Custom Copper Alloy Castings Company
Manufacturing Process of Cast Copper Parts
Copper Sand Casting
Copper sand casting uses sand to make the mold. We then pour hot, liquid copper into this mold. After the metal cools, workers take out the casting. They clean and finish the final part.
Low Mold Cost: Making the sand mold is cheap. Plus, we can reuse the sand many times.
Large Parts: This method is great for casting big and medium-sized aluminum parts. It handles complex shapes well.
Flexible Production: It works great for small jobs, mid-size orders, or very large production runs.
Copper Die Casting
Copper die casting uses high pressure. It forces hot, liquid copper into a metal mold very quickly. The metal fills the mold fast and hardens. This method is great for making many thin-walled, complex, and high-precision parts.
Smooth Finish: Copper parts come out with a very smooth surface and high size accuracy.
Fast Production: The time needed is very short, making it perfect for mass production.
Less Metal Loss: Very little metal is lost. The cooling inside the mold happens quickly.
Copper Gravity Casting
Copper gravity casting often uses metal molds. The liquid copper alloy fills the mold and then hardens under its own weight. This process works well for parts that are medium complex.
Low Mold Cost: The cost to make the mold is low. This makes it good for small to medium production runs.
Larger Parts: We can make larger copper alloy alloy parts this way. They also have better density.
Affordable Parts: The final parts made by this process are relatively cheap.
Copper Investment Casting
Copper investment casting makes high-quality parts. It uses molds made from wax or other items that can melt away. This method is often used for copper parts that have complex shapes and must be highly precise.
High Surface Quality: The parts come out with a very smooth finish.
Less Finishing Work: You won't need much post-processing, saving time and cost.
Best for Small Runs: It works well for small jobs that need high precision copper parts.
Machining
Machining is a final step for cast copper parts. It uses fine tools to improve the castings. This work boosts the part's accuracy, makes the surface much cleaner, and improves what the casting can do.
It makes the final look better.
It improves the copper part's structure and function.
It lets us make thin walls and complex shapes.
Surface Treatment
Surface treatment changes the outside of copper castings. It uses physical, chemical, or mechanical methods. This work boosts the casting's quality. It also makes parts last longer and improves how they look and function.
It makes the surface harder.
It improves the part's look and boosts its size accuracy.
It improves adhesion and resistance to corrosion (rust).
Different Materials of Cast Copper Alloy
Brass Casting
Brass is an alloy of copper and zinc. It resists rust very well. It offers good mechanical strength, a nice golden look, and casts easily. It is also easy to machine and costs less. This makes brass good for many decorative and working parts.
Great Rust Resistance: It fights seawater, air, and many chemicals well. This makes it perfect for marine jobs.
Easy to Machine: Brass is one of the easiest metals to machine. It makes clean chips and smooth surfaces while saving tool life.
Fights Germs: It naturally kills germs. This makes it safe for medical, food, and sanitary parts.
Casts Well and Holds Pressure: It fills molds easily. It makes strong, accurate castings that hold pressure well.
Nice Look: Its golden color and ability to shine make it popular for buildings and decorative items.
Brass Castings from Simis Copper Foundry:
marine hardware and fittings;
valves, pumps, and plumbing parts;
door handles and fixtures for buildings;
musical instruments;
electrical connectors;
decorative art pieces.
Brass Casting Grades Simis Uses:
Low Zinc Brasses (Red Brasses, Zinc < 15%):
Uses: Plumbing valves and fittings, pump parts, and marine hardware that fights rust.
Grades: ASTM C83600, C84400.
High Zinc Brasses (Yellow Brasses, Zinc 15-40%):
Uses: General hardware, decorative items, and architectural fittings.
Grades: ASTM C85800, C86200.
Leaded Brasses:
Uses: High-volume parts needing excellent machining, like valves and fittings.
Grades: ASTM C84400, C85700.
Silicon Brasses:
Uses: Parts that must hold pressure, marine hardware, and jobs needing high strength and rust resistance.
Grades: ASTM C87500, C87800.
Aluminum Bronze Casting
Aluminum bronze is an alloy of copper and aluminum. It offers great strength, excellent wear resistance, and fights rust well. We use heat treatment to get the best mix of strength and toughness for a job. This bronze has the highest mechanical strength of all copper alloys. This makes it a top choice for the most demanding industrial jobs.
