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Quality Built
Into Every Pour.
PPAP III
Production part approval support
Quality Philosophy
Verified Before It
Leaves the Mould
Prevention over Detection
Process parameters — melt temperature, die temperature, fill speed, cooling time — are set, recorded, and controlled. A casting produced within controlled parameters is far more likely to meet specification than one inspected after the fact.
Traceability Through Every Stage
Each batch carries a heat number linking it to the spectrometry certificate, the process record, and the inspection report. Full material and process traceability is available for every order.
First Article Before Batch Release
The first casting from every new tool and every restart after a process change is fully inspected against the drawing before the batch proceeds. No batch ships on a first-off that has not passed.
Documented & Reported
Inspection results, material certificates, heat treatment records, and pressure test certificates are held for every batch. Quality documentation packs are supplied with shipments on request.
Our Approach
Quality at the
Source.
Not the Sort.
Inspection Capability
How We Inspect
Every Casting
Optical Emission Spectrometry (OES)
Every melt is spark-tested on a calibrated OES spectrometer before pouring. The instrument analyses full elemental composition — confirming all alloying elements are within BS 1490 limits for the designated LM grade. A heat certificate recording the measured composition is issued for every melt.
100% of heats · Pre-pour · BS 1490 compliance · Certificate issued per melt
CMM Dimensional Inspection
Coordinate Measuring Machine (CMM) dimensional inspection is available for first-article castings and critical production features — producing a full dimensional report against the drawing confirming position, diameter, perpendicularity, flatness, and parallelism to tolerance. CMM inspection reports are provided on request and are available as a deliverable with the batch for components where dimensional certification is required.
First article & critical features · Full dimensional report · Available on request · Position, form & profile
Calibrated Gauge Inspection
Production inspection of dimensional features using calibrated go/no-go gauges, micrometers, vernier calipers, and height gauges on surface plates. All gauges are calibrated on a traceable schedule. Gauge records and calibration certificates are maintained and available for audit.
Production batches · Calibrated tools · Go/No-Go · Traceable calibration records
Pressure Testing
Hydrostatic and pneumatic pressure testing for pump bodies, valve bodies, manifolds, and other pressure-retaining castings. Testing is performed to customer-specified test pressure and hold duration. Test certificates recording the pressure, medium, duration, and result are issued per part and traceable to the casting heat number
Hydrostatic & pneumatic · Customer-specified pressure · Certificate per part · 100% where specified
Hardness Testing
Brinell hardness testing (HB) performed on castings after heat treatment to confirm the treatment cycle has achieved the specified hardness range. Hardness is measured at multiple points per batch to check consistency. Results are recorded on the heat treatment certificate issued with each treated batch.
Post heat treatment · Brinell HB · Multiple locations per batch · Recorded on HT certificate
Visual & Surface Inspection
100% visual inspection of every casting for surface defects — cold shuts, misruns, shrinkage depressions, cracks, and inclusions. Critical surfaces are inspected against an agreed defect acceptance standard. Non-conforming castings are segregated and not released. Dye penetrant inspection (DPI) available for safety-critical surfaces.
100% of castings · Surface integrity · Customer-agreed criteria · DPI available
Also Available on Request
- Dye Penetrant Inspection (DPI) for surface crack detection
- Radiographic (X-ray) inspection for internal integrity — report available on request
- Tensile and elongation testing to BS EN ISO 6892
Dimensional Capability
Casting Tolerances by Process
Sand Casting
CT8–CT10
ISO 8062 Grade
Ra 6.3–25
Surface (µm)
2.5–5 mm
Machining allowance
Widest tolerance range — suited to complex geometry and low-volume work. Machining to tighter feature tolerances is standard.
Tilt Gravity Die Casting (GDC)
CT6–CT8
ISO 8062 Grade
Ra 3.2–6.3
Surface (µm)
1.5–3 mm
Machining allowance
Low Pressure Die Casting (LPDC)
CT5–CT7
ISO 8062 Grade
Ra 1.6–3.2
Surface (µm)
1.0–2.5 mm
Machining allowance
High Pressure Die Casting (HPDC)
CT4–CT6
ISO 8062 Grade
Ra 0.8–1.6
Surface (µm)
0.5–1.5 mm
Machining allowance
| CT Grade | Total Tolerance | Process |
|---|---|---|
| CT4 | ±0.56 mm Total 1.12 mm on 100 mm | HPDC |
| CT5 | ±0.78 mm Total 1.56 mm on 100 mm | HPDC / LPDC |
| CT6 | ±1.1 mm Total 2.2 mm on 100 mm | LPDC / GDC |
| CT7 | ±1.6 mm Total 3.2 mm on 100 mm | GDC / Sand |
| CT8 | ±2.2 mm Total 4.4 mm on 100 mm | Sand |
| CT9 | ±3.2 mm Total 6.4 mm on 100 mm | Sand (large parts) |
Machined Feature Tolerances
Testing
What We Test & Verify
Testing beyond dimensional inspection — confirming the material is what the drawing
specifies, the process has run correctly, and the part will perform as designed.
