Shape and Internal Complexity

• Complex external configurations with intricate internal geometry are made routinely.
• Proprietary processes for cast-in passageways and pipelines.
• Simple shapes with low internal complexity are cast in our Cell Manufacturing Center.
• Virtually any shape can be cast. Let your imagination guide you.
• Our engineering team will assist your engineering team to produce the best casting design.

Size and Finished Weight

• Castings with a single longest dimension of more than 12 feet (3.6 meter) have been cast.
• Typical castings have a longest single dimension of 1.5 feet (0.5 meter) to 5 feet ( 1.5 meter).
• Magnesium castings with finished weights up to 625 lbs (2~4 kg) are cast routinely.
• Wellman has poured magnesium castings with finished weights of over 3000 lbs ( 1360 kg)!
• Typical aluminum castings have finished weights of a few pounds to over 1000 lbs. (450 kg).
• Aluminum castings weighing almost one ton (>900 kg) have been cast routinely.

Wall Thickness and Dimensional Tolerances

• Casting dimensional tolerances vary with casting size and, to a lesser degree, with complexity.
• Wall thickness of 0.080" ± 0.015" (2.0 + .38 mm) can be cast in aluminum.
• Wall thicknesses of .200" to .50" ± .030" (5.0 + .7~ mm) are common in magnesium.
• Modern in-house layout department.
• Mold assembly gaging, process fixtures, and qualifying fixtures assure dimensional accuracy.
• If thin-walled castings are what you need, our casting engineering team is prepared to answer your questions and provide design assistance.

Integrity and Mechanical Properties

• All alloys are prepared in-house from Wellman specified materials for ultimate control.
• Melts are fully documented, analyzed, and certified.
• In-house metallurgical tests go beyond ordinary melt control for gas content and grain size.
• Strict manufacturing procedures and processes along with SPC assure process control.
• Use of X-ray, fluorescent penetrant inspection (FPI), for process development and control.
• All heat treating is done in-house and is backed by a fully equipped metallurgical laboratory.
• Exceeding the toughest mechanical property specifications in complex castings is our forte.
• Using the best casting engineering coupled with strict process control and melt preparation to produce the highest internal integrity makes it happen. We stake our reputation on it.