Metal Casting Zone Info Blog

Archive for September, 2011

A video how-to: how to cast a bronze memorial plaque

Cast Iron Casting- Creating complex shapes

Our daily activities comprises of using many small and big things having vital role in many activities. Big containers, candles, bottles, hammers, work pieces, sculptures etc are few of the many materials which have found their applications in our day to day activities. All these materials are designed to offer convenience and ease while working. Many statues and sculptures are shaped using created models.

Molds are created to produce items of similar shape and this process is termed as casting. A manufacturing process in which molten material is poured into the hollow cavity and after cooling it take shape of the mold. Casting is basically solidified part which is taken from mold to complete the entire process. This process is used to design shapes which are complex and difficult to design. This practice is followed due to its cost effective nature and ability to simplify the complex shapes.

Plastic, aluminum, glass or iron, any material can be melted to form shapes. Amongst many types, grey casting offers caster huge flexibility and freedom to make numerous shapes. Cast iron is used for this type of casting and it is derived from pig iron and also termed as grey iron. Grey cast iron is called because of the grey fractured surface and presence of the graphitic flakes deflects.

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Cast iron casting produces metal parts having low physical requirements, like oil pan, protective cover etc, frame, floor, hammer, handle base. Frame, knife, wheels, valves, pipes, motor blocks etc are the products which are produced using this casting. Gear box, brake wheel, coupling plate, medium pressure valve, cylinder liner, flywheels, and cylinder blocks are prepared using grey casting and have also found extensive applications in industries.

Cast iron casting makes use of material with good vibration damping, good wear resistance and good machine ability. However, it has low tensile strength and elongation, but ductile casting process makes use of ductile iron and malleable iron having great strength, amazing ductile properties and is also tough and offer resistance to heat. Ductile casting’s characteristics make them win over ductile steel casting, as it has high and complex production cost. Pressure pipes and fittings, automotive applications, road and construction applications, general engineering applications are various areas where casted ductile iron and malleable iron are used.

Several advantages of grey casting have opened its door in various fields, but at the same time it has to be linked with many drawbacks. This casting process cannot be used for variety of working conditions, which can be provided by ductile steel casting and iron steel casting. Besides, not so good mechanical properties deprive cast iron from being welded and workable. There are many advantages and disadvantages which tells you to decide; what to choose and where?

This is a cast iron pipe that attached the upstairs bathroom. It will be removed and new PVC piping will be run elsewhere so this area can remain open.
Video Rating: 2 / 5

Southern Conference for Cast Iron Art
Sloss Historical Furnaces 2003

First Cast Iron Pour Event to launch Metal Monkeys on Sunday 31st May 2009 at The Kiln,Badshot Lea Village Hall, St Georges Rd, Badshot Lea, Farnham.

Metal Monkeys involved the community in their first public iron pour and launched the group with a grant from the Lottery distributer Awards for All. Metal Monkeys worked with two local schools and arts organisation Creative Response, who work with vulnerable people.

As well as enabling people to see the spectacle of an iron pour there was a storytelling workshop, facepainting and Hog roast/BBQ to celebrate newly created art works and collaboration!

Iron Monkeys a professional development workshop for the group also took place from 18th to 24th May 2009, funded by the National Lottery through Arts Council England. This enabled Metal Monkeys to learn about a continous pour cupola furnace under the instruction of Professor Daniel Hunt from Kansas State University, USA. Metal Monkeys have built one of only a handfull of continuous pour furnaces in the UK, the exciting advantage of this type of furnace being the production of multiple art works and artist collaboration.

Iron Monkeys has enabled the production of new art which was on show as part of Surrey Artists Open Studio Event in June 2009.

Metal Monkeys also hosted a workshop for 12 artists from 25th to 30th May.

Show the process of me doing metal castings from recycled aluminum for geodesic dome hubs. The hubs allow one to make a dome with a diameter of 4 feet up to 20 feet.

Why Changing Your Garden And Enjoying Outdooor Living Is Great

Outdoor living, urban living, changing your garden,

Out Door Living Advice

This applies equally to country or city living. While for some the garden is a passion, for many more people it is an “outdoor living room”. It’s a place where children play, families eat, friends are entertained and all types of hobbies are pursued. To have the best outdoor living area, you must first consider your lifestyle, and what you want to do in the garden.

