Plot 1, Madhav Industrial Park, Kansumra , Jamnagar 361006, Gujarat, India
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Plot 1, Madhav Industrial Park, Kansumra , Jamnagar 361006, Gujarat, India

We are one of the leading manufacturers and exporters of Brass Neutral Links, Neutral Bars, Aluminium Neutral bars, Connectors and Earth Bars from India.

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Plot 1, Madhav Industrial Park, Kansumra, Jamnagar 361006, Gujarat, India

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Bronze Sand Casting Green Sand casting

Bronze casting

Bronze sand casting, Bronze Casting foundry, Green sand castingBronze castin

 

Bronze Sand Casting & Bronze Green Sand Casting

We are a leading Bronze casting foundry from India. Bronze sand casting is a versatile and cost-effective metal casting process that involves pouring molten Bronze alloys into sand molds to produce high-strength, corrosion-resistant components. A variation of this method, Bronze green sand casting, uses moist, clay-bonded sand to create molds, offering faster production cycles and lower costs. These techniques are widely used to manufacture complex, high-precision bronze parts for industries such as marine, automotive, electrical, plumbing, and decorative applications.

Bronze sand casting is particularly valued for its ability to produce intricate shapes, excellent surface finishes, and durable components that withstand harsh environments. Whether you need industrial machinery parts, marine hardware, or artistic sculptures, bronze sand casting delivers unmatched performance and reliability.


Bronze Alloys for Sand Casting, Bronze casting alloys

Bronze alloys are selected based on their mechanical properties, such as strength, wear resistance, machinability, and corrosion resistance. Below is a comprehensive list of bronze grades used in sand casting:

1. Tin Bronzes (Phosphor Bronze)

  • C90300 (SAE 620) – High wear resistance, ideal for gears, bearings, and marine applications.
  • C90500 (SAE 62) – Excellent corrosion resistance, used in bushings and pump components.
  • C90700 (SAE 65) – Good machinability, suitable for electrical and mechanical parts.
  • C90800 – High strength and durability, used in heavy industrial components.
  • C91000 – High fatigue strength, used in high-stress applications like springs and diaphragms.
  • C91100 – Excellent wear resistance, used in bearings and thrust washers.

2. Aluminum Bronzes

  • C95200 – Moderate strength and corrosion resistance, used in marine and industrial applications.
  • C95300 – High strength and excellent corrosion resistance, ideal for marine hardware.
  • C95400 – High strength and heat resistance, used in marine, aerospace, and industrial applications.
  • C95500 – Extremely durable, used in heavy machinery components.
  • C95600 – Excellent corrosion resistance and machinability, used in pumps, valves, and marine fittings.
  • C95700 – High strength and wear resistance, used in bearings and gears.
  • C95800 – Resistant to saltwater corrosion, perfect for shipbuilding and offshore structures.

3. Silicon Bronzes

  • C87300 – Excellent electrical conductivity, used for electrical connectors and terminals.
  • C87400 – Good machinability and corrosion resistance, used in pump components and valves.
  • C87500 – High strength and wear resistance, used in gears and bearings.
  • C87600 – Known for its aesthetic finish, used in artistic and architectural applications.

4. Manganese Bronzes

  • C86300 – Superior strength, used in high-load bearings and gears.
  • C86400 – Good corrosion resistance, used in marine and industrial applications.
  • C86500 – Wear-resistant, ideal for automotive and construction machinery.

5. Leaded Tin Bronzes

  • C93200 (SAE 660) – Self-lubricating, used in bushings and bearings.
  • C93400 – High lead content, used for low-friction applications like bearings and bushings.
  • C93500 – Excellent machinability, used in gears and fittings.
  • C83600 (AKA Red Brass or Gunmetal), used in pumps Hotline clamps, transformer connectors 
  • C93600 – Low friction, ideal for valve components and fittings.
  • C93700 – High lead content, used in high-load bearings and bushings.
  • C93800 – Excellent wear resistance, used in automotive and industrial applications.
  • C94300 – High lead content, used in low-speed, high-load applications.

6. Nickel-Tin Bronzes

  • C94700 – High strength and wear resistance, used in gears and bearings.
  • C94800 – Excellent corrosion resistance, used in marine and chemical applications.

7. Other Specialty Bronzes

  • C97600 – High-strength nickel-aluminum bronze, used in aerospace and defense applications.
  • C97800 – High-strength and corrosion-resistant, used in marine and offshore applications.

8. Leaded Bronzes (Red Brass)

  • C83600 (SAE 64) – Excellent machinability and pressure tightness, used in valves, fittings, and plumbing components. Also used in electrical clamps, Transformer spades,  Transformer connectors, Spade terminals, Substation connectors
  • C84400 – High lead content, used in low-pressure valves and fittings.
  • C84800 – Good machinability and corrosion resistance, used in pump components and fittings.

9. Bismuth Bronzes

  • C89320 – Lead-free alternative with excellent machinability, used in plumbing and electrical applications.
  • C89520 – Lead-free and corrosion-resistant, used in marine and potable water systems.

