Metal Casting Zone Info Blog

Posts Tagged ‘Metal’

Ohio State 2nd-year Materials Science and Engineering students participate in metal casting lab (MSE 281), and create aluminum OSU stadia pieces.

Bangladesh Village Metal Casting

Preparing the scrap metal, the furnace and crucibles for casting and explaining a bit about the mould making process. The firing process and casting takes several hours and unfortunately we couldn’t stay. Rice husk is mixed with the clay to make it more refactory. Old crucibles are used to cap the new ones. A combination of brass, copper and zinc is used to make a ‘bell metal’. Both mould and crucible are placed in the furnace, when the metal is molten, both are removed from the furnace, a hole is pierced in the side of the crucible and the metal is poured.
Thanks to Riaz and Britto.

Dhamrai Metal Casting

Breaking the layers of clay away from a lost wax casting in brass at Dhamrai metal casting.

Clean and Maintain Aluminum Patio Furniture

Aluminum is popular metal used in outdoor furniture for many reasons. It is durable, versatile, and requires very little care on the part of the owner. It is commonly known that aluminum generally does not rust. There is a unique science behind this carefree material. When exposed to air, aluminum will develop a microscopic layer of oxide on its exterior. This oxide layer acts as a barrier which protects the metal from the elements and prevents corrosion. This quality is the most appealing characteristic when it comes to choosing a material for making outdoor furniture. It will weather any climate and any amount of precipitation. Aluminum furniture is a dependable option for outdoor living.

Aluminum furniture does not need to be covered or protected they way that wood furniture may need to be. However, some aluminum furniture comes with a powder-coating. This gives the aluminum color and helps to reduce the aluminum being scratched and dented. This coating often has great visual appeal as well as giving strength to the oxide layer, however, it does require a little extra care to maintain the original appearance. The coating, while protective and durable, can be scratched by a reckless owner or be eroded by harsh, salty environments. It is important to consider this possibility to maintain reasonable expectations of your cast aluminum furniture.

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Quick Tips:
You need to know that aluminum will not rust and this is what makes it perfect for outdoor furniture. But, aluminum will get affected by pollution in the air and water and its surface will discolor or become rough. Though aluminum does not rust it does oxidize which can result in discoloration, but will not affect the structural reliability of the metal.

Here are helpful hints for the care of aluminum outdoor furniture:
If the aluminum has become pitted or is rough to the touch, it can be polished. Smooth the surface with steel wool and soap as a cleanser and lubricant. Remember to remove all traces and residue of the steel wool from the surface of your aluminum outdoor furniture or else it can rust and stain the surface of the

If you notice that there is slight discoloration on you aluminum furniture, then it should be washed with mild soap and warm water. It helps to add a gentle natural acid like lime or lemon juice, vinegar or cream of tartar. Important! Do not to add ammonia, TSP or Soda. Always do this cleaning after the change of seasons.

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Aranmula Kannadi – A Unique Metal Mirror From India

Aranmula metal mirror is a rare piece of craft that had existed even during the Vedic period of Indian history. The myth about the origin and secret of its composition makes it a truly fascinating craft. As traditional as the mirror-making technology is, the artisans’ belief that the composition of the metal mirror is divine and some undisclosed metals alloyed with silver, bronze, copper and tin are responsible for the distortion-free images.

Aranmula Kannadi is not mass produced and is hand made with all its perfections as how one looks at it? While commercially available glass mirrors reflect an image, because of a silver coating at its rear, Aranmula Metal Mirror is the only mirror which reflects from the front plane. This had its popularity until the advent of the commercially manufactured glass mirrors which proved to be much cheaper. The demand of Aranmula Kannadi grew by bounds only a decade ago especially in foreign countries.

A huge amount of determination, perseverance and patience goes into the making of this enchanting mirror. Mud from the local paddy fields is used for the mould into which the molten alloy mix is poured to cast the mirror and the technique followed is the cire-perdue or the lost wax method of casting. Even with the utmost care, only about 60% of the cast metal mirrors can be salvaged, the rest get damaged in the process of manufacture. The metal mirror is then polished using well-ground, burnt clay powder mixed with special oil on a jute cloth. To achieve a highly reflective surface, polishing can go on from one to several days. When a satisfactory finish is achieved, the mirror is mounted on various models of artistic brass frames.

