Metal Casting Zone Info Blog

Archive for November, 2009

Made with all of the charm of antique toys, bronze sculpture experts are able to produce whimsical yet durable objects of art. From reproductions of animals, to wall art, to wine stopper, cast bronze decorative items remain preferred through time.

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Bronze was first used roughly 5000 years back in China to create items for ancestral worship. The Greeks made life sized figures, weapons, and art. The Egyptians used cast bronze to make thousands of small mannequins. Now artists use it to make cast bronze metal toys, banks, wine stoppers, candlesticks, and figures.

An amalgamate of tin and copper, bronze was discovered better to melt, it hardened stronger than copper and was more immune to corrosion than iron. Cast bronze and aluminum decorative sculpture items are way more common now, as present day artist all other metals for decorative interest, yet retain the positive qualities of the bronze.

Bronze is the hottest metal used to make sculptures. It was employed in the art foundries in Thailand, where it was valued for its color. Cast bronze has a natural patina, the green and blue coming from the copper compounds. Today cast bronze metal horses, turtles, frogs, bears and other animals wear the soft colours of these copper compounds.

Due to its durability, bronze has been valued thru the ages. Bronze cannons were some of the first things ransacked from shipwrecks due to their value. Cast bronze sculptured decorative items were frequently taken by warring states to be softened into weapons or life size statues of the new leaders of government.

luckily today bronze figures, toys, candlesticks and other artwork are available to those looking for valuable, durable, and attractive metal objects. Bronze sculpture artists and experts produce quality work that’s available from the art foundry itself or in art studios.

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Idle situation:Consistantly achieving design weight/P.O.weight.

Possible variables causing drift from idle situation.

1. Tooling:The condition of tooling i.e. excess clearances in print leading to core shift and resulting excess weight.The tooling manafacturing through CAD/CAM and wear resistant material will help to achive this objective.

2.Core setting and mould closing process: Optimizing the core setting and mould closing such that with less clearances this can be performed.Mechanisatation of this activity will help to achive this objective. 

3.Pouring: Constant head and flow to optimize the swelling tendency of mould.Use of tundish pour will help to achive this objective. This is necessary to control the buyancy force exerted by liquid metal on mould wall and to optimise the sand additives for a given situation, pouring practices must be controlled.

4.Sand properties:This will play vital role in weight control.Optimising additives w.r.t. weght,foundry defects are the real challenge for foundry process engineer.While optimizing sand properties ,we may have to use multiple regression analysis.

The traditional approaches by foundry process control can not yield higher results. 

To start with, assuming above 3 variables are constant,start ploting average weight of 10 casings, rej% due to sand , G.C.S.,acitive clay and L.O.I. 

Once the data collection is started we can find the trend.Collect minimum of 100 batches and by doing regression analysis,we can achive optimum additives to get consistency in wt and rej% due to sand.

5.Cheistry and innculation practices also have significan impct on weght control.

In addition to all the above the basic diciplaine and good practices established by each foundry must follwed to get consistant results in any foundry.

Cast iron furniture would add a good element of beauty in people’s patio and garden. Nothing exists like exclusive state of art process about manufacturing the furniture which is cast iron. The beautiful patio would add the required beauty and grace to anyone’s house. Most families live on patio in the long hot months of summer. Garden Furniture gets huge importance like those of household furnishings. This furniture must remain comfortable, easy to keep clean, fit all family needs, and must be affordable.

Possibly one may have never thought about cast iron furniture for the patio; however, this is a remarkable way of beautifying your patio. Such cast iron furniture seems to be inexpensive, more lasting and very comfortable. People today are introduced to Thermosint(c) Process that is used by the Contract Furniture Company for making cast iron furniture. Such cast iron is initially welded and sanded. Then the bare metal frame undergoes PH balance wash and a primer coating process. It is an important step in crafting cast iron to beautiful designs for furniture. Then comes the premi

This patented treatment systems for die casting, die surfaces and metal plating will extend the life of both magnesium and aluminum products. Studies have proven that technology will increase the lifespan on dies lined with our products, especially those products that encounter heat checking. If the die is treated with this product early in the lifecycle of the die, it will increase the number of casting that will made from the die.