Make Your Garden More Liveable!

For people with larger properties, such as farms or large suburban blocks, try to keep your living, play and entertainment areas away from work and storage areas.
Keep rubbish and compost areas away from bbq and eating areas. (Note: Flies breed in rubbish and compost).
Keep still water away from outdoor entertainment areas (these can be mozzie breeding areas).
Plant mints and tansy near outdoor living areas to help repel insects.
When you build anything with bolts or nails, make sure no bolts or nails are left protruding.
Put metal furniture (or play equipment) in shaded places where it won’t get too hot and scald the children.
In hot climates, check out where cooling winds come from (usually off the water in seaside areas), and leave openings in the garden to catch these winds (ie. Don’t build walls or plant hedges where they will stop a cool breeze).
In cool climates paved areas against a north facing wall will heat up more than other parts of the garden, providing a useable outdoor living area almost all year round.

For A Comfortable Time in the Garden

Provide shaded places so you can escape the sun.
Always wear a hat
In summer and in warmer climates, always apply suntan lotion.
Keep out of the sun in the middle of the day.
Keep your garden clean so you don’t attract pests
Never chance falling asleep in the full sun.
Break some mint or tansy and rub over yourself if insects pose a problem. (Tansy repels flies, most mints repel most insects).
Throw some crushed leaves of mint or tansy around the bbq, or on the table with food to help keep insects away.
Avoid using poisonous plants.
Avoid creating slippery surfaces (eg. extra wet areas or an overused extra wet area in a lawn)
Remove sharp or protruding objects which could be bumped, tripped on or knocked (eg. part of a fence, poorly laid paving, tools left lying around, farm equipment)
Avoid areas which will restrict the cool flow of air.

Buy Outdoor Living products, log cabins and garden sheds at Garden Eco

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Garden Buildings

Garden buildings are used for various reasons, including:

Somewhere to escape the heat or rain.
Somewhere to store bikes, tools or other things either for protection, or just to keep out of eyesight.
Somewhere to work in away from the house.
Somewhere for privacy away from the house (some parents use gazebos or shed to escape the kids, and some kids use them to escape the parents).

Garden Sheds
The least expensive type of shed is a prefabricated metal structure with galvanized iron walls and roof. Despite being galvanized, the walls can eventually rust, hence routine maintenance (rust proofing and painting) becomes essential if you want a longer life. Being a cheap construction these have their problems. These sheds are poorly insulated and may not be watertight. Unless anchored tightly to the ground they can blow down in a windstorm or cyclone. These problems can be reduced by bolting the shed to a pre poured, concrete slab which is raised above ground level. A window and double doors can provide useful ventilation on very hot days. Brick or timber sheds are better insulated, and if properly constructed will last longer than a tin shed; however these are more expensive alternatives.

Gazebos
Gazebos are roofed buildings designed to command a view. Open on one or more sides, they may be any shape, though traditionally they are octagonal or hexagonal with a hipped or conical roof.
They may be constructed of wood, cast iron, aluminium or cast columns of cement, with wooden shingles or palings being traditional for the roof, although corrugated or flat iron can be used.
A gazebo can provide protection from the direct sun for outdoor entertaining. There are all types of gazebos on the market today, and your choice is best determined by what you can afford and the style of garden you are trying to create. Remember though, that there may be maintenance involved. Stained timber will need restaining. Painted metal or timber will need repainting periodically.

BARBEQUES

Barbeques come in all shapes and forms, and are just about a must have item in any Australian backyard, even very small ones. No matter what sort of barbecue you have, there are some basic rules to follow in where you put it and how you use it.

