Process Of Producing Bronze, Brass, Copper Alloys

All finished parts, as required, will be shipped directly to you. Apart from continuous cast bronze, you also have a choice of brass and copper alloys, materialized from a centrifugal cast, a sand cast and wrought alloys. Here is a brief overview of some of the processes of production in creating the bronze, brass and copper alloys.

Molten metal will be poured into what is known as a ‘crucible tundish’ furnace. This pouring work is carried out with a controlled atmosphere.

The tundish furnace has the ability to maintain a large reservoir of molten metals at controlled temperatures above a placed water cooled graphite die. Any ‘doss’ that enters the tundish furnace will float to the top of a metal bath where it will summarily be removed.

Any entrainment of slag within the cast bars will not be possible. This is a feature that ensures that castings will be free of solid inclusions and porosity arising from gas or shrinkage.

Metal enters a freezing zone. The temperature must be right to ensure that all shrinkage pores from prior cast materials will be filled. This can be pulled off within a fraction of a second before the process of rapid freezing begins. All severe segregation of alloying elements is thus prevented. Other techniques are in use to further reduce segregation and vastly improve casting strength, generating fine grain structures within the casting.

continuous cast bronze

A newly frozen layer of metal will quickly shrink away from any graphite die. It is withdrawn from the die by way of a set of electrically driven pinch rolls. The newly solidified portion leaves its freezing zone. The die is gravity filled with the molten metal collected from the tundish. And then a new solidification process commences, if required.