The aluminum castings below are samples of a valve body and filter cap assembly cast at the Alcast Company aluminum foundry. This particular valve body is not cored, as all ports are machined. The manifold and filter cover, which are used in hydro static transmissions, weight 1.2 lbs. and 0.3 lbs, respectively. The filter cap also has a steel stud assembled into it by Alcast Company.
Another example of a valve body used in hydro static transmissions is this 3.75 lb. casting. This casting is made using a three piece core assembly. The core is made from resin coated sand, using our shell core process, which delivers superior surface finish.
The following valve bodies are examples of permanent and semi permanent mold castings. Previously, even after double impregnation, both castings were experiencing a high number of defects due to porosity. Since Alcast Company was approached to produce these aluminum castings, our process has delivered porosity free castings, never requiring impregnation. Alcast Company has exceeded customer expectations in both cases.
This 1.5 lb. casting is used as a vehicle control valve. Originally this part was cast iron, and experienced leaking due to porosity. It was then machined from aluminum billet to reduce the weight and to resolve the porosity issues. Due to the low pressure electro magnetic bottom fill permanent mold process used at Alcast Company, a porosity-free casting was delivered at a 66% cost savings to the customer.