Super Strength and Hardness: It provides the highest strength and hardness among copper alloys. It is as strong as some grades of steel.
Fights Wear Well: It is excellent against wear, galling, and metal-on-metal contact, even under heavy loads.
Great Rust Resistance: It fights seawater, sulfuric acid, and other strong chemicals better than most other copper alloys.
Good in High Heat: It keeps its strong traits at high temperatures, up to 400°C (750°F).
Casts Easily: It flows well and shrinks little. This makes strong, dense, and accurate castings.
Aluminum Bronze Castings from Simis Copper Foundry:
heavy-duty bearings and bushings;
gear parts and worm wheels;
valve stems and seats;
pump impellers and casings;
marine hardware and propeller parts;
chemical processing equipment;
mining machine parts.
Aluminum Bronze Casting Grades Simis Uses:
Single-Phase Bronzes (Al < 8%):
Uses: Chemical process equipment, seawater pipe systems, and parts needing good shape change.
Grades: ASTM C60800, C61000.
Duplex Bronzes (Al 8-11%):
Uses: Strong general-purpose parts like bearings, gears, valve components, and marine hardware.
Grades: ASTM C95400, C95500.
Complex Bronzes (with Ni, Fe, Mn added):
Uses: Tough jobs in chemical processing, marine work, and high-heat service.
Grades: ASTM C95700, C95800.
Tin Bronze Casting
Tin bronze is a classic alloy of copper and tin. It has great wear resistance and fights rust well. It naturally acts like a lubricant. It works well with steel shafts and has good mechanical strength. This makes it a perfect choice for high-load, slow-speed jobs and many industrial settings.
Great Wear Resistance: It works very well against friction and rubbing. This makes it ideal for bearing surfaces and sliding parts.
Good Rust Resistance: It fights seawater, air rust, and many chemicals well. It strongly resists stress corrosion cracking.
Strong Overall: It offers good strength and hardness, along with decent flexibility and impact resistance.
Casts Easily: It flows well and does not shrink much. This makes strong, accurate castings.
Easy to Machine: It machines to a smooth finish. The way it cuts changes a bit based on how much tin is in it.
Tin Bronze Castings from Simis Copper Foundry:
bushings, bearings, and thrust washers;
gears and worm wheels;
valve parts and pump parts;
marine hardware and propeller fittings;
architectural pieces;
electrical contacts.
Tin Bronze Casting Grades Simis Uses:
Low Tin Bronzes (Sn < 8%):
Uses: General-purpose bearings, valve parts, pump parts, and marine fittings.
Grades: ASTM C90500, C90700.
High Tin Bronzes (Sn 8-12%):
Uses: High-load bearings, worm gears, heavy machine parts, and industrial bearings.
Grades: ASTM C90800, C90900.
Phosphor Bronzes (with P added):
Uses: Electrical springs, contacts, bellows, and precise instrument parts.
Grades: ASTM C51000, C52100.
Leaded Tin Bronzes:
Uses: High-speed bearings and bushings. Perfect for jobs where oiling might not be enough.
Grades: ASTM C93200, C93400.
Other Bronze / Copper Alloy Casting
Bronze is a copper alloy mixed with tin or other elements (like aluminum or phosphorus). It offers high strength, wear resistance, and fights rust well. This makes it good for parts that face heavy loads and friction. Bronze grades are more varied than brass. This lets us pick the perfect alloy for strength, wear, rust resistance, and cost. It is a top choice for copper parts in high-load, slow-speed jobs and harsh environments.
Great Wear Resistance: It works very well against friction. This makes it perfect for bearing surfaces and gears.
Good Rust Resistance: It fights seawater, chemicals, and air rust well. It especially resists stress corrosion cracking.
Strong Mechanicals: It has higher strength and hardness than most brasses. Yet, it still keeps good flexibility.
Casts Easily: It fills molds easily. It makes strong, accurate castings that hold their size well.
Good Machinability: It machines to a smooth finish. It is generally not as easy to cut as brass that has lead in it.
Bronze Castings from Simis Copper Foundry:
bushings, bearings, and thrust washers;
valve parts and pump parts;
architectural fittings.
Bronze Casting Grades Simis Uses:
Silicon Bronzes:
Uses: Valve parts, pump parts, architectural fittings, and electrical connectors.
Grades: ASTM C87500, C87800.
