
Bronze Casting Bronze Shell Molding Shell Casting Permanent Mold casting Bronze casting foundry India
Bronze Shell Molding (Resin Sand Casting) at Our Foundry
Welcome to A1 Metallics Bronze foundry, Bronze casting foundry in Jamnagar, India, where precision and craftsmanship come together in our advanced bronze shell molding process. With decades of experience and state-of-the-art facilities, we specialize in delivering high-quality resin sand castings that meet the diverse needs of our clients across industries.
What Is Bronze Shell Molding?
Bronze shell molding, also known as resin sand casting, is a precision casting technique that uses a thin shell of sand bonded by a heat-activated resin. This process ensures a high degree of accuracy, excellent surface finish, and minimal post-processing, making it ideal for producing complex and detailed bronze components.
Our Bronze Shell Casting Process
We adhere to a streamlined process to ensure the highest quality castings:
- Pattern Creation:
- We start by designing a precise pattern made of metal or composite materials to form the mold.
- Our patterns are crafted with utmost accuracy to ensure consistency and repeatability in production.
- Resin Sand Preparation:
- High-quality silica sand is mixed with a heat-activated resin binder to create the mold material.
- This ensures the mold is both strong and capable of capturing intricate details.
- Shell Formation:
- The pattern is coated with the resin sand mixture and heated to form a rigid shell.
- This shell is then reinforced with additional sand layers for stability and durability.
- Mold Assembly:
- The two halves of the shell mold are carefully aligned and assembled to prepare for casting.
- Vents and gating systems are incorporated to ensure smooth metal flow and minimal defects.
- Bronze Pouring:
- Molten bronze is poured into the prepared mold under controlled conditions.
- Our expert metallurgists monitor the process to ensure the metal meets all specifications.
- Cooling and Shell Removal:
- After the bronze solidifies, the mold is allowed to cool naturally.
- The shell is then broken away to reveal the cast component.
- Finishing and Inspection:
- The casting undergoes cleaning, surface finishing, and rigorous quality checks.
- We ensure that every piece meets the highest standards of dimensional accuracy and finish.
Industries We Serve
Our bronze shell molding services cater to a wide range of industries, including:
- Marine: Propellers, pumps, and fittings.Thru Hulls, Strainers
- Aerospace: Precision-engineered components.
- Automotive: Bearings, bushings, and gears.
- Industrial: Valves, impellers, and machine parts.
- Electrical: Bronze hotline clamps, Bronze Vise connectors, Vise clamps,Wedge connectors, Transformer Spades, Bronze Transformer connectors, Spade terminals, Bronze Eye bolts,
Machining Services for Bronze Castings
In addition to casting, we A1 Metallics offer comprehensive machining services to deliver ready-to-use components. Our machining capabilities include:
- CNC Turning and Milling: High-precision machining for tight tolerances and complex geometries.
- Drilling and Tapping: For creating holes and threaded features.
- Surface Finishing: Options such as polishing, grinding, and coating to enhance aesthetics and functionality.
- Custom Fixtures: Tailored to your unique requirements for seamless integration into your application.
With our advanced CNC machines and skilled technicians, we ensure that your bronze components are machined to perfection, ready for immediate use.
Why Choose Us for Bronze Shell Molding?
- Expertise: Decades of experience in resin sand casting and machining.
- Quality Assurance: Rigorous inspection at every stage of production.
- Customization: Tailored solutions to meet your specific needs.
- Timely Delivery: Reliable and efficient production processes to meet your deadlines.
- Sustainability: Eco-friendly practices to minimize waste and energy use.
