Permanent Mold Casting

Consistent Castings with Precise Tolerances

Aluminum permanent mold castings share many attributes with its sand casting counterpart, but often prevail when a casting requires higher strength, improved cosmetics, greater complexity, larger size, or when using a mechanical steel core can reduce costs. LeClaire Manufacturing provides permanent mold casting services at our aluminum foundry in Bettendorf, Iowa.

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Advantages of Permanent Mold Casting

Strength

A product made via permanent mold casting typically increases mechanical properties by 15% due to the reduced grain structure created by the freeze rate of steel versus sand.  Many OEMs leverage the strength of permanent mold casting to convert from iron or steel castings to lighter aluminum permanent mold castings. 

Finish

The permanent mold casting process uses a reusable steel or iron mold, creating a smoother finish than its sand counterpart.                 

Applications of Permanent Mold Casting

Valve Body Castings

LeClaire has the capability to manufacture valve components using our permanent mold aluminum casting process. Our permanent mold castings can produce porosity-free cast aluminum valve bodies for use in hydraulics, pumps, transmissions and other applications. Request a quote today.

Cast Aluminum Blowers, Fans and Impellers

We manufacture aluminum ventilation components for at our aluminum foundry in Iowa. From cast aluminum fan blades for industrial ventilation to aluminum impellers for agricultural equipment, we manufacture a wide range of hubs, fans, and blowers for industrial, transportation and farming applications. Get started with a quote.

Insert Castings

The LeClaire Manufacturing aluminum foundry is the Midwest’s go-to manufacturer of steel insert castings and cast iron insert castings. Our process and experience are clear advantages in the manufacture of everything from cast aluminum cooler plates with steel tube inserts to aluminum retarder castings with cast iron inserts. We can manufacture aluminum housings and plates with cast-in tubes, with applications ranging from computer components to bearing housings. Get started today with a project quote.

Torque Converter Castings

We can manufacture torque converter aluminum castings, including turbine, impeller, and stator castings for use automotive, construction, and heavy equipment manufacturing. Whether you need raw aluminum castings or fully machined aluminum castings, our foundry and machine shop can deliver. Ask us today about manufacturing aluminum stator castings and other cast aluminum drivetrain components. Get a quote today – tell us about your project.

Aluminum Castings for Brakes, Calipers and Master Cylinders

If you manufacture cars, trucks, motorcycles, or recreational vehicles, LeClaire Manufacturing would like to be your brake casting manufacturer. At our state-of-the-art machine shop and aluminum foundry in Iowa, we can manufacture cast aluminum brake calipers and master cylinder aluminum castings at scale.

The LeClaire Manufacturing Advantage

Each step of our manufacturing process is carefully monitored and controlled to guarantee that your specifications are met. We use the latest technology to check the chemistry of our metal from start to finish. Computers are used extensively throughout the foundry operations — controlling everything from the metal quality requirements to regulating die temperatures. Real time x-ray, die penetration analysis and mechanical property testing are performed regularly to ensure that we meet or even exceed your requirements.

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Equipment

LeClaire Manufacturing utilizes automatic-tilt permanent mold machines equipped with tilt time regulators and thermo-couplers. These gravity-fed machines guarantee that optimal metal and die temperature are maintained, ensuring that our process is predictable and repeatable.

Slides and Cores

LeClaire Manufacturing casts even the most difficult permanent mold castings, with cores or without. Slides, cores and steel inserted aluminum castings all fall within the expertise of LeClaire Manufacturing.

Our design engineers review your casting design and offer cost-saving suggestions at the quoting stage of the project. Often, our casting experience allows us to suggest a slide where it was designed for a core, reducing labor costs, or to suggest ways to reduce the casting weight while maintaining structural integrity, saving on metal expenses.

Solidification Modeling

When investing in tooling to make your product, you want to confirm that the casting you designed goes thru scrutiny on how the foundry will produce the casting. Analyzing optimal metal and die temps thru reviewing fraction liquid, fraction solid, trapped air, pouring, velocity and turbulence, and many other predictive simulation modules, LeClaire gating and risering engineering drastically reduces the probability of your product containing defects. Our solidification modeling allows us to examine potential defects, collaborate on solutions with our customers, and engineer them out before the mold or pattern is made. This saves costs and assures customers receive the quality castings they expect.

Metal Pouring

Selecting the correct aluminum alloy for your casting is a critical aspect to the success of your part. LeClaire pours a variety of metals depending on our customers’ specific needs. Our aluminum alloy expertise is a result of our 50+ year history of pouring 200, 300, 500 and 700 series aluminum alloys.

Heat Treating

There is no room for error in heat treating. Accurate control yields predictable results.

Why Do Customers Prefer LeClaire Manufacturing?

“This part has been sourced through 4 foundries, and was my full-time job to babysit the supplier on this part, for 10 years, prior to the part being sourced at LeClaire; now I never even hear of it, it flows thru the shop so smoothly.”

Supplier Quality Engineer, Employer of 76,000