Test 01
Chemical Composition
Full elemental analysis by OES spectrometry on every heat before pouring. All alloying elements measured against BS 1490 limits. No metal poured without a passing result.
OES Spectrometry · Every heat · BS 1490 · Certificate issued
Test 02
Dimensional Verification
CMM dimensional inspection is available for first articles and critical features, with full reports provided on request. Calibrated hand gauges are used for production batch inspection. All results recorded against drawing tolerances. Non-conforming dimensions flagged before release.
CMM available · Calibrated Gauges · ISO 8062 · Report on request
Test 03
Hardness Verification
Brinell hardness (HB) testing after heat treatment to confirm the treatment cycle has achieved the specified condition. Multiple points per batch. Out-of-range hardness triggers process investigation before release.
Brinell HB · Post heat treatment · Multiple points · Acceptance criteria per alloy
Test 04
Pressure Integrity
Hydrostatic or pneumatic pressure testing for all pressure-retaining components — pump bodies, valve bodies, manifolds. Test pressure, hold time, and result recorded per part with certificate.
Hydrostatic / Pneumatic · 100% where specified · Test certificate per part
Test 05
Surface Integrity
100% visual inspection of all castings against an agreed defect acceptance standard. Critical surface areas receive enhanced inspection. Dye penetrant inspection (DPI) available for crack detection.
100% visual · DPI available · Customer-defined critical surfaces
Test 06
Mechanical Properties
Tensile testing (UTS, 0.2% proof stress, elongation) to BS EN ISO 6892 on separately cast test pieces from the same heat — available where mechanical property certification is specified.
BS EN ISO 6892 · UTS, Proof Stress, Elongation · On request or where specified
Test 07
Radiographic Inspection
X-ray radiographic inspection for internal integrity — revealing shrinkage porosity, gas porosity, and inclusions not visible on the surface. Used as part of our internal quality process and available as a formal inspection report on request for safety-critical components.
X-ray · Internal quality check · Report on request · ASTM E155 criteria
Test 08
Weight Verification
Casting weight recorded and compared to nominal for each batch — a consistent check on fill completeness, core condition, and process stability. Weight deviation outside tolerance triggers process review.
Calibrated weighing · 100% · Batch average vs nominal · Deviation trigger
Process Controls
Controlled at Every Stage of Casting
Process Control
Dimensional inspection alone does not guarantee quality — it only detects it. The real quality lever is process control: the parameters set, monitored, and recorded at each stage to ensure the process that produced a good first article continues to produce good castings throughout the batch.
01
Melt Preparation & Alloy Verification
02
Die / Pattern Temperature Control
03
Pour Temperature & Fill Monitoring
04
Solidification & Cooling Control
05
Post-Cast & Pre-Despatch Inspection
Why Choose Creative Alucast
Quality Management Systems We Operate
ISO 9001
ISO 9001 Quality Management System
Creative Alucast operates under ISO 9001 quality management principles — covering documented process controls, defined quality objectives, internal audits, corrective action management, and continual improvement. Our quality system ensures consistency across every casting process, alloy, and customer requirement.
IATF 16949 Automotive Quality (In Progress)
ISO 9001 Quality Management System
Creative Alucast is actively working toward IATF 16949 certification — the international automotive quality management standard that builds on ISO 9001 with requirements specific to the automotive supply chain. Customer-specific requirements, PPAP, FMEA, control plans, and measurement system analysis are already embedded in our quality process in preparation.
PPAP Level III
Production Part Approval Process — Level III
Creative Alucast supports PPAP Level III submissions — the standard required by most automotive Tier-1 and OEM customers for new part approvals. A Level III submission includes the full documentation package: design records, process flow diagrams, PFMEA, control plan, measurement system analysis, dimensional results, material performance test results, initial process capability, and a Part Submission Warrant (PSW).
5S
5S Workplace Organisation
The Creative Alucast facility operates on 5S principles — Sort, Set in Order, Shine, Standardise, Sustain. A clean, organised foundry is not cosmetic: controlled workplaces reduce contamination risk in aluminium melts, keep inspection equipment accessible and protected, and allow process deviations to be spotted immediately. 5S audits are conducted on a regular schedule.
TPM
Total Productive Maintenance
Planned preventive maintenance on all casting equipment, die heating systems, shot-blasting equipment, and machining centres is carried out under a Total Productive Maintenance programme. Unplanned breakdowns mid-batch are a leading cause of dimensional and surface quality issues in casting. TPM schedules reduce this risk and maintain process stability across the production run.
Standards & Compliance
Global Standards We Work To
BS 1490
British Standard — LM Alloys
The primary specification for all 17 LM aluminium casting alloys used at Creative Alucast. Every heat is verified against BS 1490 chemical composition limits.
All 17 LM alloys
All processes
Every heat
EN 1706
European Standard — Al Casting Alloys
European aluminium casting alloy standard. Creative Alucast cross-references all LM alloys to EN 1706 equivalents — allowing European OEM drawings to be supplied without alloy conversion.