Bronze Casting Alloys
Alloy Designation | International Equivalents | Key Constituent Metals (%) |
---|---|---|
AMS 4533 Copper | UNS C10100, EN CW004A | Cu (99.99+) |
AMS 4534 Copper | UNS C10200, EN CW008A | Cu (99.95+) |
AMS 4590 Nickel Aluminum Bronze | UNS C63020, BS CC333G | Cu (81), Al (9), Ni (5), Fe (4), Mn (1) |
AMS 4616 Silicon Bronze | UNS C65620, BS PB102 | Cu (96.5), Si (3), Mn (0.5) |
AMS 4640 Nickel Aluminum Bronze | UNS C63000, BS CC333G | Cu (82), Al (9), Ni (4.5), Fe (4), Mn (0.5) |
AMS 4880 Nickel Aluminum Bronze ‘E’ | UNS C95510 | Cu (80), Al (11), Ni (4.5), Fe (4), Mn (0.5) |
AMS 4881 Nickel Aluminum Bronze | UNS C95800 | Cu (81), Al (9), Ni (4.5), Fe (4), Mn (1.5) |
Aviva 37rc Forming Die Bronze | – | Cu (37), Zn (60), Al (3) |
C10100 (CDA 101) | EN CW004A, ISO Cu-OFE | Cu (99.99+) |
C10200 (CDA 102) | EN CW008A, ISO Cu-OF | Cu (99.95+) |
C11000 (CDA 110) | EN CW004A, ISO Cu-ETP | Cu (99.90+), O (0.04) |
C12000 | EN CW023A | Cu (99.90+), P (0.004-0.012) |
C12200 | EN CW024A | Cu (99.90+), P (0.015-0.040) |
C14500 | – | Cu (99.5), Te (0.4-0.7) |
C16200 | – | Cu (99+), Cd (0.7-1.2) |
C16500 | – | Cu (98.5), Cd (0.8-1.2), Sn (0.3-0.7) |
C17200 | EN CW101C | Cu (98), Be (1.8-2.0) |
C17300 | – | Cu (97.8), Be (1.8-2.0), Pb (0.2-0.6) |
C17500 | EN CW102C | Cu (97.9), Be (0.2-0.6), Co (2.4-2.7) |
C17510 | – | Cu (99), Be (0.2-0.6), Ni (1.4-2.2) |
C18000 | – | Cu (96), Cr (0.8), Ni (2.2), Si (0.4) |
C18150 | CuCrZr | Cu (99), Cr (0.7), Zr (0.04) |
C18200 | EN CW105C | Cu (99), Cr (0.6-1.2) |
C19140 | – | Cu (96), Ni (2), P (0.15), Pb (1.5) |
C19160 | – | Cu (94), Ni (2), P (0.15), Pb (3.5) |
C23000 | EN CW502L | Cu (85), Zn (15) |
C23400 | – | Cu (82), Zn (18) |
C26000 | EN CW505L | Cu (70), Zn (30) |
C27000 | EN CW506L | Cu (65), Zn (35) |
C27200 | EN CW507L | Cu (63.5), Zn (36.5) |
C27400 | – | Cu (63), Zn (37) |
C31400 | – | Cu (90), Zn (9), Pb (1) |
C31600 | – | Cu (89), Zn (9.5), Pb (1), Ni (0.5) |
C34500 | – | Cu (63), Zn (34), Pb (3) |
C35300 | – | Cu (62), Zn (36.5), Pb (1.5) |
C35330 | CW511L | Cu (62), Zn (36), Pb (1.7), As (0.3) |
C36000 | EN CW603N | Cu (61.5), Zn (35.5), Pb (3) |
C38000 | – | Cu (57), Zn (40), Pb (3) |
C46200 | – | Cu (63), Zn (35), Sn (1.5), Pb (0.5) |
C46400 | EN CW707R | Cu (60), Zn (39.4), Sn (0.6) |
C48200 | – | Cu (60), Zn (37.5), Sn (1), Pb (1.5) |
C48500 | – | Cu (60), Zn (37), Sn (1), Pb (2) |
C51000 | EN CW459K | Cu (95), Sn (5), P (0.2) |
C52100 | – | Cu (92), Sn (8), P (0.2) |
C52400 | – | Cu (90), Sn (10), P (0.2) |
C53400 | – | Cu (94), Sn (5), Pb (1) |
C54400 | – | Cu (88), Sn (4), Pb (4), P (0.2) |
C61000 | – | Cu (92), Al (7), Fe (1) |
C61300 | – | Cu (91), Al (7), Fe (2) |
C61400 | – | Cu (90.5), Al (7), Fe (2.5) |
C61800 | – | Cu (89), Al (9), Fe (2) |
C62300 | – | Cu (87), Al (9), Fe (3), Ni (1) |
C62400 | – | Cu (87), Al (10.5), Fe (2.5) |
C62500 | – | Cu (86), Al (11), Fe (3) |
C63000 | BS CC333G | Cu (82), Al (10), Fe (3), Ni (5) |
C63020 | AMS 4590 | Cu (81), Al (9), Fe (4), Ni (5) |