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the bulk of failures in die casting and metal plating dies made from steel is heat checking. Dies are pretreated with this product are stronger and more immune to heat checking. Our product can also reverse the has effects on of damage that has already been. This processes with not get rid of the heat checks, but it will decrease the amount of reoccurring heat checks.

to make a quality casting product, the die casting and metal plating process wants to get rid of the heat that is made by the molten metal. This will create a solid casting product. To accomplish this, the heat energy needs to be broadcast to the die steel. The heat wants to pass thru the steel surface that heats it up really fast. Next, the surface will begin to cool down. When this process is repeated again and again again, heat checks will begin to appear. These checks will be tough to see at first, but upon close inspection can be found where the molten steel is poured into the die hole. The amount of checks will expand grown into each other. This process shortens the life of the dies and has effects on the end casting products and it eventually turns into a high cost cost for your business.

the simplest and most convenient method to correct these cracks in die casting and metal plating is with a heatproof product that withstands weather. This process is a quick drying process that performs at its best on new heat cracks that are deep enough to be filled. They rely on your expertise and experience and will work with you to select the ideal time to apply this process so that there is a minimum of downtime at your facility.

Come visit us right here for more Metal Casting Info and get two Metal Casting Ebooks Casting Waxes. http://www.metalcastingzone.com/

The eight auspicious symbols of Buddhism, translated from the Sanskrit ‘Ashtamangala’, are very popular in Tibet and are used for Tibetan jewelry. It is said that Buddha didn’t like to be worshiped as a person and therefore he was reluctant to accept images of himself. Because of that he was mostly represented by the Eight-Spoked Wheel and the Bobhi Tree. Other signs were used in representing him also, like Buddha’s Footprints, an Empty Throne, a Begging Bowl and a Lion. The eight auspicious symbols are however the following: the Umbrella or parasol, the Golden Fish, the Treasure Vase, the Lotus, the Conch, the Endless Knot, the Victory Banner and the Dharma-Wheel (Dharmachackra).

The Umbrella or Parasol, translated from the Sanskrit ‘chattra’, symbolizes the sky the dome that lies above the mountain. Its most important function is to cast shadow, the shadow of protection upon oneself. As a traditional Indian symbol of royalty and protection, the umbrella is found in all cultures with a similar meaning. In Europe the umbrella was until recently a symbol of wealth reflecting one’s high social status. In Oriental cultures, the shade the umbrella casts took a religious note as the protection from the heat of suffering, desire and other forces harmful to the spirit. The vertical handle of the umbrella is compared to the central axis of the world, transforming its bearer into the center of the world. The umbrella is also compared to the mobile temple; therefore Buddha was often represented with a large umbrella over his head. Tibetan jewelry often represents the Buddhist symbol of the Umbrella.

Tibetan jewelry using the Golden Fish symbol is usually worn for good fortune. Positioned upright with their heads turned inwards, the two fish first appeared in the Indian culture as a symbol for the two sacred rivers Ganga and Yamuna. In Buddhism they symbolize happiness, fertility and abundance. The Treasure Vase symbol worn as Tibetan jewelry is meant to attract the infinite riches of this world. It consists of a fat-bellied vessel with a narrow and short neck, covered with a large jewel. It symbolizes endless wealth and prosperity. Tibetan jewelry representing the two Golden Fish and the Treasure Vase can make very nice and suitable wedding gifts representing only good wishes for the future family.

The Lotus flower is perhaps the most admired and worn symbol for Tibetan jewelry. The Lotus symbolizes the progress of the soul because of the way such a plant grows. The roots of a lotus lie in the mud, as the stem grows up to rise eight to ten inches above the surface of the water where the heavily scented flower basks in the sunlight. The beauty of the flower is extremely attractive and quite unusual due to the fact that it grows from the underwater mud. Therefore many people around the world want to be adorned with Tibetan jewelry that represents such amazing positive energy and power of life.

The Conch is a symbol for power, sovereignty and authority. The powerful blast that the conch makes when blown is believed to banish the evil spirits, to be able to stop disasters from happening and to keep away poisonous creatures. This symbol is rarely represented in Tibetan jewelry due to the fact that the actual conch shell makes a rather more powerful statement than a jewel representing it would.

