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Brake Calipers
Torque Converters
Industrial Fans
Valve Bodies
Tube and Steel Inserted Castings
Brake Calipers, return to top
We produce brake calipers for various recreation vehicles from annual volumes of 500 to 500,000. The calipers we currently produce range from .4 pounds to 3.5 pounds.
With our molding process, we can produce calipers using steel cores to create the piston area.
Torque Converters, return to top
With our shell sand core making process, we have the capability to produce very exotic blade configurations. We produce stators with various blade designs ranging from 8 pounds to 35 pounds and from 10 inches to over 17 inches in diameter.
Using a similar core making process, we produce impellers and turbines with various blade configurations ranging from 7.5 pounds to over 120 pounds and from 12 inches to over 32 inches in diameter.
Industrial Fans, return to top
We produce various components for large industrial fans. We produce hubs ranging from 6.8 pounds to 168 pounds and from 14 inches to over 30 inches in diameter.
We produce fan blades with cast-in stainless steel shaft inserts. These fan blades range from 1.7 pounds to 5.5 pounds and from 14 inches to over 26 inches in length.
Valve Bodies, return to top
The castings below are samples of a valve body and filter cap assembly cast at Alcast. 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.
Another example of a valve body used in hydro-static transmissions is this 3.75 lb. casting. This casting is made using a three core assembly. The core is made from a resin coated sand, 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 was approached to produce these castings, our process has delivered porosity-free castings, never requiring impregnation. Alcast 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 process used at Alcast, a porosity-free casting was delivered at a 66% cost savings to the customer.
Tube and Steel Inserted Castings, return to top
We produce various castings requiring steel inserts or stainless steel tubing. The picture below is an electronic cooling module to house computer components. The casting is approximately 12 in. by 12 in. with a pour weight of 4.70 lbs. of aluminum.
This picture is an example of the cooling component of an assembly used to house computer hardware on a diesel engine. The casting is approximately 14 in. by 8 in. with a pour weight of 4.5 lbs. of aluminum.