Aranmula Kannadi is unique in the make which is patent protected with a ‘Geographical indication tag’.
The British Museum in London has a 45 centimeter tall Aranmula Metal Mirror in its collection.
The Aranmula Kannadi is not created from glass but from a combination of special metal alloy.
Many people believe that owning an Aranmula Metal Mirror brings good luck, wealth and prosperity to one’s lives
Aranmula Kannadi is one among the eight auspicious items included in the “Astamangalya Set”, which is used for very auspicious occasions like marriage.

Aranmula Kannadi or Aranmula Metal Mirrors  is a very special type of metal mirror produced only in Aranmula, a village in kerala, south India. Aranmula metal mirror is a precious inherited gift. The mystery of its metal combination and production is still a secret to, which  handed over through generations of a single family.

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Preserving the Metal Garden Bench

Garden brings beauty and attraction in place like the house, school, park, and the other establishment that created garden in their vicinity. The mixed of plants, trees, the pathways, and furniture give additional color and glow creating a beautiful garden.

Garden furniture has several figures. It can be the benches, chairs, tables, and the like. Choosing the best and suitable furniture can be both fun, amusing, and works a lot of patient.

Benches are one of the furniture that has many options to choose from. The designs, the materials, the convenient, the quality, and durability are some of the attributes that a buyer will keep on looking at. The materials can be made of wood, metal, plastic, stone, and/or mixed of concrete and composites.

The metal garden bench is a type of bench that also has types of composition. The common types of metal used are the aluminum and iron garden bench. Take note that the metal bench is not for garden per se.

Cast aluminum and cast iron garden benches are both metal but does not have the same advantages and disadvantages.

Cast aluminum is lightweight while the iron is heavy. Both aluminum and iron garden benches are strong and sturdy enough to stay stand firm. The cast aluminum can be flexed enough to create detailed designs which is attractive in some buyers.

The iron also has enticing and stylish designs. Aluminum garden bench can withstand the different kinds of weather and temperature. Iron garden bench are prone to get rusted which requires extra care. Aluminum is much affordable than iron garden. When it comes to durability, iron garden bench much long last because of its endurance as iron.

In taking care and preserving the metal garden bench, there are only two tips and a must-do task to be done. That is, the repainting and cleaning should be done as maintenance of the precious garden bench.

Repainting is simply applying paint again. It can be applied using the brush or aerosol for pure metal garden bench. The purpose of repainting is to protect the bench from rust, and refresh its look or change the color and style. Cleaning, on the other hand, is can be done as often as the person wants. Abrasive chemicals must be avoided. Water and soap are enough to use as cleansing gear.

Buyers, owners, and users must have the initiative in taking care and preserving the stylishness, usefulness, and the quality of a metal garden bench. For a fact that it is made of metal, it is destined to get rusted.

Aluminum extrusion

The process of extrusion is particularly adapted for the production of a variety of metal shapes. An extrusion press is capable of producing as many shapes as there are differently shaped dies to fit it. Intricate shapes can be produced by this process which cannot be made in any other manner, and many shapes which can be produced otherwise are often made by the extrusion process until it is possible to justify single-purpose equipment.

It is common usage to designate the capacity of extrusion presses by the number of tons pressure the press can put upon the metal to be extruded: in aluminum extrusion practice, presses vary from about 200 tons to as high as 5,000 tons. For convenience, the majority of small presses are built to operate in a vertical position. For structural reasons and because of other practical considerations, the larger presses are built to operate in a horizontal position. The commercial designs vary greatly, but in general metal is either extruded at the end of the ingot container farthest from the ram, or the metal is forced through the ram, which, in this case, is hollow. Solid and hollow shapes may be produced by extrusion. Hollow shapes, such as tubes, require a mandrel suitably held in the die opening so that metal flows through the die, around the mandrel. A press may be provided with a number of container® of different sizes in which the ingot is held during extrusion. Some of the larger presses will take ingots with a diameter of 14 inches and a length of 35 inches. The dimensions of extruded shapes are limited by the diameter of the ingot container and its length, and these two dimensions are in turn dependent upon the press capacity and the physical properties of the metal or alloy to be extruded, and, to a less extent, upon the kind of section desired.