The Endless Knot is one of the most favorite symbols in Tibetan Buddhism. It is often related to the endless wisdom of Buddh and it is also significant for the interaction of opposing forces leading to their union and harmony in the universe. The symmetrical shape of the knot signifies all these things and arouses the curiosity of those who are passionate about wearing Tibetan jewelry. Giving someone Tibetan jewelry representing an Endless Knot or giving away a greeting card with such a symbol on it signifies a connection between the giver and the receiver. It is also a reminder that the roots of every future positive effect are found in the present.

The Victory Banner symbolizes Buddha’s enlightenment and his knowledge triumph over ignorance. It is said that Buddha placed the banner on top of Mt. Meru to show the world his victory over the entire universe. The Victory Banner also signifies Buddha’s triumph over the four Maras of emotional defilement, of passion, of the fear of death and of pride and lust.

The Wheel is consistent of three basic components the hub, the spokes and a perfect circle. The first element symbolizes the axes of the world and stands for moral discipline while the spokes represent the eightfold path set down by Buddha and stand for the correct application of wisdom and the rim. The perfect circle, which represents the element of limitation, refers to concentration and holds the entire meditative practice together.

These symbols remind people to embrace change and be open to novelty, but never let go of positive values which never go out of fashion. Because of the message they send out to people, the popularity of Tibetan jewelry never diminishes attracting thousands of people to believe in Buddhism.

1. Commitment

If you’re just taking up golf, you may want to wait a little while before purchasing your own clubs. Golf is a fun and healthy hobby to take up, but the equipment is not cheap and the sport itself takes a pretty good amount of skill. Before buying yourself brand new clubs, make sure this is something you truly enjoy.

2. New vs. Used

The first choice you have to make is whether you want to buy new or previously owned clubs. The advantage of a new set is that they are clean, new, and likely to be more accurate. However, used clubs can be a great way to get in to the game, and upgrading to a new set won’t make you feel guilty once you do because the first set was not costly.

3. Choosing your Irons

The prominent equipment in your golf bag is obviously your irons. The first choice you need to make when choosing an iron is whether you prefer cast iron or forged metal. It usually depends on your skill and need, most beginners use cast iron as the sweet spot is larger.

4. Shaft Choice

The shaft of your club also depends on skill and preference. Shafts come in either steel or graphite-made. Most professionals prefer steel shafts, as they’re more durable, although some golfers still look to graphite because of its lightweight that gives an easier swing. Typically, beginners use the lighter graphite shaft to start with.

5. Head Material

While each head material has its own advantage, the decision may be up to your wallet. Cast iron and stainless steel are both less expensive than the pricey titanium. The disadvantage of the stainless steel as a beginner is they are a bit heavy, which may inhibit your swing and make it harder to get used to. Titanium is the prime choice for a beginner, because the metal is both durable and light, allowing you to have a higher swing speed as well as a large head and sweet spot. The cast iron is a good compromise, at a fairer price and not too heavy to handle.

6. Head Size

As a beginner, head size can make a huge difference to your learning process. A larger head means a larger sweet spot, which is the face that hits the ball, it also means the club will be heavier and harder to control. To find a compromise between a small and large head, you could use a medium head, which has a pretty good-sized sweet spot, but is not too heavy to control.

7. Sweet Spot

The size of the sweet spot you choose on your club is totally dependent on your skill level and accuracy rating. If you have a very accurate swing, but not a quick one, you might want a lighter and smaller head, and a lighter shaft to improve your swing speed.

8. Grips

Grips should be standard to your club, but some golfers prefer to re-grip their grips for one reason or the other. If you choose to adjust your grip, make sure your aware of your hands grip size as well as the core grip of the club itself.  You can determine your clubs grip size by matching it to the shafts diameter you’re re-gripping. Measure the diameter of the butt of the shaft you’d like to re-grip tot determine this. 

9. If the Club Fits

If the club you choose is not proportionate to your body type it will harm your game. Make sure you’re choosing a club that is as close to the right size for you as possible. A salesperson should be able to tell you exactly which size club you should be using.

