Permanent Mold Casting
Permanent Mold Casting at Aurora Metals
At Aurora Metals, we specialize in permanent mold casting techniques for brass and bronze alloys, delivering consistent, high-quality castings for a wide range of applications. Our expertise in this process allows us to produce parts with superior surface finish, tight tolerances, and excellent mechanical properties.
The Permanent Mold Process
Permanent mold casting is a cost-effective approach to today's requirements for near net shape castings. Due to its flexibility and design freedom, it has become a fundamental foundry process at Aurora Metals. We offer it as a readily acceptable alternative casting method for components traditionally made from sand castings, welded assemblies, forgings, investment castings, and even complex configurations machined from bar stock.
Our permanent mold process utilizes metal casting dies in conjunction with metal or sand cores, where applicable. The basic casting sequence is as follows:
- Mold Preparation: We preheat the metal mold to elevate its temperature to operable conditions.
- Mold Assembly: The mold, consisting of two or more parts, is assembled and closed.
- Casting: Molten metal is introduced at the top of the mold. If steel cores are present, they are removed shortly thereafter.
- Solidification: The metal is allowed to cool and solidify within the mold.
- Part Removal: Once solidified, the mold is opened, and the casting is ejected.
- Cycle Repetition: The mold is reassembled, and the cycle is repeated for the next casting.
Aurora Metals Division, LLC remains dedicated to pushing the boundaries of what's possible in precision casting.
Advantages of Our Permanent Mold Casting
Improved Properties and Alloys
The molten metal is poured into a metal die, which acts as a heat sink that rapidly solidifies the casting, often resulting in improved physical and mechanical properties. This is due to the finer grain structure achieved by the rapid solidification of the alloy. As a result, we can suggest reduced section thicknesses and weight while maintaining physical strengths.
Superior Design Criteria
Parts produced using our rigid metal dies can be cast to size with excellent dimensional repeatability. This allows for holes and shapes to be cast ready for tapping and/or reaming. We also easily accommodate insert casting.
Weight Reduction
With parts cast to tighter tolerances, we can reduce section thicknesses and machining stock, allowing for reductions in secondary operations.
What We Do
Our Services
Aurora Metals offers a comprehensive suite of precision casting services, catering to diverse industry needs:
Lead Lined Wood Doors
Customizable sizes and veneers with fire labels up to 90 minutes.
Lead Lined Control Frame and Hollow Metal Doors
Available in custom profiles.
Lead Drywall
Our lead drywall is designed for easy installation, ideal for various structural applications to shield against harmful radiation.
Protective Glass
We offer protective glass with standard to enhanced shielding options, including safety laminated glass for door lites and side lites, ensuring safety and visibility in critical areas.
Lead Lined Steel Welded Doors & Frames
Designed for extreme door weights, custom jamb depths, and profiles with special hardware reinforcements.
Linear Accelerator Doors and PET Shielding
Tailored design for heavy radiation shielding.
Lead Plywood Interlocking Panel Systems and Lead Bricks
Enhanced Surface Finish
Our permanent mold castings offer a greatly improved surface finish compared to sand casting, usually 125 RMS. This superior surface condition often leads to a reduction in finishing operations.
Alloy Versatility
We specialize in casting a variety of non-leaded alloys, including:
- Aluminum Bronzes
- Silicon Brasses
- Aluminum
Casting Capabilities
- Weight Range: From 1 ounce to 20 pounds
- Tolerances:
◦ +/- .005 possible in production on some dimensions less than 1"
◦ +/- .015 for dimensions 1" (more practical and cost-effective)
Quality Assurance
At Aurora Metals, quality is the foundation of everything we do. Our unwavering commitment to excellence is encapsulated in our quality policy:
"Committed to customers' success by: Providing quality casting on a timely basis, while continuously improving our processes."
We proudly hold the ISO 9001:2015 certification, a testament to our Certified Quality Management System. This internationally recognized standard ensures that our processes, from procurement to production and delivery, adhere to the highest quality benchmarks.
Experience Precision and Quality with Aurora Metals' Permanent Mold Casting
With our state-of-the-art permanent mold casting capabilities, Aurora Metals is your trusted partner for high-quality, precision castings. Whether you need job-shop quantities or high-volume production, our team is ready to deliver solutions that meet and exceed your expectations. Experience the Aurora Metals difference – where tradition meets innovation, and quality is cast into every product we create.
