Woodland/Alloy Casting Inc. is a full-service aluminum casting provider,
servicing numerous industries including aviation, electrical, industrial, marine and defense.
Specializing in green sand molding, air set molding and permanent mold, Woodland/Alloy
Casting has the capabilities and expertise to meet is customers’ casting needs ranging from
parts weighing just a few ounces to 2000 lbs.
Woodland/Alloy Casting prides itself on delivering quality aluminum castings “on time, every
time.” With the convenience of being able to perform molding, core making, melting, heat
treatment, cleaning and surface preparation all under one roof, Woodland/Alloy Casting is
able to continuously satisfy those time and quality standards for its customers. While exploring
ways to simulate solidification and streamline their casting process, Woodland/Alloy Casting
discovered solidThinking’s casting simulation software, Altair Click2Cast. Woodland/Alloy Casting
found that by employing this intuitive tool it was able to completely optimize and improve their
casting process while continuing to maintain the goal of quality castings on time, every time.
Altair Click2Cast in the Casting Simulation Process
One of Woodland/Alloy Casting’s most recent projects was transitioning a marine exhaust
housing part from a lost foam casting to a sand casting. With this material modification in mind,
there were a number of factors to consider when manufacturing this new casting. “We wanted
to produce a sound casting, while still keeping ingates and risers to a minimum, this would allow
for the yield to remain low and help reduce the time needed to remove the rigging,” explains
Andy Ceretto, Quality Control Manager of Woodland/Alloy Casting. In order to create this
sand casting, a new gating system was designed that would feed the casting from the bottom
flange and push the metal to the top of the casting. Once the updated design was finalized,
Woodland/Alloy Casting tested the new gating system by running a simulation in Altair Click2Cast.
Woodland/Alloy Casting was able to conclude that the new gating system would produce a
casting with zero defects. Before utilizing Altair Click2Cast, Woodland/Alloy Casting would have
conducted numerous costly and time consuming tests, requiring a number of molds to determine
the outcome of the new gating system. Ceretto states, “By employing Altair Click2Cast, we were able to
conclude the new gating system would work
properly after running just two simulations.
Aluminum Sand Casting
Transitioning a marine exhaust housing part from
a lost foam casting to a sand casting with an
updated gating system while still maintaining a
Employing Altair Click2Cast to run a
casting simulation on the newly designed gating
system of the exhaust housing.
• The simulation ran in Altair Click2Cast produced
results that confirmed the new gating design
would be sufficient and provide a casting free
• Reduced time in trial and error in creating
numerous gating systems for numerous tests.
• Cost savings in eliminating the process of
having to create new gating system samples
and molds to test.
“When deciding on a casting
simulation software, there were
a number factors: reasonable
cost, ease of use and the ability
to perform the basic functions
that a high price software
performs, and Altair Click2Cast met
all those criteria.”
Quality Control Manager, Woodland/Alloy Casting, Inc.
With the enhanced casting process in place, Woodland/Alloy Casting is continuing to see the
benefits of both cost and time savings due to the simulation capabilities that are offered in
Altair Click2Cast. Woodland/Alloy Casting has employed Altair Click2Cast on a number of casting projects
since first discovering the software last year and is continuing to explore all the features, settings
and tools that the software provides.