C63200 | – | Cu (82), Al (9), Fe (4), Ni (5) |
C63400 | – | Cu (82), Al (10), Fe (4), Ni (4) |
C63600 | – | Cu (89), Al (7), Si (1), Fe (3) |
C64200 | AMS 4634 | Cu (91), Al (6.5), Si (2), Fe (0.5) |
C64700 | – | Cu (94), Ni (3), Si (3) |
C65100 | – | Cu (98.5), Si (1.5) |
C65300 | – | Cu (97), Si (3) |
C65500 | – | Cu (97), Si (3), Mn (0.1) |
C65610 | – | Cu (97), Si (2.8), Mn (0.2) |
C65620 | AMS 4616 | Cu (96.5), Si (3), Mn (0.5) |
C66100 | – | Cu (94), Si (3), Pb (3) |
C66800 | – | Cu (76), Zn (21), Al (2), Fe (1) |
C67300 | – | Cu (65), Zn (32), Al (2), Fe (1) |
C67310 | – | Cu (65), Zn (31.5), Al (2.5), Fe (1) |
C67400 | – | Cu (65), Zn (32), Al (2), Fe (1) |
C67410 | – | Cu (64), Zn (33), Al (2), Fe (1) |
C67420 | – | Cu (63), Zn (34), Al (2), Fe (1) |
C67500 | – | Cu (89), Al (8), Fe (3) |
C67600 | – | Cu (88), Al (9), Fe (3) |
C69300 | – | Cu (77), Zn (21), Si (2) |
C69400 | – | Cu (82), Zn (14), Si (4) |
C69430 | – | Cu (81), Zn (15), Si (4) |
C70600 | EN CW352H | Cu (90), Ni (10), Fe (1.5) |
C71500 | EN CW354H | Cu (70), Ni (30), Fe (0.7) |
C75200 | – | Cu (65), Ni (18), Zn (17) |
C79200 | – | Cu (62), Ni (12), Zn (24), Pb (2) |
C79300 | – | Cu (61), Ni (12), Zn (24), Pb (3) |
C83600 (red Brass, LG2) | – | Cu (85), Sn (5), Zn (5), Pb (5) |
C84400 | – | Cu (81), Sn (3), Zn (7), Pb (9) |
C86300 | – | Cu (63), Zn (25), Mn (3.5), Fe (3.5), Al (5) |
C90200 | – | Cu (88), Sn (12) |
C90300 | – | Cu (88), Sn (8), Zn (4) |
C90500 | – | Cu (88), Sn (10), Zn (2) |
C90700 | – | Cu (89), Sn (11) |
C91100 | – | Cu (84), Sn (16) |
C91700 | – | Cu (84), Sn (8), Ni (8) |
C92200 | – | Cu (88), Sn (6), Zn (4), Pb (2) |
C92300 | – | Cu (87), Sn (8), Zn (3), Pb (2) |
C92500 | – | Cu (87), Sn (10), Zn (1), Pb (2) |
C92900 | – | Cu (84), Sn (8), Ni (4), Pb (4) |
C93200 | – | Cu (83), Sn (7), Pb (7), Zn (3) |
C93400 | – | Cu (81), Sn (7), Pb (9), Zn (3) |
C93600 | – | Cu (81), Sn (7), Pb (10), Zn (2) |
C93700 | – | Cu (80), Sn (10), Pb (10) |
C94100 | – | Cu (78), Sn (10), Pb (12) |
C94700 | – | Cu (86), Sn (10), Ni (4) |
C95400 | – | Cu (86), Al (11), Fe (3) |
C95500 | – | Cu (81), Al (11), Ni (4), Fe (4) |
C95510 | AMS 4880 | Cu (80), Al (11), Ni (4.5), Fe (4) |
C95520 | – | Cu (82), Al (11), Ni (3), Fe (4) |
C95800 | – | Cu (81), Al (9), Ni (4.5), Fe (4) |
C95900 | – | Cu (82), Al (12), Ni (3), Fe (3) |
C96900 | – | Cu (84), Sn (8), Ni (8) |
C97600 | – | Cu (64), Ni (18), Zn (14), Sn (4) |
C97800 | – | Cu (66.5), Ni (25), Sn (5.5), Zn (3) |
CuCrZr | C18150 | Cu (99), Cr (0.7), Zr (0.04) |
CuNi 90/10 | C70600 | Cu (90), Ni (10), Fe (1.5) |
CuNi10Fe1Mn | – | Cu (87), Ni (10), Fe (1), Mn (1) |
CuNi30Fe1Mn | – | Cu (67), Ni (30), Fe (1), Mn (1) |
CUNI3SI | – | Cu (94), Ni (3), Si (3) |
NBM 995 | – | Cu (89), Sn (11) |
NFL14706 | – | Cu (91), Al (7), Fe (2) |
UN3S | – | Cu (94), Ni (3), Si (3) |
Note: Percentages are approximate and may vary within allowable limits.
Contact us for all your needs of Bronze Shell casting, Bronze cast and machined Parts , Transformer connectors of Bronze , LG2 Bronze Casting etc.