How To Measure Bronze Bushings

Bronze bushings are resistant to corrosion and friction and are a long-lasting solution that won’t lose its shape over time. However, to reap all of these benefits and more, you are going to have to invest in bushings that are the right fit. 

Installing the wrong size bushing can be detrimental to your application. And, ordering the wrong size can halt production. Reduce your risk by knowing how to measure bronze bushings properly.  

Common Applications for Bronze Bushings

Bronze bushings can be found in all sorts of applications due to their many advantages – and their ease of use. This makes them a great solution for hydraulic cylinders, bicycles, surveillance systems, printer rollers, escalators, kitchen appliances, medical and dental tools, ATMs, engines, and so much more. 

If you believe that bronze bushings are the perfect fit for your project or if you currently have bushings you need to replace with bronze, how can you tell what size you need? How are bronze bushings measured? 

Measuring Bronze Bushings

Measuring bushings can be a bit confusing. Do you measure the interior ring or the exterior ring? And what happens if it is a flange bushing with an additional area to measure — does it count?

If you need to order bronze bushings, then you are going to need their precise size to ensure an accurate fit. That means you need to know how to properly measure it. So, let’s break it down. 

The inner diameter of a bronze bushing, generally referred to as ID, is measured from side to side using the inside walls. The outdoor diameter, or OD, is a measurement of the outer walls, straight across from the outside of each side. 

The overall length (OAL) of a bronze bushing refers to the length of the part from bottom to top when sitting flat on a surface. 

When it comes to flange bronze bushings, additional measurements are needed including the outer diameter and the thickness of the flange itself. These are referred to as the flange outer diameter (FLOD) and the flange thickness (FLTH), respectively. 

The unit of measurement for bronze bushings is inches. And they are referred to as “-ths of an inch.” Except, of course, the interior diameter or ID which is clearly broken down into four decimal points for precision purposes. 

When ordering your new bronze bushings you would use the sequence of ID, OD, OAL, and, if applicable, FLOD and FLTH. 

What Size Bronze Bushings You Need? 

If you are still not sure of how to properly measure the size of your bronze bushings, it is a good idea to get in contact with a knowledgeable professional within the industry. After all, getting the right part to complete your job is so important. Remember, you will need to know the exact size in order to be able to order the proper bronze bushings. 

Whether you know exactly what you want or you need some help with the calculations, the team at Atlas Bronze is here for you. We offer standard and made-to-order bushings for a perfect fit and can help you find exactly what you are looking for.  

Contact us today at (800) 478-0887.

What is Naval Brass?

 

Brass is one of the most common alloys due to its strength, durability, and immense malleability. This makes it very beneficial in a number of applications. Naval brass, on the other hand, is a specific type of brass with a slightly different composition that is often found in marine applications - hence its name. It, too, is very strong though corrosion-resistant which makes it successful for a lifetime in salty water. Just what is naval brass? Let’s take a closer look.

Brass vs. Naval Brass: The Composition

The composition of a metal alloy matters. One small change in it can impact its strength in certain situations - and in certain applications. As mentioned, brass is a metal alloy that is made up of copper and zinc. This composition is often in the range of 55 to 90 percent of copper and 10 to 45 percent of zinc. It does contain trace amounts of others, too, like lead and tin. The makeup of naval brass is a bit different. Generally, it will have higher levels of copper than other brass alloys. A common ratio of the metals that build this alloy includes 59% copper, 40% zinc, and 1% tin. Even though the amount of tin found in naval brass is low, it is what gives this metal alloy great resistance to corrosion while housed in the harsh conditions found in seawater. Low levels of lead are sometimes found in brass alloys. And while it may seem like an insignificant addition, it should never be overlooked. The addition of lead is what helps with the metal’s machinability. When you have the perfect combination, the metal can be more workable and stronger than initially thought.

