Premier Aluminum Casting Methods

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Premier Aluminum Casting Methods

Premier produces permanent mold castings using four methods. This versatility can best serve each application and various casting designs.

Low Pressure

Air pressure is used to force molten metal upward into a closed die cavity. This is an excellent process for circular designs as well as pressure tight vessels. These castings approach the surface finish of die castings and create a denser casting, without the higher tooling cost.

Tilt Pour

Molten metal is transferred from a holding cup into the mold in a precise microprocessor controlled sequence. This method offers high quality consistent parts to the widest variety of sizes and shapes.

Static Pour

Molten metal is ladle-poured from the top directly into a die cavity. This method is normally used for center-feed castings and accommodates a wide range of small to large castings.

Semi-Permanent Mold

Preformed sand cores are used with the methods described above. This allows casting of internal shapes, features or undercuts when “hard tooling” is not the best option.

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Aluminum Castings: Process Comparisons

Process	Typical Size Range	Tolerances	Surface Finish	Min. Draft Required	Min. Section Thickness	Typical Tooling Costs	Part Cost	Nominal Lead Time
V-PROCESS	Up to 150 lbs	+.010″ for the first 1″, then add +.002″ per inch. Add a maximum .020″ across parting line.	125 – 150 RMS	None	.125″	$3000-$15,000	Very High	Samples: 2 to 6 weeks. Production: 2 to 6 weeks after approval.
Sand Castings	Ounces to tons	+1/32″ to 6″, then add + .003″ per inch. Add + .020 to .090″ across parting line.	250-500 RMS	1 to 5 degrees	.25″	$2000-$15,000	Low	Samples: 2 to 6 weeks. Production: 2 to 6 weeks after approval.
Investment (lost Wax)	Ounces to 20 lbs	+ .003″ to 1/4″ + .004″ to 1/2″ + .005″ to 3″, then add + .003″ per inch	63-125 RMS	None	.060″	$3000-$20,000	High	Samples: 8 to 10 weeks. Production: 5 to 12 weeks after approval.
Permanent Mold	Ounces to 100 lbs	+ .015″ to 1″, then add + .002″ per inch. Add + .010″ to .030″ across parting line.	150-300 RMS	2 to 5 degrees	.150″	$10,000-$50,000	Low	Samples: 8 to 20 weeks. Production: 10 to 12 weeks after approval.
Plaster Mold	Ounces to 50 lbs	+ .005″ to 2″, then add + .002″ per inch. Add + .010″ across parting line.	63-125 RMS	1/2 to 2 degrees	.070″	$3000-$15,000	High	Samples: 2 to 10 weeks. Production: 4 to 8 weeks after approval.
Die Casting	Ounces to 15 lbs	+ .002″ per inch. Add + .015″ across parting line.	32-63 RMS	1 to 3 degrees	.030″ to .060″	$125,000-$250,000	Lower	Samples: 12 to 22 weeks. Production: 8 to 14 weeks after approval.