Aluminum Castings Company LLC – QMS Certified to ISO 9001:2015 & PED 2014 with TUV Rheinland of North America
Aluminum Castings Company LLC – QMS Certified to ISO 9001:2015 & PED 2014 with TUV Rheinland of North America
Braking system aluminum castings require disciplined control of geometry, alloy chemistry, machining features, and inspection. Aluminum Castings Company supplies cored and uncored aluminum sand castings for OEM and industrial programs with requirements defined by customer drawings and specifications.
The Galesburg, Illinois foundry combines green sand and air set molding with in-house core making, spectrometer alloy verification, CNC machining, finishing, and dimensional inspection. Process and acceptance requirements are reviewed before production so the manufacturing route reflects the component’s critical features.
For a fit review, see the company’s industries served work and request a quote with the drawing, alloy, volume, machined condition, and required testing.
Sand casting can support housings, bodies, covers, brackets, mounting structures, and other customer-designed brake system components. It is useful when a part has substantial sections, complex external geometry, internal passages, or production quantities that fit expendable-mold manufacturing.
Application suitability cannot be determined from the part name alone. Loads, pressure or fluid exposure, temperature, corrosion conditions, wall thickness, alloy, heat treatment, machining, and inspection requirements must be evaluated from the current drawing and specification.
Aluminum sand casting is a practical option when the design requires geometry that would be costly to machine from solid stock, or when cored features can reduce material removal. It can also support prototype and repeat production while keeping tooling decisions aligned with expected volume.
The foundry reviews each program for process fit. No universal braking approval or performance claim is implied. Customer specifications govern qualification, acceptance, and any application-specific validation.
Mold stability and core location affect wall thickness, parting-line condition, internal geometry, and machining stock. The sand mold department uses controlled green sand and air set processes, while shell and cold box core making supports complex internal features.
Alloy integrity is checked with an in-house spectrometer. Available aluminum alloys include 319, 355, 356, 535, and Almag 35, with the final alloy selected from the customer’s mechanical, corrosion, machining, heat treatment, and documentation needs.
Cleaning, trimming, grinding, and CNC machining are coordinated with the as-cast process. This is important when bores, sealing surfaces, mounting faces, or other defined features must remain aligned with the casting datum structure.
The foundry reviews critical dimensions, datums, wall sections, cores, machining stock, alloy, production quantity, inspection methods, and documentation before committing to the route.
Tooling and core boxes are developed or reviewed for repeatable mold assembly. Green sand or air set molding is selected according to size, complexity, finish, and volume.
Alloy chemistry is verified before controlled pouring. After solidification, castings are cleaned and prepared for any required heat treatment, machining, coating preparation, or assembly support.
Specified features are machined and verified against the agreed plan. CMM inspection, dimensional checks, X-ray, or other non-destructive testing may be applied when the customer requirement calls for them.
Tooling should not begin until the buyer and foundry agree on drawing revision, alloy condition, critical datums, machined surfaces, wall requirements, core geometry, and inspection responsibility. If the component has pressure, leak, fatigue, coating, heat treatment, cleanliness, or traceability requirements, those conditions must be stated explicitly.
The quote should distinguish as-cast dimensions from machined dimensions and identify which supplier controls each operation. That alignment helps the foundry plan tooling, machining fixtures, process checks, and final records without relying on assumptions.
Inspection must be tied to the drawing and the component risk. Aluminum Castings Company’s quality and casting inspection capabilities include dimensional verification, CMM inspection, alloy verification, X-ray, and non-destructive testing.
The customer should identify critical characteristics, sampling or lot requirements, material certifications, test methods, records, and acceptance criteria during quotation. This prevents a general inspection practice from being mistaken for application-specific qualification.
If a first-piece, capability, leak, or special validation report is required, the buyer should define the method and approval point before production quantities are released. The foundry can then include the required checks and records in the manufacturing plan.
Yes. Aluminum Castings Company is located at 340 South Kellogg Street in Galesburg, Illinois and serves manufacturers nationwide. Foundry, machining, finishing, and inspection coordination is managed through the same location.
Direct communication helps engineering and purchasing teams address revisions, production releases, inspection questions, and corrective actions without adding unnecessary supplier handoffs.
Potential fit depends on the drawing, alloy, pressure and leak requirements, wall sections, testing, and applicable specifications. Provide the complete requirement so the foundry can confirm capability before quoting.
Yes, when the geometry and tolerances are suitable for available shell or cold box core processes. Core prints, placement, support, and inspection are reviewed with the part design.
Yes. Available machining includes 3-, 4-, and 5-axis CNC work, drilling, boring, and tapping. The required datums, tolerances, and inspection plan should be included with the quote package.
Capabilities include dimensional checks, CMM inspection, alloy verification, X-ray, and other non-destructive testing. The selected method depends on the customer’s drawing and acceptance criteria.
Send the current drawing or model, alloy, annual usage, release quantities, casting weight if known, heat treatment, machining and finish requirements, critical characteristics, tests, records, and timing.
Aluminum Castings Company supports OEM programs that need aluminum sand casting, in-house core production, alloy verification, machining, finishing, and inspection aligned to customer-defined requirements.
Request a quote for a manufacturing and capability review of your braking system casting.
Your engineered aluminum casting solution starts here.
Call: 309-343-8910 | Email: sales@aluminumcastingscorp.com
Aluminum Castings Company LLC – QMS Certified to ISO 9001:2015 & PED 2014 with TUV Rheinland of North America
