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METALCAST MEETS THE DEMANDS WHEN IT COMES TO SPECIFIC METALS FOR SPECIFIC PARTS.
At MetalCast, we pride ourselves on being able to offer a multitude of casting types to serve your casting needs.
Copper Alloys with MetalCast
MetalCast are exclusive manufacturers of the copper alloy ingots for the. we use best fresh material Cu, Sn, Pb, Zn, Ni, to make best quality ingot and we are the number one choice for many foundries around the world. Following heavy investment in 2018, MetalCast’s now houses the latest in ingot melting technology and supplies the most comprehensive range of copper alloy ingots available, ncluding brass, gunmetal, tin bronze, silicon bronze and aluminium bronze. Our short lead times, alloy quality, value and customer service ensures that we are a strong partner for today and tomorrow. ALLOY GUIDEAluminium Bronze
Containing aluminium from 8 to14% and often with varying amounts of other elements such as nickel, iron, manganese and silicon, the aluminium bronzes provide a range of strong, tough alloys.Nickel Aluminium Bronze
Containing aluminium from 8 to14% and often with varying amounts of other elements such as nickel, iron, manganese and silicon, the aluminium bronzes provide a range of strong, tough alloys.Die Cast Brass
An important use is for bathroom and plumbing fittings. Conventional polishing procedures can produce a good surface finish ready for lacquering or electroplating.High Tensile Brass
High tensile brasses are more highly alloyed with the addition of manganese, iron and aluminium which enhances mechanical properties such as strength, hardness and resistance to wear, impact and abrasion.Sand Cast Brass
Sand cast brasses are relatively simple to cast and have a wide range of uses for small to medium sized castings at comparatively low cost.Gunmetals
These copper, zinc, tin, lead alloys have good sand casting characteristics, fluidity, machinability, strength and excellent resistance to most forms of corrosion. Used extensively for water fittings.Tin Bronze
Binary alloys of copper and tin with a tin content typically in the range 10-12% and fairly low impurity limits have intrinsically high corrosion resistance.Phosphor Bronze
The addition of phosphorus, usually in the range 0.4 – 1.0%, to tin bronze provides an increase in hardness and strength but usually at the expense of some ductility.Silicon Bronze
Typically containing around 4% silicon and up to 1% each of manganese and iron the attributes exhibited by these alloys include: excellent melt fluidity and clean pouring with minimal smoke.Lead Bronze
These copper, tin, lead alloys are essentially bearing alloys for bearing applications requiring only moderate loads and speeds compared to those that would require phosphor bronze.Master Alloys With MetalCast
Our products include master alloys of copper with base metals such as iron, manganese, Aluminium, Silicon, Nickel They are produced in our specialised foundry using high-grade raw materials to ensure low residual impurities. The chemical composition conforms to the IS, BS, ASTM, European standard or may be made to your own specification. ALLOY GUIDECopper Aluminium
In the form of broken ingot is used for alloying aluminium into copper alloys.Copper Phosphorus
In the form of broken ingot is used for alloying Phosphorus into copper alloys.Copper Iron
In the form of 90/10, 80/20 and 70/30 plate, it facilitates the alloying of iron into various copper alloys in order to change characteristics.Copper Manganese
In the form of 70/30 and 50/50 ingot, it is used in a number of applications including the improvement of mechanical properties and corrosion resistance.Copper Nickel
In the form of 70/30 plate, the main applications are adding nickel to aluminium bronzes and precipitation hardening of low alloyed copper.Copper Silicon
In the form of 90/10 and 85/15 broken pieces, it improves fluidity and castability in some copper alloys. It can also facilitate the precipitation hardening of low alloy copper.QUALITY
As a premium producer of copper alloys we have always invested heavily in customer aftercare. Our technical team have extensive foundry knowledge and casting experience ranging from the manufacture of automotive, Switchgear, Heavy Engineering, Rubber Machinery. Our specialist personnel are on hand to provide advice, from general specification queries to casting related problems and we offer onsite customer support, which further enhances the service we extend to our worldwide consumer base.
GRAVITY DIE CASTING
At MetalCast we are able to produce quality aluminium gravity die castings for a range of industries, including Defence, Machine Tools, Compressors, Pumps, Valves, power grid ext.
What is Gravity Die Casting?
Gravity Die Casting is a permanent mould casting process, where the molten metal is poured from a vessel or ladle into the mould. The mould cavity fills with no force other than gravity, filling can be controlled by tilting the die. Undercuts, and cavities can be incorporated into the component form with the use of sand cores. This process gives a better surface finish than sand casting as well as better mechanical properties, both due to rapid solidification.
however, the metal moulds are a higher cost than sand. Advantages of this process include the possibility of low gas porosity, and fine grain sizes can be achieved.
Compared to sand casting, this process requires less finishing and fettling and gravity die casting tends to produce a higher quality product. The Gravity die casting production method is generally less cost effective in the manufacture of tooling compared with sand casting.
Gravity Die Casting Process
Gravity die casting is often a manual process, with the molten metal added with the use of a ladle. However, for some high volume applications it is also possible to use an automated ladle to pour the molten metal. The speed and the direction of the filling can also be controlled by tilting the die.
Apart from the method by which the molten metal is poured into the die cavity, and the gravity die material, the casting process is essentially the same as sand casting. It involves four steps:
- The die is heated and then sprayed with a refractory coating, and closed. The coating both helps control the temperature of the die during manufacture and it also assists in the removal of the casting.
