bronze sand casting 2 bronze sand casting

Bronze Sand Casting

Bronze sand casting is a versatile and time-honored metal forming process used to create a wide range of products. This method combines the durability and beauty of Bronze with the flexibility and cost-effectiveness of sand casting.  At our Bronze sand casting foundry in Jamnagar India,  we cast articles and products form 30 grams to 10 Kgs in Bronze using black sand and green sand methods. Our Bronze sand casting foundry is eco-friendly and is well known worldwide for high quality, dependability and competitive pricing. We make our own ingots for Bronze sand casting in various alloys rendering us highly competitive in the marketplace.

 

The Bronze Sand Casting Process

Bronze Sand casting is one of the oldest and most widely used casting methods. Here’s a step-by-step overview of the bronze sand casting process:

  1. Pattern Creation: A pattern of the desired part is created, usually from wood, metal, or plastic.
  2. Mold Preparation: The pattern is packed in special casting sand to create a mold. The sand is a mixture of silica sand, clay, and other additives that help it maintain its shape.
  3. Core Installation: If the part requires hollow sections, sand cores are placed in the mold.
  4. Melting the Bronze: Bronze ingots are melted in a furnace until they reach the proper pouring temperature, typically between 1,900°F and 2,200°F (1,040°C to 1,200°C).
  5. Pouring: The molten bronze is carefully poured into the mold through a gating system.
  6. Cooling and Solidification: The bronze is allowed to cool and solidify within the mold.
  7. Removal and Cleaning: Once cooled, the casting is removed from the sand mold and cleaned. Any excess material from the gating system is removed.
  8. Finishing: The cast part may undergo additional finishing processes such as machining, polishing, or patination.

Applications of Bronze Sand Castings

Bronze sand castings find applications across various industries due to their excellent properties, including corrosion resistance, low friction, and aesthetic appeal. Here are some common applications:

  • Marine hardware (propellers, rudders, bearings)
  • Architectural elements (doorknobs, handrails, decorative fixtures)
  • Industrial machinery components
  • Sculptures and monuments
  • Historical restorations (church bells, statues)
  • Automotive components (bushings, valve seats)
  • Pumps and valves for water systems
  • Bronze Gears
  • Decorative garden ornaments
  • Marine products like Thru Hulls and Strainers in LG2
  • Heritage restoration projects
  • Public art installations
  • Industrial bearings and bushings
  • Plumbing fixtures and fittings
  • Hotline clamps
  • Bronze ground rod clamps
  • Bronze Pipe fittings
  • Vise Connectors
  • Bronze Impellers
  • Bronze Transformer Spade terminals

Common Bronze Alloys Used in Sand Casting

Different bronze alloys are used depending on the specific requirements of the application. Here are some commonly used alloys in each region:

United States

  1. C83600 (85-5-5-5): Contains 85% copper, 5% tin, 5% lead, and 5% zinc. This versatile alloy is used for bearings, bushings, and valve components due to its good machinability and wear resistance.
  2. C90300: A tin bronze with high strength and excellent corrosion resistance, often used in marine applications such as propellers and underwater fittings.
  3. C95400: An aluminum bronze alloy with excellent wear resistance, used in heavy-duty industrial applications like gears, bearings, and pump components.
  4. C92200: Known as Navy M, this alloy contains 88% copper, 6% tin, 1.5% lead, and 3.5% zinc. It’s used in marine applications and for pressure-tight castings.
  5. C93700: A high-lead tin bronze (80% copper, 10% tin, 10% lead) known for its excellent bearing properties. It’s used in heavy-duty bearings and bushings.
  6. C86300: A manganese bronze alloy with high strength and good wear resistance. It’s used for marine propellers, pump impellers, and wear plates.
  7. C87600: An aluminum-silicon bronze with good corrosion resistance and high strength. It’s used in marine hardware, valve components, and pump parts.
  8. C95500: A nickel-aluminum bronze with excellent strength and corrosion resistance. It’s used in marine propellers, pump impellers, and valve components for seawater service.
  9. C91300: A tin bronze with good strength and corrosion resistance. It’s used in gears, bearings, and general engineering applications.
  10. C94700: A nickel-tin bronze with high strength and good wear resistance. It’s used in heavy-duty bearings and bushings, especially in corrosive environments.

These alloys offer a range of properties to suit various applications:

  • Tin bronzes (like C90300 and C91300) offer good corrosion resistance and strength.
  • Leaded bronzes (like C83600 and C93700) provide excellent machinability and bearing properties.
  • Aluminum bronzes (like C95400 and C95500) offer high strength and excellent corrosion resistance, especially in marine environments.
  • Silicon bronzes (like C87600) combine good strength with excellent corrosion resistance.

Europe

  • CuSn12: A high-tin bronze (12% tin) used for bells and musical instruments.
  • CuSn10: Contains 10% tin, offering a good balance of strength and ductility. Used in general engineering applications.
  • CuAl10Fe5Ni5: An aluminum bronze with high strength and excellent corrosion resistance, often used in marine environments.

United Kingdom

  • LG2 -Gunmetal : A leaded gunmetal alloy (88% copper, 10% tin, 2% zinc) widely used for general engineering purposes, valve bodies, pump components, and marine fittings. It offers good corrosion resistance and is suitable for casting.
  • LG1: Another leaded gunmetal alloy with a slightly different composition (85% copper, 5% tin, 5% lead, 5% zinc). It’s known for its excellent machinability and is often used for bearings, bushes, and general engineering components.
  • PB1: A phosphor bronze alloy (5% tin, 0.2% phosphorus) known for its spring properties and wear resistance. It’s commonly used in applications requiring good elastic properties and fatigue strength.
  • AB2: An aluminum bronze alloy (9% aluminum, 2% iron) with high strength and good corrosion resistance. It’s particularly useful in marine environments and for components requiring high wear resistance.

Advantages of Bronze Sand Casting

  • Ability to cast complex shapes
  • Suitable for both small and large parts
  • Cost-effective for low to medium production runs
  • Excellent surface finish and dimensional accuracy
  • Wide range of alloys available to suit different applications

Bronze sand casting continues to be a crucial manufacturing process, blending traditional techniques with modern engineering to produce high-quality, durable parts for a wide range of industries.

Related Terms to Bronze Sand Casting:  Bronze casting, Gunmetal casting, Sand casting, Pump propeller casting, Bronze pump casting, Sand casting of Gunmetal, Indian bronze sand casting foundries,