Bronze and Copper Casting Foundry in Jamnagar India:
India has a rich history of metalworking, dating back thousands of years. Today, the country continues to be a major player in the global bronze and copper casting industry. This post explores the world of bronze and copper casting by Conex Metals at their Indian casting foundry highlighting the products they create and the alloys they use. Our Bronze casting foundry at Jamnagar offers sand casting, Gravity casting, Centrifugal casting, Permanent mold casting, Shell molding-raisin sand casting etc.
The Art and Science of Casting
Casting is a manufacturing process where molten metal is poured into a mold and allowed to solidify, taking on the shape of the mold cavity. Bronze and copper casting foundries in India use various techniques, including:
- Sand casting
- Investment casting (lost wax)
- Die casting
- Centrifugal casting
- Raisin Sand casting- Shell molding of Copper and bronze
These methods allow for the production of a wide range of products, from intricate artistic pieces to large industrial components.
Products Cast in Bronze and Copper Foundries
Indian foundries produce an impressive array of products using bronze and copper alloys. Some common items include:
- Statues and sculptures
- Architectural elements (door handles, decorative panels)
- Industrial components (bushings, bearings, gears)
- Plumbing fixtures and fittings
- Electrical components
- Musical instruments (bells, cymbals)
- Marine hardware (propellers, rudders)
- Bronze Pump impellers
- Hotline clamps
- Transformer bushings
- Transformer tank connectors Transformer terminals spade terminals Bronze spades for transformers
- Automotive parts
- bronze hotline clamps and transformer terminals spades spade connectors
- Bronze vise clamps vise connectors
- Bronze aerial lugs Copper aerial lugs
- Copper lay in lugs and compression terminals
- Bronze marine hardware Bronze Eye Bolts Bronze Terminals
- Bronze Flanges
- Bronze couplers threaded Bronze couplings for ground rods earth rods
- Bronze Grounding Clamps and Connectors Ground rod clamps
- Bronze Ingots Billets
- Bronze Marine Fittings and Boat Hardware
- Bronze Nuts and Fasteners
- Bronze Pipe Fittings
- Bronze Substation connectors Powerline connectors hardware
- Bronze Transformer Connectors Transformer Spades Transformer Spade Terminals
- Gunmetal casting and Gunmetal Lg2 fittings
- Hose Fittings and Hose Couplings
- Shell Moulding of Bronze Ab1 Ab2 PB1 PB2 casting (Sand casting, Gravity casting, investment casting, Raisin sand casting, Shell moulding)
Alloys Used in Indian Foundries
Our bronze foundry work with a variety of copper-based alloys, each with unique properties suited for different applications. Here’s a table of common alloys used in copper, brass, red brass, and bronze casting:
| Alloy Type | Common Name | Composition | Properties | Typical Uses |
| Copper | C11000 (ETP Copper) | 99.9% Cu | Excellent electrical conductivity, good corrosion resistance | Electrical components, heat exchangers |
| Copper | C10200 (Oxygen-Free Copper) | 99.95% Cu | High conductivity, excellent workability | Electronic components, vacuum devices |
| Copper | C12200 (Phosphorus Deoxidized Copper) | 99.9% Cu, 0.02% P | Good weldability, high ductility | Plumbing tubes, roofing |
| Brass | C85800 (Yellow Brass) | 65% Cu, 35% Zn | Good machinability, moderate strength | Plumbing fixtures, decorative hardware |
| Brass | C36000 (Free-Cutting Brass) | 61.5% Cu, 35.5% Zn, 3% Pb | Excellent machinability | Gears, valves, fittings |
| Red Brass | C23000 (Red Brass) | 85% Cu, 15% Zn | Good corrosion resistance, moderate strength | Plumbing components, marine hardware |
| Red Brass | C83600 (Leaded Red Brass) | 85% Cu, 5% Sn, 5% Pb, 5% Zn | Excellent pressure tightness, good machinability | Valve bodies, pump components |
| Bronze | C90500 (Tin Bronze) | 88% Cu, 10% Sn, 2% Zn | High strength, good wear resistance | Bearings, bushings, gears |
| Bronze | C95400 (Aluminum Bronze) | 85% Cu, 11% Al, 4% Fe | High strength, excellent corrosion resistance | Marine propellers, pump impellers |
| Bronze | C91100 (High-Leaded Tin Bronze) | 82% Cu, 7% Sn, 7% Pb, 4% Zn | Excellent machinability, low friction | Bearings, bushings |
| Bronze | C93200 (High-Leaded Tin Bronze) | 83% Cu, 7% Sn, 7% Pb, 3% Zn | Good wear resistance, high load capacity | Heavy-duty bearings, worm gears |
| Bronze | C51000 (Phosphor Bronze) | 95% Cu, 5% Sn, 0.2% P | High elasticity, good fatigue resistance | Springs, diaphragms, electrical connectors |
| Bronze | C63000 (Nickel-Aluminum Bronze) | 82% Cu, 9% Al, 5% Ni, 4% Fe | High strength, excellent corrosion resistance | Marine hardware, underwater fasteners |
| Bronze | C65500 (Silicon Bronze) | 97% Cu, 3% Si | High strength, good corrosion resistance | Marine fittings, architectural hardware |
| Bronze | C92200 (Leaded Bronze) | 86% Cu, 6% Sn, 1.5% Pb, 6.5% Zn | Good machinability, low friction | Bearings, bushings, valve seats |
| Bronze | C86500 (Manganese Bronze) | 58% Cu, 39% Zn, 1% Fe, 1% Mn, 1% Al | High strength, good wear resistance | Marine propellers, gears, bushings |
| Bronze | C54400 (Phosphor Bronze) | 88% Cu, 10% Sn, 2% P | High spring properties, good fatigue resistance | Springs, diaphragms, bellows |
| Bronze | C67500 (Manganese Bronze) | 58.5% Cu, 39% Zn, 1.4% Fe, 1% Mn, 0.1% Pb | High tensile strength, good corrosion resistance | Marine propellers, pump impellers |
| Bronze | C87800 (Silicon Bronze) | 82% Cu, 4% Si, 14% Zn | High strength, excellent corrosion resistance | Architectural applications, marine hardware |
Challenges and Opportunities
While the bronze and copper casting industry in India is thriving, it faces several challenges:
- Environmental regulations: Stricter environmental norms require foundries to invest in cleaner technologies.
- Competition from other materials: Plastics and composites are replacing some traditional metal applications.
- Skill development: There’s a need for continuous training to keep up with evolving technologies.
However, these challenges also present opportunities for innovation and growth. Many Indian foundries are investing in advanced technologies, such as 3D printing for mold making and computer simulation for optimizing casting processes.
Conclusion
Our Bronze and Copper casting foundry in India continue to play a vital role in both traditional and modern manufacturing. With a wide range of products and alloys at our disposal, our Bronze casting and Copper casting foundry is well-positioned to meet the diverse needs of industries worldwide. As the sector evolves, we can expect to see more innovations and advancements in this ancient yet ever-relevant craft of Bronze casting and Copper casting.