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For extrusion the ingots are usually preheated and placed in the press. Depending upon the particular design of press, the die may be placed in position either before or after the press is charged. Pressure is then applied to advance the ram against the ingot and force the metal through the die opening. In some cases, more especially in smaller presses, the ram is stationary so that the container with the ingot to be extruded moves against the ram. During extrusion the pressure applied is controlled so that the metal flows through the die at a predetermined rate. With pure metal the rate of metal flow is not particularly important but with certain alloy compositions the rate of metal flow has a pronounced effect upon the surface of the extruded product, and also affects the physical properties. This is particularly true when the extruded material has a cross-section of irregular out-line. After   the   extrusion   operation   there   remains in the container a  certain  portion of the  charged  ingot. In most instances this butt portion is scrapped, especially when the physi­cal properties of the product are of prime importance.

The ingots used are, for the most part, cast in suitable molds. In some cases, however, the billet used may be a product of a working operation, as for example, rolled rounds. For the production of solid extruded sections a solid ingot is used, and for hollow sections a hollow ingot is used. Hollow ingots may be cast as such, but they may also be produced by a piercing operation on a solid ingot or billet.

Both pure metal and aluminum alloys are extruded. Pure metal is used for the production of molding and such articles as do not require the physical properties obtained in strong alloys. Aluminum alloys are employed in the production of many structural shapes such as I-beams, channels, H-beams, angles, tees and special and intricate shapes which cannot be produced in any other manner, such as specially designed sections for aircraft construction. This class of product is usually heat treated after the extrusion operation. The extrusion process is also employed for the production of tubing blooms and to provide forging stock.

Click on Aluminum extrusion for more information

Scrap Aluminium to Auto Components
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Sterling Silver and Allergies to Metal

Sterling Silver and Allergies

The truth is people are not usually allergic to silver or sterling silver.  a metal known as nickel, which has been used in sterling silver. Sterling silver is an alloy consisting of 92.5% silver and 7.5% other metals, traditionally copper, and sometimes some manufacturers will use nickel in sterling silver as a less pricey alternative to other metals.

Pure silver is  soft to produce any functional pieces and loses shape  easily. Other metals are added to improve qualities such as ductility, firescale, tarnish resistance, and reducing casting porosity.

Why Sterling Silver?

Nickel, is a hard and ductile, silvery white metal that has been mistaken for silver in the past. Nickel is commonly used in jewelry including with precious metals jewelry such as gold, white gold, sterling silver and platinum and also most cheap or costume jewelry. Nickel is what gives white gold it’s white color by alloying more of it with yellow gold, as gold isn’t found naturally white or any other color than yellow. Other metals are used to make other colors of gold, for instance silver is used to make green gold and copper is used to make rose gold. Nickel adds plenty of other properties besides color, such as strength and durability, and it’s a strong lustrous effect.

Metal Allergy Occurrence

Allergies to nickel occur in approximately 10% of the population, it is known as contact dermatitis, and nickel is the most common metal to cause an allergic reaction. An allergy to nickel used in jewelry usually causes a reddening of the skin, as well as itching or burning in the area of contact and sometimes blistering of the skin, or a rash. there’s differences in severity of metal allergies and sometimes if you do not have a severe allergy to a certain metal then a piece of jewelry containing a  small portion of that metal may not cause a reaction, whereas a piece of jewelry containing a high amount will cause a slight reaction.

Metal Allergy Development

While some are genetically predisposed to have a reaction to some metals, others can develop a metal allergy over time with regular exposure. This is common among most kinds of allergies. So, it is possible to have a favorite piece of jewelry, regardless if it is made from a precious metal such as gold or platinum or silver, that has been worn plenty of times or consistently for years suddenly cause a reaction.

Nickel free jewelry is also more pricey as it uses other higher priced metals in place of nickel. It should not be assumed that nickel free jewelry is actually allergy free. People can be allergic to any type of metal including brass, copper and  never gold or silver. it is recommended that if any jewelry causes any discomfort, such as the symptoms described above, you should seek a metal allergy check from your physician to make certain you know what metal is causing this. Otherwise you might make the wrong assumption and wind up buying a whole new wardrobe of jewelry that may cause a reaction as well.

Company: Yiwu Dushang Jewelry Co.,Ltd

Address:    3f,No.13-15,Building 4,A zone,Futian jewelry street,yiwu city,zhejiang,china(322000)

Site:     http://www.silver-jewelry-wholesaler.com

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Wrought Iron Creates Old World Decorating Charm

Wrought iron-what is it and why use it to decorate your kitchen? You may usually think of wrought iron when you picture a tall, ominous gate in front of a castle. Or, you remember that romantic bench in the park. You may have seen heavy, black metal pot racks in an authentic Italian restaurant. Whether commercial or household, wrought iron has a long history and many uses today.

