A Comprehensive Guide to Brass Casting

Some of the methods through which brass can be cast are such as sand casting, metal casing, investment casting, die casting and vacuum casting.

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Sand casting

Sand casting is one example of the simplest way to make a mold out of molten brass. The pattern is heated at high temperature in an oven then molten brass poured into it. The molds are made out of sand and sometimes they are disposable and others they are reusable. Sand casting is very effective for producing brass castings that come in various designs and sizes. Currently, sand-casting is among the key processes used in manufacturing brass hardware.

Metal Casting

In metal casting process, permanent metallic molds are utilized to make casts. This technique is usually used when high level precision and large-scale production are required.The molds used in metal casting can be reused.

Investment Casting

Lost-wax or precision&#; or &#;investment&#; &#; these are some other names for the same technology where refractory materials create shapes that will hold melted wax later on: one-time use only. Then this wax solidified inside the mold just breaking down under heating action. After cooling, liquid metal was poured into the hollow space left after wax melting away from old caster&#;s form . Finally, once cooled down to solid state, the mold was destroyed to release the item from its cavity.

Die Casting

This method involves injecting hot molten bras into a metal mould at very high pressure so as to fill all cavities within it during injection procedure.. This technique allows manufacture of accurate parts with stronger mechanical characteristics using less amount of material than other conventional ones.

Vacuum Casting

It involves pouring liquid or molten metals into a mold that has been subjected to low pressures or even vacuum conditions so as to eliminate bubbles and other impurities from the casting.

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A number of creative forms are available through brass casting techniques! Factors to be considered when selecting a particular method of brass casting include casting quality, shape and quantity requirements, production costs and equipment availability. Each technique has unique properties, benefits and appropriateness. Furthermore, depending on our needs we can make accurate choices and thus venture into the world of art where there are limitless possibilities.

An impression of the core shape is then made. I used plaster. I found a small plastic container which I modified it with cardboard so that the casting used the least possible material, but still held together (more on this later)

Small metal angles supported the silicone shape in the container.

To calculate the amount of plaster needed,

Calculate the volume needed in cubic centimetres and add 10% for wastage. Multiply this by 0.6. That is how much water you will need in millilitres.

Multiply the water figure by 1.42. That is how much plaster you will need, in grams. It works every time.

The plaster, was mixed, minimizing bubbles by vibrating and vacuuming and then poured into the mould until it came half way up the silicone pattern. After it set, the surface was trimmed, any bubbles were flattened out, then some registration marks were made so that after the mould is split apart, it will go back together in the correct way,

(See photos)

The mould was coated in vaseline, and the second half poured. Once set, the plaster was taken out of the plastic moulding box, the 2 halves carefully split, and the pattern removed.

If you were making hard sand cores using sodium silicate, it might be possible to mould the core in this plaster mould, but I use baked sand cores, and the baking tends to destroy the plaster, and the sand is often difficult to get out of the plaster moulds, so I use the plaster as a pattern for an aluminium mould, which overcomes these difficulties. (see photo) It means having to mould them in sand and cast in aluminium, but it isn't a huge task.

This is why I try to minimise the amount of plaster in the mould, Plaster wastage isn't an issue, but when it's cast in aluminium, large areas of metal with different thicknesses can cause shrinkage, which is undesirable.

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