Bronze is one of the oldest metal alloys of mankind and its casting began more than 3000 years. Bronze consists primarily of copper and tin, as well as varying proportions of other elements such as zinc, aluminum, antimony, nickel, phosphorus and lead, among others. Bronze alloys are used in many different applications and its different compositions allow for great support and high loads.
The casting process has evolved much over the years and in line with the needs of the industrial development and of modern life. Factors such as growth, improvement of machinery, which requires greater precision, demanded new technologies for the manufacture of metal parts.
Present over 58 years in the market, Italbronze works with the most modern processes, such as continuous casting and centrifugation, which guarantee more safety and quality to the final product.
The continuous casting process consists of merging and giving a profile to the final product all in one single operation, thus eliminating intermediate cooling times in molds. This ensures better control of the physical and geometrical properties of each product.
The continuous casting process adopted by Italbronze presents the following advantages:
- Reduction of the porosity of the material – a casting defect that can occur internally to the part.
- Prevents the emergence of gas holes.
- Casted materials have more homogeneous structure in relation to parts of the same thickness (cooling module) produced in sand molds – giving the material the best mechanical properties and the desired geometry
- The bars are produced in a format close to the final dimension of the part.
- Reduction in the final cost of the part since less machining process will be needed.
In summary, the main advantages of continuous casting are greater productivity, product uniformity, less energy consumption, reduction of manpower and better product quality.
Another process adopted by Italbronze is centrifugation, in which cylindrical shapes can be casted by using the centrifugal force in a rotating mold forcing the metal to come to its interior through pressure. The process has an homogenizer effect on the metal, which by being heavier expels the gases and impurities from the inside of the heated alloy, which allows a homogeneous distribution and increased mechanical resistance of the material.
Some advantages of using centrifugation are:
- Allows you to work with a minimum of costs;
- Improvement of mechanical characteristics such as tensile strength, yield strength, elongation, and hardness;
- By being processed at high speed it eliminates gas porosity and inclusions, avoiding waste of time and waste of machining,
- The time of manufacture is reduced;
- Increase in efficiency of the usage of molten metal;
- Best surface finishes of the parts.
Italbronze’s casting processes respect sustainability practices, ensuring the responsible use of resources, preserving people’s health and the environment.