Bronze Products FlipBook final (1)

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Methods of Manufacture Continuous Cast Process Continuous casting is a process in which solidifying metal is extracted through an open ended mold fitted with a cooling unit. Heat is extracted and the metal exits the mold as a solid with a constant cross section. It allows lower cost production of metal sections with better quality, due to finer control through automation of the casting process. Generally a saw is set up after the withdrawal rolls, in order to cut the casting at constant lengths. The castings are semi-finished products. Continuous Cast Vertical Withdrawal Rolls Metal Graphite Die Water Cooling Jacket Automatic Saws Automatic Saws Withdrawal Rolls Water Cooling Jacket Continuous Cast Horizontal Graphite Die Metal Centrifugally Cast Process Centrifugal casting is done by pouring molten metal into a rotating mold. The centrifugal force acting on the mold helps in feeding and positioning the metal in the mold. Mold rotation is continued until after the metal is solidified. Centrifugal casting results in denser and cleaner metal as heavier metal is thrown to parts of the mold away from the center of rotation and the lighter impurities like slag, oxides and inclusion are squeezed out to the center. The castings produced have a close grain structure, good detail, high density and superior mechanical properties. Horizontal Centrifugal Casting Vertical Centrifugal Casting Metal 2 Wrought Alloys Extrusion is the process by which long straight metal parts can be produced. The cross-sections that can be produced vary from solid round, rectangular, to L shapes,Tshapes,Tubes and many other different types. Extrusion is done by squeezing metal in a closed cavity through a tool, known as a die using either a mechanical or hydraulic press. There are two main types of Extrusions: Hot Extrusions and Cold Drawn. The forging process involves working metal parts above their recrystallization temperature and gradually shaping them into the desired configuration through the hammering or pressing of the work piece. Hot Extrusion Forging - Open Die Process Forging - Closed Die Process Die Metal Metal Side View Metal Force Pulling Force Metal Metal Die Water Cooled Mold Die Cold Drawn Process Plain View Metal Hot Roll Process Metal Die Smooth Rollers Water Cooling
Sintered <strong>Bronze</strong> Process Sintered <strong>Bronze</strong> Process The process of powder metallurgy has three basic steps: 1. First, the metal, in this case, bronze or bronze alloy, is made into a powdered form. This can be achieved by a number of methods including grinding, chemical decomposition and the most common atomization. 2. The metallic powder is then poured into a die or mold cavity and compacted under great pressure in order to adhere the particles. This occurs at room temperature. 3. The metal part is then inserted into a furnace where the extreme heat fuses the metal particles together to form a rigid, high strength and porous component. This part of the process is called sintering. Metal Powders Optional Secondary Machining Mixing Compaction Sintering Finished Product Additives (Lubricants or Binders) Optional Secondary Finishing 3
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Bronze Products FlipBook final (1)

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