Key Characteristics of Naval Brass

Because of its design, naval brass does have a few key characteristics that set it apart from traditional brass - aside from its ability to succeed in extreme conditions underwater. For example, when compared to brass, naval brass is:

• More durable
• More costly
• More corrosion resistant
• Less machinable

Naval brass also has a higher melting point than brass - and is not recommended for high-temperature applications. This is what makes it so fitting for marine applications.

Applications for Naval Brass

Yes, naval brass is often used in seawater applications due to its ability to handle saltwater for long periods of time. In the early 1900s, brass tubes were used on ships only to end up experiencing dezincification. This condition happens when the zinc in the alloy erodes due to corrosion. To battle this, naval bass was created and is now one of the most commonly used alloys for ships. It can be found in both saltwater and freshwater situations, used as propeller shafts, decorative fittings, shafting, marine hardware, pumps, valves, and more on ships and other marine equipment. There is no set time frame for how long naval brass will last in one of these water-submerged applications. But it is safe to say that it will last for many years - and definitely longer than traditional brass alloy.

Learn More About Naval Brass at Atlas Bronze

Interested in naval brass for your underwater application? Atlas Bronze can help. Our experts can answer any questions you may have and can help guide you to the right solution for your needs. Contact us today at (800) 478-0887.

The Surprising Role of Copper in Green Energy Solutions

 

The push for green energy sources has never been stronger, as scientific studies show real evidence of global warming and climate shift. Green energy, also referred to as renewable energy, is defined as any source of energy derived from nature, such as sun, wind, or water. In order to be considered green energy, it must not produce any form of pollution. What do green energy and copper have to do with each other? As it turns out, quite a bit. Read more to learn about the surprising role of copper in green energy solutions.

What is Copper?

Copper is an element derived from naturally occurring ores in the earth. It is a type of metal found on the periodic table of elements, abbreviated Cu. Copper is a soft, shiny metal that has an orange appearance when new, and over time it becomes brown and eventually green as it oxidizes. One of the most important qualities of copper is that it is a conductor of electricity, which largely defines how it is used and its value.

How is Copper Refined?

Copper ore is mined directly from the earth and refined through a multi-step process until it is purified. Then it can be made into a variety of copper products, such as electrical wiring, water pipes, cookware, auto parts, and even household hardware like doorknobs.

Green Benefits of Copper

Copper has many qualities that make it environmentally friendly:

• Completely recyclable. Copper can be recycled without losing any of its properties. It is the same amount of copper before and after recycling.
• Long lasting. Among the many types of metal, copper lasts just as long or longer than some others and is especially corrosion resistant when exposed to moisture, which is why copper pipes are used in plumbing.
• Can be refined by bioleaching. One way that copper refining is lowering its impact on the environment is through the use of bioleaching, a process that uses bacteria to separate copper from ore.

The Connection Between Copper and Green Energy

When it comes to the role of copper in green energy solutions, the most valuable characteristic is its ability to conduct or transfer energy. Copper wiring is used to deliver the electrical energy that is created by harnessing the power of wind, water, and sunlight. The efficiency of copper as a conductor reduces carbon dioxide emissions and less energy is required overall to produce electricity. Renewable energy systems contain at least 6 times the amount of copper in other forms of energy production.

Are Green Energy and Renewable Energy the Same?

Green energy and renewable energy are similar, but not the same. A renewable energy source is something that comes from nature and can be replenished. For an energy source to be renewable and also green, it must not produce any emissions or pollutants that harm the environment. Green energy is the term reserved for the cleanest possible energy sources that have the lowest impact on the earth and its atmosphere.

Why Purchase Copper Products from Atlas Bronze?

Atlas Bronze is a leading manufacturer of copper alloy forgings. Our customers include a variety of industries from power generation to military to aerospace. If you’re in need of quality copper materials, Atlas Bronze is a manufacturer you can trust. Call 800-478-0887 or contact us today for more information or shop our online store.

Brazing vs. Welding: What’s the Difference?

In manufacturing, there will almost always come a time when you have to bring two metals together and create a solid, sturdy connection. 