10. Swing Speed

Assuming that you have swung a golf club a couple of times before deciding to buy, you should have a relatively good idea of your swing speed ability. If your swing speed is pretty high, factor in a heavier shaft to improve your accuracy. A low swing speed is okay too, just compensate with a light, flexible shaft and a medium sized-head with a pretty good sweet spot.

Metal handicrafts were quite popular from the ancient Indus Valley civilization. Metal sculptures and statues narrate the ancient civilization. Metal casting, carvings, inlay and appliqué are known in the Indian metal handicraft industry. Metal articles require heavy working and with increasing usage of advanced mechanical production methods, the quality of these products has improved considerably. Different part of the country displays its own unique handicrafts be it in metal, wood or other such handicraft items. Metal works from Tanjavur, stone carvings from Mamallapuram, Silks from Kanchipuram are all available in Chennai. Indian Handicraft sector is renowned world over for their most popular craft items like pottery, earthenware, wooden work, metal work, sculpting, scarves, shawls, textiles, embroidered and knitted goods, zari items, jewelry, etc.

A huge collection of products in indian handicrafts like photo frames, bowls, glass bowls, candle stands, incense stick stands, table tops, mats, cushion covers, mats & rugs, religious statues, wall hangings, ladies bags, handmade bags, handmade paper products and many more. Aluminum handicrafts includes diverse objects such as candle holders, printed pots, picture frames, ice buckets, photo frames, flower vases, wall scones, ice scoops, pillar holders, tea lights, tableware, oil burners, garden urns, mirror frames, etc. Indian crafts are becoming increasingly popular both in India and abroad due to their high quality. Recent times have seen notable increase in the demand for these types of products.

The expensive form of metal works is in white metal.  White metal flower vases, white metal coasters, white metal photo frames, white metal table lamp, idols or statues made of white metal, candle holders, jewelry boxes and others, are few of the items made out of such metal. Aluminum handicrafts are engraved with a range of traditional patterns and designs. Ornamentation on aluminium can vary from chiseling, punching or inlay work, all requiring high calibre and painstaking work.

Make use of the fantastic selection of expensive handicrafts, sculptures and textiles. Bronze and copper are commonly used in the making of Indian metal handicrafts. Metal works include wall hangings, candle holders, water pitchers, sculptures, bell metal works, sculptures etc. The practice of using metal in ornaments and jewellery which form the antique collection can be dated back to the ancient times. Metal crafts apart from beautiful jewelry also comprises of belts, pillars, crowns, decorative pieces, photo frames, wall hangings etc. Other popular handicraft items made out of metal are jewelry boxes with beautiful designs etched out, kitchenware, household utensils, personal use items, home accessories etc.

Dave Madden, President of Container Exchanger recently discussed the efficacy of reusable metal containers, noting that, “Automotive molders, automotive components, durable goods manufacturers, metal stamping, metal casting… really absolutely any industrial company that must store or ship intermediate product all benefit from reusable metal containers.  In other words, you have sub-assemblies or large parts that are transported to an “internal” customer (a different part of the plant).”  Madden provided several examples such as the casted transmission housing gets put in a metal bin and is taken to machining and assembly line, or sub-assemblies that are transported to an external company en-masse.

There are many benefits of metal bins including durability and reusability; some are collapsible making return shipments more cost effective.  Some metal bins are very heavy-duty, so they can hold a lot of heavy product, like casted or machined metal parts.  This product can then be stacked and stored in a relatively small space.  Wire baskets are effective because they are affordable.  “A light-duty wire basket is pretty cheap for the internal storage volume and they are often used to hold cardboard for recycling or transporting and storing light stamped parts or molded parts,” suggested Madden.

Price savings of Used Reusable metal bins are significant; used metal bins are often 30% – 50% of the cost of new (70% off the new cost).  The only expendable bulk solution is a Gaylord box.  These boxes sell for $20 each for a good box and one has to buy a pallet.  A wire basket might run $80 used.  Gaylord boxes might last 4 uses or so, whereas the wire basket would last 200+ (both estimates and depend on usage).  The payback comes after only 13 uses.  And if the basket lasted only 200 uses, there would be a savings of 1500% compared to using a Gaylord box. 

