Let’s Start a Project
Let’s Start a Project
Walker Die Casting P.O. Box 1189, 1125 Higgs Road Lewisburg, Tennessee 37091
Ph 931-359-6206 FAX 931-359-8030
A proud Allison business
Member since 1977, Automotive and Commercial Castings
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Production

Our integrity extends to our process.

Our process allows for complex designs as well as superior efficiency and productivity, especially at high volumes. But we’re not just about high volume jobs.

40+ million Pounds of aluminum castings shipped by Walker in 2020

700,000 Pounds/day Our combined reverberatory and barrel furnace melting capacity

17 Loading docks with easy access to our 100,000-square-foot warehouse

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Production

Production Capabilities

We cast the best parts for today. And tomorrow.

Our expert technicians listen to you and put your ideas to work. To create the high-integrity, net-shape castings we’re known for, our high pressure casting process uses casting pressures in excess of 12,500 pounds per square inch. We provide an extraordinary range of casting machines — from 1,000 to 4,500 tons — to accommodate your needs, even if your needs change. All Walker die casting machines are linked to a centralized process and production monitoring system to improve efficiency and equipment effectiveness.

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Furnace

Abundant capacity for every job.
Our 80,000 pound high capacity furnace melts aluminum at a rate of 8,000 pounds per hour. It’s also energy efficient and clean.

The right raw materials.
The aluminum alloys we use are typically received pre-certified to American National Standards Institute specifications for 380 and 413 designations. Additionally, every shipment is subject to verification by in-house spectrograph analysis to ensure it conforms to customer requirements.

A clean process.
The combined reverberatory and barrel furnace melting capacity is in excess of 700,000 pounds per day. Proper filtering and handling practices precede delivery of metal to the holding furnaces, which themselves are strictly maintained and periodically reconditioned in-house. Molten metal is degassed before delivery to the casting machine holding furnaces, which are equipped with silicon carbide filters to remove any remaining impurities. We use automatic-ladle and dosing type holding furnaces.

Uninterrupted flow.
Our 60,000-80,000-pound reverberatory and 15,000-pound barrel furnaces are supplied with molten aluminum as well as sow and ingot. Multiple-furnace melting and molten receiving capabilities ensure an uninterrupted material source for casting operations.

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Casting

Ready to scale up with you.
Our range of die cast machines in a variety of tonnages give us flexibility to take care of you — even if your needs change.

Smooth systems.
All die cast machines are networked into a central system that monitors the various parameters within preset limits. This system is capable of charting 24 different parameters of the casting process, including cycle time, cavity pressure, cavity fill time and intensifier pressure.

Simple process.
We reduce process variation for improved efficiency and quality at the casting operation. Our investment in extraction and spray automation are part of our strategy to embrace innovation to give you a competitive advantage.

Expert tooling.
A wide range of trim presses are available for use with most standard die sets. Additionally, the Walker tooling engineering group is experienced in managing the design and procurement of custom trim machines where gate sawing or multi-axis actuation is required.

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Secondary Processes

A smooth finish for every part.
We trim, clean, coat and seal your parts for corrosion and leak protection as well as durability.

Flash removal and cleaning.
Our three pass-through belt-feed shot blasters have a variety of settings for different aggressiveness of finish — from heavy to light. The technicians in our secondary processing department are experienced with continuous-feed, hanger/spinner and tumble type shotblast systems. Castings are routed to the appropriate shotblast system depending on size, shape and surface finish desired. Three continuous feed systems are operated for maximum flexibility in part cleaning and finishing.

Testing.
Parts with pressure-tight requirements are tested prior to delivery. Our tooling engineering and maintenance groups have extensive experience in managing the design, procurement and operation of air-under-water, mass-flow and air-decay leak test equipment.

Sealing.
Resin impregnation is increasingly being validated for critical function castings. A 600 gallon anaerobic impregnation system is available to treat complex or heavily machined parts. The system helps improve acceptance rates for pressure-tight applications.

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Machining

Shaped, tooled and on time.
Our technology, design and experienced team ensure your finished product hits the spot.

Tooling design.
Our goal is to tightly hold aluminum while avoiding deformation and distortion during the cutting process. We’ve invested in 38+ computer numerical control (CNC) machining centers with the latest technology from market-leading manufacturers to ensure we provide high precision machining while keeping down cycle times.

Our machining department engineers are experienced in creating optimized machining processes, designing robust tooling, as well as daily operations of precision high speed horizontal machining centers such as Mori Seiki, Makino and Toyoda.

Cleaning and testing.
Finish-machined parts are often leak-tested after cleaning with air-decay or mass-flow type systems to verify casting integrity. The part or assembly is then serialized for traceability and packaged for preservation according to engineering requirements.

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