Centrifuged bronze casting
Mercobronze has an unique experience in the preparation of pieces manufactured through centrifuged bronze casting. To guarantee the quality of the products produced in centrifugation, the company produces its own molds and has a technical team highly specialized in the use of this efficient casting technique. This self-sufficiency gives the company the conditions to meet the most different types of orders, with efficiency in production and quickness in delivery.
Manufacturing of pieces through centrifuged bronze casting
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Parts manufactured through centrifuged bronze casting
The centrifuged bronze casting method is used to manufacture cylindrical components, such as centrifuged tubes, mechanical tubes, rings, bearings, rollers, bushings, ball valves and cylinder liners, in addition to a wide range of parts that do not require machining. Compared to other techniques, centrifugal casting has the best value for money for unique and on larger scale parts.
Centrifugal casting consists of pouring molten metal into a mold using centrifugal force. This force is created by the fast rotational movement during the casting process. In this way, the liquid metal is forced against the walls of the mold, where it will solidify and acquire the expected shape. The centrifugal force reaches a force equivalent to 100 times the force of gravity.
There are two forms of centrifugal casting: vertical and horizontal.
Vertical centrifugal casting: The vertical centrifugal casting process is used to produce non-symmetrical or cylindrical parts. In this method of casting, rotation occurs on an axis perpendicular to the floor. Vertical rotary mold machines have the motor axis connected directly or indirectly to the mold, through transmission. A cylindrical mold is connected to the motor axis and rotates at high speed.
Graphite, sand or ceramic molds can be used, which result in practically ready-made parts, reducing the need for post-casting machining. The inner diameter and wall thickness vary depending on the quantity of metal injected by centrifugation into the rotating mold.
Horizontal centrifugal casting: In horizontal centrifuges, the mold or die rotates in a horizontal plan at high speed, around 2,000RPM. This is the method used in the production of tubular components, which combines high quality and low cost. The process is perfect for casting long cylindrical parts such as centrifuged tubes, mechanical tubes and long cylinders with end flanges, among others. It can also be used in the manufacturing of short parts, such as bushings, rings and flanges.
Both in vertical and horizontal centrifuged casting, it is the internal dimension of the mold that determines the external diameter of the part, while the amount of injected metal determines the internal diameter.
Advantages of centrifuged bronze
Although centrifugation allows the use of a wide variety of metal alloys, bronze is one of the most used metals in this casting technique as it has the required characteristics:
- High fluidity
- Large solidification range
- Low shrinkage and oxidation
- Good resistance to hot cracking
The main advantages of centrifuged bronze in the manufacturing of parts are:
- Greater control and elimination of impurities, such as oxides, sulfides and gases
- High resistance to friction and flow
- No microporosity
- Fewer defects compared to other manufacturing processes
- Reduced production time and cost
- Less material waste
- Longer service life
- Minimization or elimination of runner or feeding systems, which reduces losses and increases yield
- Good surface finishing
- Elimination of gases and porosity, due to the centrifugal force
Centrifuged bronze main applications
This casting modality is mainly indicated for the manufacturing of circular parts. The reason is that the application of centrifugal force allows impurities to be expelled, the alloy to be compacted and cracks to be eliminated. The result is parts with a high degree of finishing, compactness and measurement accuracy.
The industrial sectors that most use centrifuged bronze parts are: hydroelectric, basic sanitation (water and sewage), automotive, pulp and paper, hydraulics and naval.
The centrifuged bronze is used in the manufacturing of items such as:
- Symmetrically shaped parts that rotate on an axis
- Parts where dimensional integrity is required and critical
- Mechanical tubes, bushings, sleeves and rings
- Helical gears and hub gears
- Bearings
- Seals
- Components of valves and pumps
- Steam turbine parts
- Gaskets and labyrinth rings
- Brake drums and discs
- Crusher equipment parts
- Mining equipment parts
- Ball bushings
- Paper industry components
- Clutch drums
Please contact us and learn about the solutions that Mercobronze has to your company!