Location and Landscaping around the BBQ

Keep it clear of plants which could catch on fire. (Fire resistant plants include Agapanthus, Coprosma, Ficus, Ligustrum, Pelargonium, Populus (Poplar) and most cacti or succulents).
Build a wall or fence (preferably fire resistant), nearby to protect the barbecue from wind.
Locate a table, seat or bench near the barbecue to place uncooked (or cooked) food on.
Outdoor tables and chairs should be far enough away to avoid any problem with smoke, or spitting fats or cooking oils.
Install lighting so that you can see how the cooking is going at night. Be sure that people standing around the barbecue don’t throw shadows over the barbecue.
Put plants which can be used in cooking near the barbecue (eg. Thyme, Sage, Oregano).
Gravel is the best surface under a barbecue, because it won’t develop ugly permanent stains from oils and fats, etc. Concrete and sandstone are some of the worst materials for staining.

Types of BBQ’s

Wood barbeques are appropriate if you live in a treed area, where there is an abundance of firewood, such as in country areas, or you have access to wood offcuts (perhaps from a joinery). They are normally built from concrete blocks, brick or stone. Always remember the fire needs air around it to burn. The best wood barbeques are ones where the fire is on a metal grill raised above the base, allowing air to move in below the fire, and ash to drop through. The hot plate above the fire should slope slightly backwards to allow fat to drain off to the rear. If it drains to the front, it is dangerous and can stain paving, shoes or anything else in front of the bbq. If built properly, with a tall chimney, it is relatively smoke free. Another simple way to build a wood barbecue is to dig a pit in the ground, sit a metal grill in the pit and place a metal plate on top of a few bricks to bridge the hole.
Outdoor Ovens. The “Webber” style barbecue has become very popular in recent years. Using heat beads as the fuel and fire lighters to start it up is not exactly cheap, but it is very easy to use and particularly appreciated when you want to cook a roast on a hot Christmas day. The main disadvantages are that you must remember to buy the heat beads and firelighters, and you must be positive that there is sufficient heat being generated before putting the top on. Most people who own this type of barbecue have experienced the occasional late or cold meal, because “someone didn’t get the heat beads going hot enough”.
Gas Barbeques. Gas is clean and reliable. It isn’t expensive to buy or use, and is instant heat, unlike heat beads or wood fire. The only real problem arises when you don’t check the gas level and run out of gas half way through a barbecue.

Find More Cast Iron Door Stops Articles

Aluminum Casting modern molding technology

Complex Aluminum Casting Casting is a form of electromagnetic pump low pressure casting technology at the core, aluminum smelting and molding compound purification technology and manufacturing core of new technology, producing high-quality Aluminum Casting modern molding technology. Electromagnetic pump low pressure die casting molten metal transfer system has a steady flow, flow control convenience, ease the process of pouring molten aluminum oxide in the inspiratory and easy to realize the advantages of process automation, which is used not only Foundry improve the quality of Aluminum Casting Foundry, but also can improve the working environment. Reduce labor intensity, realize the automation and modernization of foundry production.

Purification of molten Enamelware alloy casting is an important part of aluminum smelting and compound purification installations in addition to gas injection and spin foam ceramic filter with high outgassing and unless the performance of metal inclusions. In addition, it uses a new long-life lining material, and has independent thermal insulation / heating system can be used for a large number of continuous production, but also for the intermittent production. The technology of molten aluminum purification efficiency, long life and low cost effective, and easy to install, use and flexible. Casting Experience tells us that to solve the complex problems of quality Aluminum Casting in three main aspects:
(1) liquid aluminum smelting and melting,
(2) the smooth transfer of molten aluminum
(3) the size and stability of the mold and sand core process.

Core making process modeling can be seen on the casting quality and yield have a direct impact. Casting porosity, sticky sand, scarring, thermal cracking and surface quality, dimensional accuracy, the use of sand with the performance of a great relationship. Modeling and manufacturing of new technology is PEPSET core resin binder used for the original zirconium sand sand of a resin from the hard sand, hard sand of the kind of self-hardening mechanism of an independent, non-hardening chemical reaction initially, to be time to start hardening, curing reaction once started fast. So Coach Bags, since after a hard, high strength, fat gas collapsing small and has a good performance is the complexity of the casting surface to ensure the quality and stability of dimensional accuracy.

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Cast Iron Radiators ? Timeless Elegance for Your Home

Cast iron radiators can be the perfect choice if you are upgrading your home interiors. When you are decorating your home it can be difficult working out what to do with heating systems.