Container Exchanger (www.containerexchanger.com) is dedicated to the sale and resale of reusable packaging and containers. The firm resells folding bulk containers, metal storage bins, plastic industrial totes, plastic pallets, and used gaylord boxes nationwide. When a company is finished using a returnable packaging fleet, Container Exchanger represents the seller and finds a buyer for the used bulk packaging. Sellers enjoy a high sales price for a better return on investment. Buyers save significantly in comparison to new packaging prices.

Container Exchanger

www.containerexchanger.com

David Madden, President

pr@containerexchanger.com

404-551-5599

Container Exchanger (www.containerexchanger.com) is dedicated to the sale and resale of reusable packaging and containers. The firm resells folding bulk containers, metal storage bins, plastic industrial totes, plastic pallets, and used gaylord boxes nationwide. When a company is finished using a returnable packaging fleet, Container Exchanger represents the seller and finds a buyer for the used bulk packaging. Sellers enjoy a high sales price for a better return on investment. Buyers save significantly in comparison to new packaging prices.

Dave Madden, President of Container Exchanger recently discussed the efficacy of reusable metal containers, noting that, “Automotive molders, automotive components, durable goods manufacturers, metal stamping, metal casting… really absolutely any industrial company that must store or ship intermediate product all benefit from reusable metal containers.  In other words, you have sub-assemblies or large parts that are transported to an “internal” customer (a different part of the plant).”  Madden provided several examples such as the casted transmission housing gets put in a metal bin and is taken to machining and assembly line, or sub-assemblies that are transported to an external company en-masse.

There are many benefits of metal bins including durability and reusability; some are collapsible making return shipments more cost effective.  Some metal bins are very heavy-duty, so they can hold a lot of heavy product, like casted or machined metal parts.  This product can then be stacked and stored in a relatively small space.  Wire baskets are effective because they are affordable.  “A light-duty wire basket is pretty cheap for the internal storage volume and they are often used to hold cardboard for recycling or transporting and storing light stamped parts or molded parts,” suggested Madden.

Price savings of Used Reusable metal bins are significant; used metal bins are often 30% – 50% of the cost of new (70% off the new cost).  The only expendable bulk solution is a Gaylord box.  These boxes sell for $20 each for a good box and one has to buy a pallet.  A wire basket might run $80 used.  Gaylord boxes might last 4 uses or so, whereas the wire basket would last 200+ (both estimates and depend on usage).  The payback comes after only 13 uses.  And if the basket lasted only 200 uses, there would be a savings of 1500% compared to using a Gaylord box. 

Container Exchanger

www.containerexchanger.com

David Madden, President

pr@containerexchanger.com

404-551-5599

Have you ever wondered as you looked at a piece of gold jewelry just how it it was made. How did the jeweler start out with raw bulk product and end up with the finished product. Jewelery is created using many methods but the most common method is by the “lost wax” casting method. It was developed in ancient times and it is still used to this day, although modern tools are now used.

The reason that is is called lost wax is, because the object that is to be created is first sculpted out of wax to the exact specifications that the finished product is going to look like. After the wax sculpture is completed it is then encased in a silica encasement or in the case of jewelery it is then encased in plaster. Then after the plaster encasement has hardened and dried it is put into an oven or kiln. This will cause the wax to melt and burn out leaving its hollow image inside of the plaster encasement.

Then the plaster encasement with the hollow shape of the piece of jewelry is placed into a casting centrifuge which is a device that will use centrifugal force to drive molten gold down through an opening in the chunk of plaster where it will fill the hollow spot left by the wax melting out. After it has cooled the plaster is broken open to reveal a piece of gold jewelry where the wax sculpture once was.

Its the same technique that is used to create larger bronze sculptures, only with bronze it is done on a larger scale and the centrifugal caster isn’t used. The lost wax casting method was what was used to bring civilization out of the Iron Age and into the Bronze Age. In ancient times primitive metal smiths would use bees wax to shape objects such as axes and arrow heads. These was objects were then encased in clay and placed in the bottom of fire pits to burn off.