While many factors will help determine the best approach, it usually always comes down to brazing and welding. Which one is best for your application? How do you know which one to choose? And what is the difference between brazing and welding? 

Let’s take a closer look at each so that you can better identify the best option for your particular application. 

What is Brazing? 

Brazing is a process or technique used for joining together at least two pieces of metal. It works by using a filler material of your choice with a low melting point to hold the two pieces of metal together. 

The idea is that the heat used to melt the filler should not be enough to melt the base metal you are joining together, keeping its properties and integrity fully intact. 

What is Welding? 

Welding is another process or technique used to join together at least two pieces of metal. Instead of using a filler, you will melt the actual base metals so that they come together and harden as one. 

To keep the proper form of the metal, pressure may or may not be used with welding. 

Brazing vs. Welding: Which Do You Choose? 

How do you know which method of joining metals will work best for your project? As mentioned above, there are a few different factors that you can consider. Together, they can point you toward brazing or welding.

The Types of Metal Used

You have to consider the types of metal you are using. Are they both the same? Are they different? The metals you use in your application will play a role in determining the best way to join them. 

For instance, when using the same type of metal, welding often works just fine. However, because welding melts the metal, this can be tough when you have metals with two different melting points. 

If you find yourself in a situation with metals that have very different properties, brazing will be the ideal solution for creating the joint between them. This way you won’t have to worry about melting one metal too much while getting enough heat to melt the other. 

The Thickness of the Metal

Both brazing and welding work well for metals of different sizes — especially when it comes to thick metals. 

Working with thin metals, on the other hand, brazing is often the best option due to its delicate nature.

The Size of the Assembly

When you are working with large assemblies, you have to have power behind your heat so that you can secure both of them together. The heat needs to radiate through them and that is something that brazing just cannot succeed at. 

Welding works best in this situation. 

The Finished Appearance

When a joint is going to be visible, appearance often matters. So, even if both welding and brazing are suitable for a project, the one that gives the most desired finished appearance is often the go-to option. Between welding and brazing, choose brazing. 

Brazing or Welding? Find Your Metal at Atlas Bronze

At Atlas Bronze, we have the metals you are looking for to meet the needs of your application — from bronze alloys and iron alloys to sintered bars and made-to-order plates and castings, we have just what you need. 

To learn more about aluminum bronze or any other metal your application calls for, contact us at (800) 478-0887.

The Shrinkage Factor Of Aluminum Bronze Material Explained

For various reasons, it is common for metal to shrink as it transforms from its liquid form to a solid form. It is important to gain an understanding of what to expect when working with metal so that allowances can be made when referring to the finished product. 

After all, shrinkage is not always visible. 

Let’s take a closer look at the shrinkage factor of aluminum bronze material, including what it is and why it happens. 

Understanding the Shrinkage Factor

When working with metal, it is important to understand that there will be a shrinkage factor you will need to consider. Without doing so, you can find yourself with a defective end product that leads to its inability to function properly. 

Aluminum bronze material, specifically, can encounter shrinkage at different steps, including: 

• Liquid shrinkage. Shrinkage at this stage occurs before it begins to cool and harden. In other words, it can already begin to happen before the metal has cooled. 

• Solidification shrinkage. Liquid aluminum alloy will shrink as it begins to solidify. The reason for this is that solid alloys are much more dense than liquid alloys. 

• Pattern shrinkage. When a patternmaker begins to mark a metal once it has cooled, you risk shrinkage, as well.  

Factors the Impact the Shrinkage of Aluminum Bronze

There are a few factors that influence the shrinkage of aluminum bronze material, as well as other metals. These include things like the temperature at which it is poured, its chemical composition, the casting or mold conditions, and so forth. 

• Pouring temperature. Simply stated, the higher the pouring temperature, the greater amount of shrinkage that will occur. 

• Chemical composition. Different elements that are used to make up a metal or metal alloy will play a role in just how great or small the shrinkage is. 

