Mercury Castings

What We Offer: 

• Production of high-strength, dimensionally accurate aluminum components ideal for high-volume, tight-tolerance applications 

Advantages: 

• Superior surface finish and dimensional consistency 
• Thin-wall capability for lightweighting (2-3mm) 
• Rapid cycle times for high productivity 
• Excellent mechanical properties with minimal porosity 

Applications: 

• Powertrain components 
• Chassis and suspension parts 
• Cosmetic parts 
• Defense-grade housings and enclosures 

Machine Sizes: 

• 900 to 4500 tons 

Alloys Available: 

• 362 (XK360) 
• A380 
• 367 
• 368 
• Additional alloys available upon request 

We partner with your engineering and design teams early in the development process to ensure your parts are optimized for manufacturability long before tooling begins to reduce risk, cost and time to launch.

What We Offer:

• Collaborative Design Reviews: Identification of casting and machining constraints upfront avoids redesigns, delays and unexpected cost drivers.
• Tooling Feasibility Analysis: Detailed assessments of gating, venting and thermal behavior for HPDC dies and lost-foam patterns are completed prior to tool build.
• Advanced Simulation Tools: Using MAGMASOFT® and other industry-leading tools, we model flow, solidification, porosity and cooling to predict part behavior and enhance quality.
• Early Engagement Advantage: Collaboration early in the design process offers shorter lead times, fewer surprises during production, and a smoother, more predictable product launch.

Our full-service tool room offers in-house design, 5-axis CNC machining, EDM sinker and wire machines, welding rejuvenation and maintenance work. We service everything we build.

Advantages:

• Faster lead times and tighter quality control
• Tooling optimized for longevity and performance
• Use of premium grade, domestically produced steel

Our fully equipped heat treatment facility provides a complete range of services for both aluminum and steel components, ensuring optimal mechanical properties, dimensional stability and long-term durability. Every process is backed by strict temperature control, advanced quenching systems and in-house metallurgical verification that guarantees consistent results from prototype through production.

From lightweight aluminum castings to high-strength steel components, our heat treatment plant combines metallurgical expertise with state-of-the-art process controls to deliver repeatable, high-quality results every time.

Capabilities:

• Aluminum Heat Treatment
  • Full T6 and T7 solution and aging cycles for structural and performance-grade aluminum castings and components. Our controlled furnaces and rapid quenching systems ensure uniform hardness, strength and elongation across every part.
  • Optimized T5 heat treatment for high-pressure die-cast aluminum parts. Our precision-controlled process boosts strength and stability while preserving surface integrity and delivering components that perform reliably and maintain an exceptional appearance suitable for the most demanding applications.
• Steel Heat Treatment
  • Marquenching/Martempering: Molten salt austenitizing and hot brine quenching deliver controlled transformation and minimal distortion, ideal for precision steel components requiring toughness and dimensional accuracy.
  • Atmosphere Carburizing: Enhanced surface hardness and wear resistance through controlled atmosphere carburizing, followed by a warm oil quench for balanced case depth and core strength.
• Heat Treat Laboratory
  • Our dedicated metallurgical analysis lab supports all operations with microstructural evaluation, hardness testing and process validation. This ensures every batch meets or exceeds mechanical property specifications and customer standards.