- Molten metal is then manually poured into the die, (although in some cases a machine can be used) and allowed to solidify.
- The die is then opened and the cast parts either removed by hand or in some cases ejector pins are used on the mechanised machines.
- Finally, the scrap, which includes the gate, runners, sprues and flash, is removed from the casting(s). The castings are then processed to remove sharp edges and excess material, then blast cleaned (if required) prior to despatch to the customer.
Gravity die casting is a natural partner to sand casting, and allows us to offer the customer the most cost effective route for casting manufacture.
Aluminium Gravity Die Casting at MetalCast
Gravity die casting allows us to create high quality parts and components to even the most exacting of customer specifications. At MetalCast we produce aluminium gravity die castings for OEM and tier and so companies.
PRODUCTION CASTINGS
Whether your quantity requirements call for short run or high volume, MetalCast can accommodate your needs. Out typical sand casting production quantities range from 25 to 50 units, 500 to 10,000 units, and 10,000 to 500,000 units.
PROTOTYPE CASTINGS
1. Provide us with your design concept so far. This can be a finished CAD model, or a rough sketch. We’re happy to sign an NDA if required.
2. We will review your designs, and meet with you to fully understand the application and discuss the design and manufacturing options.
3. Using our 3 seats of Solid works ,we will optimise your design for manufacture. We will add taper, gating and ejection points for castings.
4. We will submit our design proposal for your consideration, along with quotations for the various manufacturing options.
5. We can manufacture prototypes if required, for evaluation, testing, and marketing purposes, prior to committing to production tools.
SHELL MOLD CASTING
Also known simply as shell molding, shell mold casting is a casting process that involves the use of resin-covered sand for the mold. Molten metal is poured into the mold’s cavity, at which point the mold vaporizes to create a hard shell. Although it sounds complex, shell mold casting is a relatively simple process that’s comprised of just six steps.
1) Creating the Pattern The first step in shell mold casting is to create the pattern. The patterns used in this molding process typically consist of two pieces of metal, such as iron or steel, in a custom shape as desired for the finished casting.
2) Creating the Mold After the pattern has been created, a mold is created. During this step, both of the pattern parts are heated and then treated with a lubricant. The pattern parts are then inserted into a large container, known as a dump box, that contains the resin-covered sand. Once inserted into the dump box, the pattern parts themselves will become covered in the sand.
3) Assembly of Pattern Parts Now it’s time to assemble the pattern parts. During this step, the top and bottom pieces of the pattern are joined together. Depending on the type of pattern, it may feature a locking mechanism that holds the two pieces together. Once fully secured, they are then inserted into a flask. Here, they’ll be exposed to molten metal, which is the proceeding step after the pattern parts have been assembled.
4) Exposure to Molten Metal The fourth step in the shell mold casting process pouring molten metal into the mold’s cavity. Different types of metals and alloys can be used in this molding process, including steel and iron. Regardless, the metal or alloy is heated until it turns to a liquid state, after which the molten metal is poured into the mold’s cavity to form of a hardened shell.
5) Wait to Cool The molten metal must cool before it will create a hardened shell and, thus, the casting. Typically, the pattern parts are allowed to cool at room temperature. As the pattern parts cool, the molten metal will harden to create a shell.
6) Ejecting the Casting The sixth and final step in the shell mold casting process is ejecting the casting from the mold’s cavity. Because this casting process uses a two-pieced pattern, castings are easily ejected by “opening” the pattern. The top and bottom pattern parts are separated from each other, at which point the newly created casting can be safely ejected.
Aluminium Bronze
Containing aluminium from 8 to14% and often with varying amounts of other elements such as nickel, iron, manganese and silicon, the aluminium bronzes provide a range of strong, tough alloys.Nickel Aluminium Bronze
Containing aluminium from 8 to14% and often with varying amounts of other elements such as nickel, iron, manganese and silicon, the aluminium bronzes provide a range of strong, tough alloys.Die Cast Brass
An important use is for bathroom and plumbing fittings. Conventional polishing procedures can produce a good surface finish ready for lacquering or electroplating.High Tensile Brass
High tensile brasses are more highly alloyed with the addition of manganese, iron and aluminium which enhances mechanical properties such as strength, hardness and resistance to wear, impact and abrasion.Sand Cast Brass
Sand cast brasses are relatively simple to cast and have a wide range of uses for small to medium sized castings at comparatively low cost.Gunmetals
These copper, zinc, tin, lead alloys have good sand casting characteristics, fluidity, machinability, strength and excellent resistance to most forms of corrosion. Used extensively for water fittings.Tin Bronze
Binary alloys of copper and tin with a tin content typically in the range 10-12% and fairly low impurity limits have intrinsically high corrosion resistance.Phosphor Bronze
The addition of phosphorus, usually in the range 0.4 – 1.0%, to tin bronze provides an increase in hardness and strength but usually at the expense of some ductility.Silicon Bronze
Typically containing around 4% silicon and up to 1% each of manganese and iron the attributes exhibited by these alloys include: excellent melt fluidity and clean pouring with minimal smoke.Lead Bronze
These copper, tin, lead alloys are essentially bearing alloys for bearing applications requiring only moderate loads and speeds compared to those that would require phosphor bronze.Copper Aluminium
In the form of broken ingot is used for alloying aluminium into copper alloys.