Aluminium Sand Casting – FAQs

In a world where precision, performance, and cost-efficiency drive engineering decisions, aluminium sand casting continues to be a highly relevant and reliable manufacturing process. From automotive to aerospace, defence to heavy industry, the demand for high-quality aluminium castings remains strong—especially in the context of lightweighting and sustainability goals.

At Taural India, aluminium sand casting is more than just a foundry process—it's a core competency backed by deep expertise, world-class infrastructure, and a commitment to precision. Whether you're a design engineer, buyer, or product manager, understanding the essentials of sand casting can help you make informed decisions.

To simplify the journey, here’s a list of Frequently Asked Questions (FAQs) about aluminium sand casting—answering what it is, why it’s used, and how Taural India delivers excellence through this process.

1. What is Aluminium Sand Casting?

Aluminium sand casting is a process in which molten aluminium is poured into a cavity formed by a sand mould. Once the metal solidifies, the sand mould is broken away to reveal the final cast part. It’s ideal for producing complex shapes in low to medium volumes, especially when flexibility and cost-effectiveness are important.

2. Why Use Aluminium in Sand Casting?

Aluminium is lightweight, corrosion-resistant, and highly durable. Its excellent strength-to-weight ratio makes it perfect for structural and high-performance components. It also offers:

• Good thermal and electrical conductivity

• Excellent machinability

• 100% recyclability

This makes aluminium sand casting a preferred solution across automotive, aerospace, and industrial sectors.

3. Which Industries Use Aluminium Sand Castings?

At Taural India, we serve multiple sectors with precision aluminium castings:

• Automotive (engine brackets, housings, EV motor parts)

• Aerospace (mounts, supports, structural elements)

• Defence (weapon system parts, vehicle components)

• Industrial Machinery (pumps, valves, compressors)

4. What Are the Advantages of Sand Casting Over Other Methods?

Compared to processes like die casting or investment casting, sand casting offers:

• Lower tooling costs

• Design flexibility for complex or large parts

• Rapid prototyping and modifications

• Ideal for custom or small-batch production

5. What Tolerances and Surface Finishes Are Achievable?

Taural India maintains tight process control to deliver:

• Dimensional tolerance: typically ±0.5 mm to ±1.5 mm

• Surface finish: Ra 6.3 to 12.5 μm (with optional surface treatment)

• We also offer CMM measurement, X-ray, and NDT testing for critical parts

6. What Aluminium Alloys Do You Use?

We work with a wide range of alloys based on customer requirements:

• A356 / AlSi7Mg – High strength, corrosion resistance

• AlSi12 – Excellent fluidity and castability

• AlSi9Cu3 – Widely used in automotive

Custom alloys can also be developed for specialised applications.

7. Do You Offer Heat Treatment and Machining Services?

Yes, we offer:

• Heat treatment (T5, T6, solution & ageing)

• CNC machining for precision dimensions

• Surface finishing including shot blasting and anodizing

We provide both raw castings and fully finished parts as per customer needs.

8. What Is Your Production Capacity?

Taural India supports both prototyping and high-volume production. Our foundry is equipped with:

• Automated sand moulding lines

• In-house pattern development

• Advanced melting and pouring systems

We are capable of scaling production to meet growing demands across global markets.

9. How Long Does It Take to Develop a New Part?

• Prototype development: typically 3–5 weeks

• Production-ready tooling and casting: around 6–8 weeks

These timelines may vary depending on complexity, material, and finishing requirements.

10. Is Aluminium Sand Casting Environmentally Friendly?

Yes. Aluminium is 100% recyclable without loss of quality. At Taural India, our foundry incorporates:

• Energy-efficient furnaces

• Recyclable sand systems

• Minimal material waste

This aligns with global sustainability goals and supports circular manufacturing practices.

11. Do You Assist with Casting Design?

Absolutely. Our design and engineering team collaborates with clients from the early stages to:

• Optimise designs for casting

• Reduce weight and material usage

• Minimise machining requirements

• Ensure manufacturability and cost-efficiency

12. What Quality Standards Do You Follow?

Taural India is certified to:

• ISO 9001 – Quality Management

• IATF 16949 – Automotive Industry Quality Standard

We employ robust quality checks, including:

• X-ray and ultrasonic testing

• CMM inspection

• Mechanical and chemical analysis

Conclusion: Precision, Performance, and Partnership

Aluminium sand casting continues to offer unmatched value in producing strong, lightweight, and intricate components. At Taural India, we combine decades of global casting expertise with local execution excellence to deliver components that meet the highest standards of quality and performance.

Whether you're exploring aluminium casting for a new EV platform, a defence component, or an industrial part, our team is ready to support your project from concept to completion.