Leaded Bronzes:
Uses: High-load, slow-speed bearings, bushings, and washers. Perfect for jobs where oiling might be poor.
Grades: ASTM C93200, C93800.
Brass Casting
Brass is an alloy of copper and zinc. It resists rust very well. It offers good mechanical strength, a nice golden look, and casts easily. It is also easy to machine and costs less. This makes brass good for many decorative and working parts.
Great Rust Resistance: It fights seawater, air, and many chemicals well. This makes it perfect for marine jobs.
Easy to Machine: Brass is one of the easiest metals to machine. It makes clean chips and smooth surfaces while saving tool life.
Fights Germs: It naturally kills germs. This makes it safe for medical, food, and sanitary parts.
Casts Well and Holds Pressure: It fills molds easily. It makes strong, accurate castings that hold pressure well.
Nice Look: Its golden color and ability to shine make it popular for buildings and decorative items.
Brass Castings from Simis Copper Foundry:
marine hardware and fittings;
valves, pumps, and plumbing parts;
door handles and fixtures for buildings;
musical instruments;
electrical connectors;
decorative art pieces.
Brass Casting Grades Simis Uses:
Low Zinc Brasses (Red Brasses, Zinc < 15%):
Uses: Plumbing valves and fittings, pump parts, and marine hardware that fights rust.
Grades: ASTM C83600, C84400.
High Zinc Brasses (Yellow Brasses, Zinc 15-40%):
Uses: General hardware, decorative items, and architectural fittings.
Grades: ASTM C85800, C86200.
Leaded Brasses:
Uses: High-volume parts needing excellent machining, like valves and fittings.
Grades: ASTM C84400, C85700.
Silicon Brasses:
Uses: Parts that must hold pressure, marine hardware, and jobs needing high strength and rust resistance.
Grades: ASTM C87500, C87800.
Aluminum Bronze Casting
Aluminum bronze is an alloy of copper and aluminum. It offers great strength, excellent wear resistance, and fights rust well. We use heat treatment to get the best mix of strength and toughness for a job. This bronze has the highest mechanical strength of all copper alloys. This makes it a top choice for the most demanding industrial jobs.
Super Strength and Hardness: It provides the highest strength and hardness among copper alloys. It is as strong as some grades of steel.
Fights Wear Well: It is excellent against wear, galling, and metal-on-metal contact, even under heavy loads.
Great Rust Resistance: It fights seawater, sulfuric acid, and other strong chemicals better than most other copper alloys.
Good in High Heat: It keeps its strong traits at high temperatures, up to 400°C (750°F).
Casts Easily: It flows well and shrinks little. This makes strong, dense, and accurate castings.
Aluminum Bronze Castings from Simis Copper Foundry:
heavy-duty bearings and bushings;
gear parts and worm wheels;
valve stems and seats;
pump impellers and casings;
marine hardware and propeller parts;
chemical processing equipment;
mining machine parts.
Aluminum Bronze Casting Grades Simis Uses:
Single-Phase Bronzes (Al < 8%):
Uses: Chemical process equipment, seawater pipe systems, and parts needing good shape change.
Grades: ASTM C60800, C61000.
Duplex Bronzes (Al 8-11%):
Uses: Strong general-purpose parts like bearings, gears, valve components, and marine hardware.
Grades: ASTM C95400, C95500.
Complex Bronzes (with Ni, Fe, Mn added):
Uses: Tough jobs in chemical processing, marine work, and high-heat service.
Grades: ASTM C95700, C95800.
Tin Bronze Casting
Tin bronze is a classic alloy of copper and tin. It has great wear resistance and fights rust well. It naturally acts like a lubricant. It works well with steel shafts and has good mechanical strength. This makes it a perfect choice for high-load, slow-speed jobs and many industrial settings.
Great Wear Resistance: It works very well against friction and rubbing. This makes it ideal for bearing surfaces and sliding parts.
Good Rust Resistance: It fights seawater, air rust, and many chemicals well. It strongly resists stress corrosion cracking.
Strong Overall: It offers good strength and hardness, along with decent flexibility and impact resistance.
Casts Easily: It flows well and does not shrink much. This makes strong, accurate castings.
Easy to Machine: It machines to a smooth finish. The way it cuts changes a bit based on how much tin is in it.