Conventional radiators are effective but they are not always the most stylish option on the market. They are often bland and purely functional in design and this can detract from interior design schemes. Traditional Cast iron radiators can offer the ideal solution. Not only do they provide a timeless elegance for your rooms but they are also very functional as well for heating systems.

Period Cast Iron Radiators

Period cast iron radiators offer quality engineering for your home. These radiators are long lasting and the dense metal makes them very durable. This means cast iron radiators will continue to provide effective service for many years. There are some antique cast iron radiators on the market that are over a hundred years old and still in perfect working order.

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If you are refurbishing your home in a period style then you can get a wide range of cast iron radiators. There are options available in Victorian, Georgian and Edwardian styles. There are also designs available that reflect period American and French design influences. This means you should be able to find the perfect cast iron radiators to match your period interior design schemes. You can buy these as new reproductions or refurbished original antiques.

Modern Cast Iron Radiators

Cast iron radiators are becoming popular again as a home heating solution. This is because they not only offer an attractive option for rooms but they are also very economic. You can heat your home cost effectively with cast iron radiators and this is good news for anyone looking to keep their fuel bills as low as possible.

- This is why many companies are now manufacturing cast iron radiators for the modern market.

- You can buy brand new cast iron radiator sets designed in a wide range of modern styles.

- These radiators are made using traditional methods and offer a similar classic look to the original designs.

- You can choose from a great selection of paint finishes for your cast iron radiators. This includes some stunning bold colours that can create a real impact on your design schemes.

Bespoke Cast Iron Radiators

If you want something a little more special then look out for bespoke cast iron radiator companies. They will be able to offer you cast iron radiators designed to your exact specifications.

Bespoke services will of course be more expensive than buying pre-made radiators ‘off the shelf’. However this is ideal if you want something totally original for your home heating systems or you have awkward spaces that cannot be heated by conventional radiators.

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Porch Columns to Define Your Porch

Porch columns are an easy way to update or change the look of your porch in a dramatic and interesting way. With many style and price options, porch columns just may be the design element you are looking for.

While commonly made from wood, fiberglass, FRP or stone, front porch columns are made to serve on a structural level as well as add to the beauty of porches. They are often made to match porch railings for an overall look and are available in a variety of designs for instant curb appeal.

Wood porch columns are best when they are made from mahogany, poplar, cherry, pine, oak, maple, teak or redwood. They come in many styles and can be bought smooth or with detailed carvings that add to their classic beauty. Either square or round, they can also be combined with stone or brick for a different look and feel.

Fiberglass porch columns are popular because of their impact-resistance as well as their aesthetic appeal. While fiberglass columns can also be round or square, smooth or ridged, they can be made to look like more classic styles. Depending on the situation, they may also be load bearing. You can paint them and they are weather, moisture and insect resistant. They are more impact resistant than wood and require very little maintenance as they can withstand heat, sunlight, rust, insects and rot.

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You may also want to consider aluminum front porch columns as they can be very cost effective and elegant. Again, there are many styles available and can be pre-painted. Aluminum columns can also be used for load-bearing and non load-bearing applications, yet are lightweight enough that they can be carried and installed easily. Aluminum is also a popular option for front porch railings.

Another option is pre-cast stone columns for your front porch. With advances in the manufacturing business, it is now possible to recreate beautiful ancient Roman columns without the heaviness and sometime delicate nature of natural stone. Pre-cast stone is also less expensive and less labor intensive. Natural stone has to be chiseled from a larger stone and then you still have to be watching for cracks or crevices that are hard to see.

You can pick the color and other design elements when working with pre-cast stone that is harder to come by with natural stone. Because the pieces are manufactured, you have the flexibility of buying one-piece shafts, halves or even sections to cover steel supports. Pre-cast stone adds a unique and truly beautiful look to your porch columns for a great price.

Additional options for your front porch columns are brick and wrought iron. Both are fairly common choices for use as porch columns and have their advantages. Both are very strong and durable, and can be made to look simple or ornate. With these two materials, you need to find an experienced installer to create a beautiful and original look for your porch, but it is worth it!