10. High-Strength Bronzes

  • C86300 (Manganese Bronze) – Superior strength, used in high-load bearings and gears.
  • C86500 (Manganese Bronze) – Wear-resistant, ideal for automotive and construction machinery.
  • C95500 (Aluminum Bronze) – Extremely durable, used in heavy machinery components.

Bronze Sand Casting Processes

1. Black Sand Casting (Dry Sand Casting)

Black sand casting uses heat-resistant black sand molds, offering better dimensional accuracy and surface finish. It is ideal for large and complex bronze castings, such as marine parts and industrial gears.

Process Steps:

  • Pattern Making – A pattern (wooden, plastic, or metal) is created to form the mold cavity.
  • Molding – Black sand is packed around the pattern to create the mold.
  • Core Placement – Sand cores are inserted to form hollow sections within the casting.
  • Metal Pouring – Molten bronze is poured into the mold cavity.
  • Cooling & Solidification – The casting cools and solidifies inside the mold.
  • Shakeout & Cleaning – The mold is broken, and excess sand is removed.

2. Green Sand Casting

Green sand casting uses moist clay-bonded sand (a mixture of silica sand, bentonite clay, and water). It is faster and more cost-effective than black sand casting, making it ideal for smaller parts like electrical connectors, pipe fittings, and decorative items.

Process Steps:

  • Pattern Making – A reusable pattern is used to create the mold cavity.
  • Molding – Green sand is compacted around the pattern to form the mold.
  • Core Insertion – Cores are placed to create internal features (if needed).
  • Metal Pouring – Molten bronze is poured into the mold cavity.
  • Cooling & Shakeout – The casting solidifies and is removed from the mold.
  • Cleaning & Finishing – Excess material is removed, and finishing processes are applied.

Types of Bronze Parts Produced via Sand Casting

Bronze sand casting is used to manufacture a wide range of components for various industries, including:

  • Sanitary Fittings – Valves, faucets, and pipe fittings for plumbing systems, Bronze Tees, Bronze elbows, Bronze pipe fittings, 
  • Electrical Connectors – High-conductivity bronze parts for electrical panels and terminals, Bronze vise connectors, Bronze Spade terminals, Bronze transformer spades and spade terminals, Transformer ground clamps, Transformer ground connectors, Grounding clamps , bronze grounding pipe clamps, Substation connectors of Bronze, Grounding clamps,
  • Pipe Fittings – Elbows, tees, and couplings for fluid transportation.
  • Pump & Valve Components – Pump housings, Bronze Pump impellers, and  Bronze  cast valve bodies for fluid control.
  • Marine Hardware – Propellers, ship bearings, Strainers, thru hulls, and deck fittings for marine applications.
  • Automotive & Machinery – Engine bushings, gears, and transmission components.
  • Decorative & Architectural Parts – Sculptures, railings, and bronze ornaments.

Finishing Processes for Bronze Sand Castings

After casting, bronze parts undergo finishing operations to enhance their surface quality, dimensional accuracy, and performance.

  1. Sand Blasting – Removes surface impurities and smooths rough surfaces.
  2. Machining & CNC Finishing – Ensures tight tolerances and fine details.
  3. Polishing & Buffing – Provides a mirror-like finish for decorative and marine components.
  4. Chemical Passivation & Coatings – Protects bronze from oxidation and tarnishing.
    • Lacquering – Prevents oxidation and maintains appearance.
    • Nickel Plating – Increases wear resistance and improves aesthetics.

Industries Served by Bronze Sand Casting

Bronze sand casting serves a wide range of industries due to its durability, corrosion resistance, and versatility:

  1. Marine & Shipbuilding – Corrosion-resistant propellers, bearings, and deck hardware.
  2. Plumbing & Sanitary Industry – Valves, faucets, and pipe fittings for water systems.
  3. Electrical & Electronics – High-conductivity connectors and switchgear components, Bronze Transformer connectors,  Bronze Substation connectors, bronze grounding connectors,bronze  Grounding lugs
  4. Automotive & Heavy Machinery – Gears, bushings, and bearing housings for durability.
  5. Aerospace & Defense – Aircraft bushings, hydraulic components, and structural fittings.
  6. Decorative & Architectural – Statues, plaques, railings, and bronze sculptures.

Why Choose Bronze Sand Casting?

  •  Cost-Effective – Ideal for small to medium production runs.
  •  Highly Durable – Withstands high pressure, wear, and corrosion.
  •  Precision Casting – Produces complex shapes with minimal machining.
  •  Excellent Corrosion Resistance – Perfect for marine and outdoor applications.
  • Versatile Applications – Used in industrial, plumbing, electrical, and decorative industries.

Conclusion

Bronze Sand Casting and Green Sand Casting are essential manufacturing processes that enable the production of high-quality, durable, and corrosion-resistant bronze components. With a wide variety of bronze alloys, precise molding techniques, and effective finishing methods, these processes cater to industries such as marine, automotive, electrical, plumbing, and architecture. We can offer Bronze CNC machined parts, Bronze CNC machined castings, Bronze milled parts, Bronze CNC turned parts and components.


Need Custom Bronze Castings?

Contact us today for custom Bronze casting Bronze Sand casting solutions, prototyping, and bulk manufacturing! Our Bronze casting foundry team of experts is ready to provide high-quality bronze castings tailored to your specific requirements.

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