistance. It’s approximately 69% lighter than bronze and offers superior machinability and polishability—making it ideal for applications where both performance and appearance matter.
Typical applications include:
- Marine hardware and propulsion components
- Electrical and utility enclosures
- Non-sparking industrial tools and safety equipment
- Pumps, brackets, and housings
- Structural and transportation components
This alloy maintains mechanical integrity even in harsh, corrosive environments and performs exceptionally in post-casting operations such as anodizing, powder coating, and CNC machining. Its combination of strength-to-weight ratio and corrosion resistance makes it a top choice for electrical and marine industries, as well as specialized government and defense programs.
Why Choose Alcast Company for Almag 35 Aluminum Sand Castings?
Proven Expertise in Pouring Alloy 535
Alcast Company stands apart as one of the few U.S. foundries with deep, proven experience pouring Aluminum Alloy 535 (Almag 35). This alloy is notoriously challenging to cast due to its chemistry and cooling characteristics—but our advanced process controls, skilled foundry team, and metallurgical expertise have made us a leader in producing complex, reliable 535 components.
When other foundries decline these jobs, Alcast succeeds.
Proudly Made in the USA
Based in the United States, Alcast Company delivers vertically integrated casting solutions—from prototype development to full-scale production. Every casting is produced under rigorous American quality standards, ensuring consistency, traceability, and reliability.
We are proud to support U.S. manufacturing across key industries including government, defense, marine, and electrification.
Expertise in Complex Sand Casting Projects
Our green sand and air set (no-bake) casting processes accommodate a wide range of part sizes and configurations—from small precision housings to large, heavy-duty castings. With advanced molding and pattern technologies, Alcast ensures dimensional precision, metallurgical consistency, and repeatable performance.
Our molding systems include:
- Automated green sand molding lines
- Air set molding systems for large and complex castings
- Precision core placement for tight-tolerance geometries
In-House Sand Core Production for Total Quality Control
Alcast manufactures all sand cores in-house, whether shell, cold box, or oil sand. This full control over core quality and timing ensures consistency and efficiency in every pour. Our core-making team is experienced in building complex, highly cored molds that meet demanding design specifications—ideal for electrical housings, cooling systems, and military-grade components.
Full-Service Capabilities: Machining, Finishing, and Assembly
Alcast Company provides complete, end-to-end production solutions to streamline your supply chain. Our integrated services include:
- Heat treating for enhanced mechanical properties
- Precision CNC machining to achieve exact tolerances
- Surface finishing, powder coating, and painting for corrosion resistance
- Mechanical assembly and kitting for production-ready components
These capabilities allow Alcast to deliver finished, ready-to-install aluminum parts that meet all your performance, quality, and delivery requirements.
Certified Quality Management System
Alcast Company’s operations are governed by a Quality Management System certified to ISO 9001:2015 and PED:2014 standards. We maintain comprehensive documentation, traceability, and inspection protocols to ensure compliance with U.S. and international standards.
For applications that operate under pressure or in critical service environments, Alcast’s quality assurance systems provide the confidence your program demands.
Key Markets Served
- Government (DoD and DoT)
Components for defense, transportation, and infrastructure programs requiring proven reliability and certified performance. - Electrification (Utility, Energy, Data Centers)
Precision-cast aluminum housings and enclosures for high-voltage, heat-sensitive, and corrosion-prone systems. - Marine and Coastal
Lightweight, corrosion-resistant parts that perform under saltwater exposure and high-stress conditions. - Industrial and Transportation
Structural and mechanical components requiring strength, precision, and long-term durability.
Partner With Alcast Company
From concept to completion, Alcast Company produces aluminum sand castings that exceed expectations in strength, precision, and reliability. Our engineering and production teams collaborate closely with clients nationwide—especially in government, electrification, and marine industries—to deliver efficient, cost-effective casting solutions for complex applications.
Contact Alcast Company today to request a quote or speak with an aluminum casting expert about your Alloy 535 project requirements.