Monday, May 22, 2017

Casting Options: Methods of Manufacture

When you begin a project, there may be a perfect vision in your head, but to get it to the final stages there are a lot of decisions that need to be made to achieve the highest quality of product.

Over the years Atlas Bronze has acquired the keen knowledge of how your material is made, the lead time for the material and the ultimate cost will depend on the some of the following factors:

  • Desired Alloy
  • Specification (if noted)
  • Size Range
  • Quantity
  • Lead time needed
Each alloy group has unique methods for how the material is made or cast and we take into account for all the factors in determining the best method to offer a customer.  This is possible because we have over 100+ years of combined experience in our Sales Group. 

The best way to help you determine the best fit for your needs would be to CONTACT US by either email or call 1-800-478-0887.
Some of the most common methods of casting for Bronze Alloys are as follows:
Sand Casting

Sand casting is probably the oldest method in practice. In this process the mold is prepared using sand or silica and the molten liquid metal is poured into it. The mold is made of two parts, the cope and the drag. A wooden pattern is placed between these two parts, called the mold cavity. The liquid metal enters here and casts itself. The shape of the mold cavity is similar to the final object after the refining

Centrifugal Casting

The Centrifugal casting process uses a mold which is fixed to a motor on an axis to rotate it at high speeds. The speed of rotation depends on the metal to be cast and the shape required. This method is mainly used for the production of cylindrical components like pipes. As the motor rotates, the metal gets pushed towards the outer walls of the cast and solidifies. The centrifugal process is unsuitable for making linear-shaped and dense 


Continuous Casting

Continuous casting, as the name implies, converts molten metal into a continuous moving ingot shape with a rectangular or round cross section. Time, energy, and labor are saved. Generally, a water-cooled mold is employed, receiving molten metal in one end and delivering a continuous solidified product out the other. The molds can be vibrating or moving, slow or fast.

          Atlas offers high quality Sand Casting, Centrifugal Casting, and Continuous Cast products at competitive prices and great lead times.  Your alloy, specification or application might indicate the part needs to be made as any one of the listed methods.   Speak to one of our Sales Representatives to determine if your application should be made as a Continuous, Centrifugal or Sand Casting product.

For more information or to see what else we could do to help, please visit our website at

Friday, May 12, 2017

Ground Plate: The Ultimate Time & Money Saver!

 Ground Plate is Atlas Bronze's specialty product.  This material is a cost saver and time saver.  Since the material is stocked in a ground condition +/- .002 on the thickness (we aim for +/- .000 so if you need a closer tolerance we will mic material upon request).

Our bronze flat stock is machined from continuous cast, fine grain plate. Our bars are supplied ground top & bottom.  

No milling or grinding is necessary on the top or on the bottom. It's already done for you!!  No need to block it in, taping it down or tow clamp it anymore! 

Standard stocked ground plates are available in C95400 Aluminum Bronze & C93200 Bearing Bronze from ¼ to 1” x 12” wide x 144” cut to your size.  We can also grind any plate Alloy you like.  Just call or email us with your requirements.

Our Bronze Ground Plate was developed to save you time and money and here is a list of reasons why you will love it!

  • Time Saver
  • Tight Tolerance
  • Minimal Machining for customers
  • Fewer Setups + lower costs
  • Chemical Certs for trace-ability
  • Standard Sizes in Stock
  • Can ship the same day!

You can see an example of what grinding a large plate might look like below...

Call us, email us or visit us on our Online Store to purchase yours TODAY!

1-800-478-0887 • •

Tuesday, May 2, 2017

The Wrought Alloys

Here at Atlas we offer a broad variety of Wrought Alloys. Wrought Alloys under the Bronze products tab on our website are generally available in sheet/ plate, rods, tubes or bar stock. We have a great inventory selection of products that can be pulled right from our shelves.

They are typically produced by rolling and extrusion mills or by a Forging Mill. In either case the material starts out as a particular shape (i.e. Round or Square block or billet) and is then cast into the desired form by either "Extruding or Pushing" the material or by "Hammering or Forging" the material down into shape. Additionally some of our material is available in an "As cast and cold drawn condition". This process involves casting the rod and then repeatedly cold drawing it to it's final dimension and annealing it during the process when necessary.  A more detailed explanation for each can be found below...

Hot Extrusion

In extrusion, a bar or metal is forced from an enclosed cavity via a die orifice by a compressive force applied by a ram. Since there are no tensile forces, high deformations are possible without the risk of fracture of the extruded material.
The extruded article has the desired, reduced cross-sectional area, and also has a good surface finish so that further machining is not needed. Extrusion products include rods and tubes with varying degrees of complexity in cross-section.

The Extrusion process allows for solids, tubes and profiles to be made. Contact one of our Sales Representatives and find out if your application, spec and material require an Extruded product.



There are 2 main types of Forging methods. Closed Die Forgings and Open Die Forgings.

In Closed Die Forgings a single piece of metal, normally hot, is deformed mechanically by the application of successive blows or by continuous squeezing. A force is brought to bear on a metal slug or preform placed between two (or more) die halves. The metal flows plastically into the cavity formed by the die and hence changes in shape to its finished shape.

In Open Die Forgings the metal is between flat dies with no pre-cut profiles. The dies do not confine the metal laterally during forging. Deformation is achieved through movement of the workpiece relative to the dies.

Cold Drawn

Drawing is the pulling of a metal piece through a die by means of a tensile force applied to the exit side. A reduction in cross-sectional area results, with a corresponding increase in length. A complete drawing apparatus may include up to twelve dies in a series sequence, each with a hole a little smaller than the preceding one.

Cold Drawing is where one casts a Rod (solid shape) or profile first and then after a careful pre-treatment procedure and de-scaling of the bar they are drawn through a forming die. This operation is typically repeated several times.
Metals can be formed to much closer dimensions by drawing than by rolling. Drawn products include wires, rods and tubing products. Seamless tubing can be produced by cold drawing when thin walls and very accurate finishes are required. This process tightens the cross-sectional tolerances, leading to improved dimensional accuracy and surface quality.
Cold drawn material offer extensive advantages, among other things:
  • Smooth and scale-free surface
  • Sharp edges
  • Uninterrupted grain orientation
  • Increased tensile strength and yield point

Atlas Bronze offers a number of alloys Cast & Drawn. Contact one of our Sales Representatives and find out if your application, spec and material require a Cast & Drawn product.

Hot Rolling

Rolling is the most widely used deformation process. It consists of passing metal between two rollers, which exert compressive stresses, reducing the metal thickness. Where simple shapes are to be made in large quantity, rolling is the most economical process. Rolled products include sheets, structural shapes and rails as well as intermediate shapes for wire drawing or forging. Circular shapes, ‘I’ beams and railway tracks are manufactured using grooved rolls.

Initial breakdown of an ingot or a continuously cast slab is achieved by hot rolling. Mechanical strength is improved and porosity is reduced. The worked metal tends to oxidize leading to scaling which results in a poor surface finish and loss of precise dimensions. A hot rolled product is often pickled to remove scale, and further rolled cold to ensure a good surface finish and optimize the mechanical properties for a given application.

Atlas Bronze offers a number of alloys Hot Rolled. Contact one of our Sales Representatives and find out if your application, spec and material require a Hot Rolled product.