Wrought iron is a tough, malleable, ductile and easily welded iron alloy. The term was used throughout western history, most specifically for finished iron goods, as produced by a blacksmith. This type of iron use dates back to Roman times and was very popular in Europe during the reign of William and Mary. It could stand up to use in battle as well as everyday use in shops and homes. It was preferred over cast iron as cast iron was very brittle.

In the 1800s, wrought iron was the most common form of malleable, or bendable, iron. It was typically used to make swords, cutlery, and other blades. Other popular uses were: rivets, nails, wire, chains, nuts, bolts, horseshoes, handrails, racks and ornamental ironwork. This strong metal was very popular in the 1860s for making iron clad warships and railways. The Eiffel tower is actually made from a form of wrought iron called puddle-iron!

Cast iron, carbon, or mild steel, and cheaper steel became more available in the 1900′s and caused a gradual decline in wrought iron manufacture. The last production works in Great Britain closed in 1974. True production of this desirable metal was, unfortunately,   labor intensive and expensive. Some of the production machinery originally used in Great Britain is now preserved in the Ironbridge Gorge Museum, in Shropshire, England. It is still used commercially for beautiful restoration projects using recycled iron scrap.

Today, when you see garden furniture advertised as wrought iron, it may actually be made of mild steel. The description is still used because the pieces are wrought (or worked) by hand. This metal is used, today, to make home décor items such as Baker’s racks, wine racks, pot racks, étagères , table bases, desks, gates, beds, plant racks, candle holders, curtain rods, bar and bar stools. The beauty, strength and elegance of wrought iron makes it very suited to making unique, handsome products and furnishings.

Using wrought iron hand-craftsmanship in your kitchen will add beautiful, Old World, charm to your home. It will also add to the rustic appeal of your cabin or lodge. Hanging, or wall mounted, pot racks can sturdily display cookware and accessories while adding extra storage. Such kitchen accessories can be simple or elaborate, adorned with French curls and scrolls, or classic and elegant. Black is most common, however, the metal can easily be painted any color to compliment your home decor. 

Wrought iron is an old fashioned metal that is still an excellent choice for home decorating due to its malleable capabilities, strength, and variety of uses, both indoors and out. Including items such as pot racks, trivets, wine racks, and shelves will give your kitchen a rustic, Tuscan, and classy ambiance. Wrought iron is an Old World metal that you will enjoy in your home today!

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A Brief Introduction of Molding Sand

When people speak of sand casting, the first thing that comes to their mind is the sand on the beach. They do not think that sand casting is one of the most popular methods which are used to produce metal parts. In order to help people get a general idea about it, the article will introduce some information about the sand casting.

Generally speaking, the sand used in foundry industry includes two kinds, namely molding sand and core sand. The molding sand is composed of 85% natural sand, 9% clay and 6% water. Sometimes, in order to improve its property, coal powder, vegetable oil and wood flour will be added into the mold sand.

Although the sand is the main material for sand casting, it is quite different from the common sand on the beach. Anyone who has built sand castles on the beach knows how fragile sand castles are. So it is impossible to use the beach sand to hold molten metal. One question that comes to the mind is what properties can help the molding sand hold molten metal. Generally speaking, the molding sand has the following features. What comes first is permeability. The ability of allowing the steam to pass through the walls of mold material is called permeability. After the high-temperature molten metal is poured into the mold, there are a lot of gases in the mold. If the gas can not be removed successfully, the casting will produce some defeats. In addition, the permeability is also influenced by the clay content, water content and graininess. The next feature is refractoriness. This is the ability of withstanding high temperatures of sand. From this point, people also can deduce that sand used for casting steel must be more refractory than one for brass or aluminum because of the greater pouring temperature. Also, a sand used to cast large heavy castings must be more refractory than one used for light thin castings of the same metal. The third feature is strength. The ability of resisting the external force is called strength. If the strength of mold sand is not high enough, the castings easily collapse. However, the strength can not be too high. Or else, the sand castings will produce some defeats due to the decrease of permeability. The fourth feature is plasticity. It refers to the ability of maintaining the shape under the effect of external force. Because the molding sand has the good plasticity, the molding operation is very convenient and the shape of mold is quite accurate.

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Making a cylinder head for a single cylinder hit and miss engine.
Core making moulding casting and machining operations.
The engine is an Olds Gearless, a 4 srtoke with no gears.
An eccentric on the crankshaft operates a ratchet wheel to give the necessary timing.