EN equivalent supplied
Cross-reference table
ASTM B179
US Standard — Al Casting Alloys
American standard for aluminium casting alloys. LM alloy to ASTM equivalents are mapped and published on the Creative Alucast global standards comparison page
ASTM equivalent supplied
Export markets
ISO 3522
International Standard — Al Casting
ISO standard for aluminium alloys for castings. Used in international contracts and global supply chains where neither BS nor EN is the primary reference.
International contracts
ISO equivalent
ISO 8062
Casting Tolerances — CT Grades
International standard defining casting dimensional tolerance grades. Creative Alucast specifies achieved CT grades for each process on all quotations and order acknowledgements.
All processes
Dimensional control
JIS H 5302
Japanese Standard — Al Die Casting
Japanese industrial standard for aluminium die casting alloys. Referenced by Japanese OEMs and Tier-1 suppliers. JIS cross-references provided for all relevant LM alloys.
Japanese OEM supply
JIS equivalent
ASTM E155
Reference Radiographs — Al & Mg Castings
ASTM E155 provides the standard reference radiographs used for evaluating the severity of discontinuities in aluminium and magnesium castings — covering gas porosity, shrinkage, inclusions, and cold shuts across eight categories. Radiographic inspection results at Creative Alucast are evaluated against ASTM E155 acceptance criteria for applicable components.
Radiographic inspection
Internal quality
Report on request
ASTM B917
Heat Treatment — Al Alloy Castings
ASTM B917 specifies the procedures and requirements for heat treatment of aluminium alloy castings — covering solution heat treatment temperatures, quench methods, and artificial ageing conditions for the principal casting alloy temper designations (T4, T5, T6, T7). Creative Alucast heat treatment cycles for applicable LM alloys are aligned with ASTM B917 parameters.
Heat treatment
T4 / T5 / T6 / T7
All HT alloys
Heat Treatment
Heat Treatment Conditions
| Condition | Description | Typical UTS Improvement | Primary Alloys | Verification |
|---|---|---|---|---|
| T4 | Solution treatment + natural ageing. Improves ductility with moderate strength gain. Minimal distortion. | +20–30% | LM25, LM4, LM6 | HARDNESS HB |
| T5 | Artificial ageing only (no solution treatment). Moderate strength increase with minimal distortion risk – most common condition for GDC and LPDC castings. | +15–25% | LM25, LM16, LM4, LM13 | HARDNESS HB |
| T6 | Solution treatment + artificial ageing (peak hardness). Highest strength condition from heat treatment. Full mechanical property testing available. | +40–60% | LM25, LM4, LM16 |
HARDNESS HB + TENSILE |
| T7 | Solution treatment + over-ageing (stabilised). Lower strength than T6 but better dimensional stability – specified for precision machined parts after heat treatment. | +30–45% | LM25, LM16 | HARDNESS HB |
| AS-CAST (F) | No heat treatment applied. Used where alloy properties in the as-cast condition are sufficient – typically LM2, LM5, LM6, LM20 and LM27, which do not require heat treatment. | Baseline | LM2, LM5, LM6, LM20, LM27 |
VISUAL + DIMENSIONAL |
Documentation
Full Traceability.
Every Batch.
Material / Heat Certificate
OES spectrometry result for every melt — full elemental composition against BS 1490 limits. Heat number, alloy grade, and date recorded.
Dimensional Inspection Report
Gauged dimensional results against drawing tolerances for every batch. CMM inspection reports available on request for first articles and critical feature verification
Heat Treatment Certificate
Condition (T4/T5/T6/T7), furnace temperature record, soak time, quench details, and Brinell hardness results. Issued per batch where heat treatment is performed.
Pressure Test Certificate
Test medium, pressure, hold duration, and result (pass/fail) recorded per part. Issued for all pressure-tested components — traceable to the casting heat number.
Process Record
Melt temperature, pour temperature, die temperature, and cycle time recorded for each production run. Available for root cause analysis if a quality issue arises.
Delivery / Dispatch Certificate
Batch quantity, heat number, alloy, process, drawing revision, and inspection status confirmed at despatch. Full quality pack available with every shipment on request.
FAQ
Quality Questions
Does Creative Alucast verify alloy chemistry on every heat?
Yes. Every melt is verified by optical emission spectrometry (OES) before pouring — confirming that each alloying element meets the BS 1490 specification for the designated LM alloy grade. No metal is poured without a passing composition result. A heat certificate recording the measured composition is available for every batch.
What dimensional inspection does Creative Alucast perform?
Can Creative Alucast supply pressure-tested castings with certificates?
What casting tolerances does Creative Alucast achieve?
Does Creative Alucast perform heat treatment?
What quality documentation is supplied with a casting order?
Standard documentation includes a material / heat certificate (OES composition), dimensional inspection report, and a delivery certificate confirming alloy, process, drawing revision, and batch quantity. Heat treatment certificates, pressure test certificates, and mechanical test reports are added where those operations are performed. A full quality documentation pack is available with every shipment on request.