Low Pressure Permanent Mold Aluminum Casting
The permanent mold aluminum casting process our aluminum foundry uses is an electro-magnetic, low pressure, bottom fill process that is proprietary and only found in Alcast Company’s foundry!
Our casting techniques remove much of the typical margin for error or variation in the aluminum casting process. Through our electric melting, temperature monitoring, triple filtration, and unique electro-magnetic metal delivery system; oxides are filtered out and the metal entry turbulence commonly found in traditional tilt pour or static pour aluminum foundries is eliminated. This manufacturing process produces castings with the lowest porosity ratio that are less likely to crack or warp. Since this is an automated and controlled process, we can ensure consistent results.
What is Permanent Mold Aluminum Casting?
Permanent mold aluminum casting is a high-quality manufacturing process that uses a durable, reusable metal mold instead of a disposable sand mold. Don’t be fooled by lower cost iron tooling, Alcast only uses H13 steel because it is repairable and offers superior life expectancy. This process improves efficiency, consistency, and part durability. To ensure precision and protect the mold, it is coated with specialized refractory materials that help control the cooling and solidification of the molten aluminum.
How Our Casting Process Delivers Superior Results
At our state-of-the-art low pressure aluminum foundry, we use proprietary Mitchener Molding Machine which harnesses electro-magnetic, low-pressure, bottom-fill technology to ensure exceptional quality and consistency.
Using our proprietary aluminum foundry machinery the molds are held closed hydraulically with over 20,000 pounds of force during the casting process. Then using our electro-magnetic, low pressure, bottom fill, process the mold is filled from the bottom for a pre-determined amount of time, and the alum. casting is then allowed to solidify before being removed from the mold. In our foundry we use this process to manufacture torque converters, fan blades, brake calipers, valve bodies, master cylinders, cast aluminum wheels, blowers, and more.
How Mitchener Molding Machines Work:
- Precision Engineering: The mold is securely held in place with over 20,000 pounds of hydraulic force during casting.
- Superior Metal Flow: Aluminum is bottom-filled into the mold at a controlled rate, reducing turbulence and defects.
- High-Quality Finishing: The final castings have smooth surfaces, making them ideal for chrome plating, painting, or shot blasting.
- Versatile Applications: We produce a range of components, including:
- Automotive parts – brake calipers, master cylinders, valve bodies, manifolds
- Industrial components – fan blades, torque converters, blowers
- Custom aluminum castings – wheels, bearing housings, gear boxes and more
- Complex Casting Capabilities with Steel Cores
For more intricate part designs, we incorporate reusable steel cores into the casting process. These cores are automatically inserted and removed using hydraulic and pneumatic systems, allowing us to manufacture precision-engineered components with enhanced complexity and performance.
Why Choose Alcast Company for Permanent Mold Aluminum Casting?
- Higher Strength & Durability – Permanent molds produce parts with fewer defects and higher structural integrity than traditional sand casting.
- Better Surface Finish – Our process delivers smooth, high-quality surfaces without additional machining.
- Reduced Porosity – The low-pressure fill system minimizes air pockets, ensuring superior material density and enhanced performance.
- Cost-Effective Production – Reusable molds and efficient automation mean faster turnaround times and lower per-unit costs for bulk orders.
Permanent Mold Aluminum Foundry Features
- 2000lbs holding furnace
- Electro-magnetic delivery system
- Electric melting up to 1000lbs/hr.
- Argon cleaning & degassing
- Triple ceramic filtration
- Four temp. control zones
- Continuous feed gate/riser
- Moderate tooling costs
Permanent Mold, Bottom Fill Benefits
- Proprietary only to our foundry
- Tranquil metal entry
- Little to no weight limits
- Excellent surface finish
- Minimized shrink porosity
- Low & high volume EAU
- Excellent integrity
- Complex shapes
- Pressure Tightness
Request Your Aluminum Casting Quote
If you’re looking for high-quality aluminum castings with precision, strength, and a superior finish, our advanced permanent mold casting process is the perfect solution. Contact us today to discuss your custom casting needs and experience the difference for yourself. Request your quote now to learn more.