Tin Bronze Castings from Simis Copper Foundry:
bushings, bearings, and thrust washers;
gears and worm wheels;
valve parts and pump parts;
marine hardware and propeller fittings;
architectural pieces;
electrical contacts.
Tin Bronze Casting Grades Simis Uses:
Low Tin Bronzes (Sn < 8%):
Uses: General-purpose bearings, valve parts, pump parts, and marine fittings.
Grades: ASTM C90500, C90700.
High Tin Bronzes (Sn 8-12%):
Uses: High-load bearings, worm gears, heavy machine parts, and industrial bearings.
Grades: ASTM C90800, C90900.
Phosphor Bronzes (with P added):
Uses: Electrical springs, contacts, bellows, and precise instrument parts.
Grades: ASTM C51000, C52100.
Leaded Tin Bronzes:
Uses: High-speed bearings and bushings. Perfect for jobs where oiling might not be enough.
Grades: ASTM C93200, C93400.
Other Bronze / Copper Alloy Casting
Bronze is a copper alloy mixed with tin or other elements (like aluminum or phosphorus). It offers high strength, wear resistance, and fights rust well. This makes it good for parts that face heavy loads and friction. Bronze grades are more varied than brass. This lets us pick the perfect alloy for strength, wear, rust resistance, and cost. It is a top choice for copper parts in high-load, slow-speed jobs and harsh environments.
Great Wear Resistance: It works very well against friction. This makes it perfect for bearing surfaces and gears.
Good Rust Resistance: It fights seawater, chemicals, and air rust well. It especially resists stress corrosion cracking.
Strong Mechanicals: It has higher strength and hardness than most brasses. Yet, it still keeps good flexibility.
Casts Easily: It fills molds easily. It makes strong, accurate castings that hold their size well.
Good Machinability: It machines to a smooth finish. It is generally not as easy to cut as brass that has lead in it.
Bronze Castings from Simis Copper Foundry:
bushings, bearings, and thrust washers;
valve parts and pump parts;
architectural fittings.
Bronze Casting Grades Simis Uses:
Silicon Bronzes:
Uses: Valve parts, pump parts, architectural fittings, and electrical connectors.
Grades: ASTM C87500, C87800.
Leaded Bronzes:
Uses: High-load, slow-speed bearings, bushings, and washers. Perfect for jobs where oiling might be poor.
Grades: ASTM C93200, C93800.
Application of Copper Alloy Castings
Custom Copper Alloy Castings by Simis Foundry
Copper Alloy Castings Company's Custom Steps
Confirm customization requirements
Design Review and Samples
Simis engineers first check the 3D and plane drawings. This makes sure your design is ready for manufacturing. If you have a sample part, we can make the new parts based on that sample.
Define Part Requirements
We confirm what the part needs to do. This includes things like its strength, hardness, wear, and rust resistance. We also set the exact size, tolerance, and finish quality needed.
Confirm Casting Material
Our engineers help you pick the right cast copper material. This choice depends on where the part will be used and your technical needs. We give advice based on material cost, strength, and resistance to wear or rust.
Choose the Casting Method
We select the best casting process for your part. We base this choice on your price goal, the part’s shape, its required accuracy, and the material.
Make Molds and Samples
We build the casting molds using your approved drawings or samples. Then, we cast the first batch of samples using the chosen material and process.
Full Sample Inspection
The finished samples go through a full check. This confirms they meet all design standards and your quality demands. We give you reports covering size, performance, material makeup, and non-destructive testing.
Production and quality control
Mass Production
After you check and approve the sample, we start the mass production plan. We get all the materials ready based on your order. We use the exact same machines and process as we did for the sample. This makes sure every single part we make is the same.
Quality Control During Production
We run tight quality checks while making the parts. We pull parts for checks often during the process. We test their size, look, and strength. This ensures every batch of cast copper parts is consistent and meets your needs.
Final Product Quality Inspection
We use multiple inspectors for the final check. They do many tests on the finished product. These tests cover size accuracy, surface quality, and part strength. This step makes sure all cast copper parts meet your quality standards.
Packaging and Delivery
We securely package and ship all approved parts. We pick the right packaging to prevent damage during shipping. We also choose the best delivery method (air, sea, or land) to get your parts to you on time.
To order custom parts, please email us your design drawings and 3D models. Our team will review the detailed part parameters and the 3D model to provide you with an accurate quote.