• Molds and Castings. The type of shrinkage that occurs here is the result of the mold itself. It is more of a blocked shrinkage due to the size and shape of the mold/casting. For instance, a mold’s design may cause different cooling rates. This can impact the finished product and its amount of shrinkage. 

What is the Shrinkage Factor of Aluminum Bronze? 

Remember, there are a number of factors that impact just how much metal will shrink - including aluminum bronze. Though, on average, you should expect your metal to shrink anywhere between 1.6% to 6%. 

Tips to Minimize Aluminum Bronze Shrinkage

Believe it or not, there are a few steps you can take to minimize the amount of shrinkage you encounter with your aluminum bronze. Below are a few tips to get you started. 

• Make sure you control the temperature of your liquid metal as you pour it. 

• Pour it fast.

• Create a riser that will allow the additional liquid metal to compensate for shrinkage. 

• Improve your casting structure

The more time you take to perfect your system, the greater chance you have of minimizing your metal’s shrinkage. 

Learn More About Working with Aluminum Bronze

Interested in working with aluminum bronze? At Atlas Bronze, we understand just how imperative it is to fully understand the metal you are working with if you want an end product that exceeds expectations. 

To learn more about aluminum bronze or any other metal your application calls for, contact us at (800) 478-0887.

What Are Sintered Bronze Bearings Made From?

Sintered bronze bearings are one of those component parts that play a fundamental role in so many applications. Not only are they effective at what they do without requiring any maintenance, but they are also a cost-effective solution. 

Without losing its strength, the porous metal created from the sintering process is what gives them their traits - and makes these bronze bearings a go-to for many. 

But how are they made? And what exactly are sintered bronze bearings made from? Let’s find out. 

What are Sintered Bronze Bearings Made From? 

Sintered bronze bearings are made from powder metallurgy. 

Powder metallurgy is a metal-forming process in which bronze or bronze alloys are made into a powdered form through various processes, such as atomization, chemical decomposition, and grinding. 

This powder is poured into a mold cavity and pressed with great force in an attempt to compact the particles. 

The mold with the metal is then placed directly into a furnace. This heats the metal to just below its melting point. As a result, it comes together to form a very strong and porous component part. 

This process is known as sintering metal. 

Because this metal is so porous, it creates a great self-lubricating bearing. It is the fact that this metal is so porous that makes it a great option for self-lubricating bearings. As they work they are able to create a film that provides lubrication - keeping friction to a minimum while in motion. 

To get this effect, there is a second phase that follows the powder metallurgy known as oil impregnation. In a very brief overview, this refers to all of the pores being impregnated with grease so that it will continue to lubricate the bearing continuously. 

Applications for Using Sintered Bronze Bearings

Sintered bronze bearings are ideal and versatile enough to be used across many different industries. It is not uncommon to see them used in all sorts of applications - not to mention that they are affordable and easy to procure, too. 

A few of the most common places you may find them include:

• Aircraft accessories

• Spacecraft

• Automobile accessories

• Small appliances

• Motors

• Power tools

• Construction equipment

• Farm equipment 

• Business/packaging machines

Advantages of Sintered Bronze Bearings

So, why choose sintered bronze bearings over the alternative? Are they more effective at fulfilling their role than other metal, plastic, or rubber bearings?

Let’s just say that sintered bronze bearings are a highly-effective solution - and come with many advantages over the competition. A few of their most stand-out traits include: 

• Being self-lubricating 

• Requiring no maintenance

• Operating with low noise

• Having high sliding velocities

• A low friction coefficient

Regardless of how you intend to use them, you will likely be surprised by how well they hold up - without any maintenance. 

Looking for Sintered Bronze Bearings? 

If you have used sintered bronze bearings before and know what you are looking for, Atlas Bronze has a long list of sizing options to meet your needs. However, if you are in search of a better solution for your application, our metal experts are available to guide you - and answer any questions you may have along the way. 

Contact us today at (800) 478-0887. 

What is Centrifugal Casting?

Centrifugal casting is a process that has been around for over a century. It involves pouring molten metal into a mold to create pipes using centrifugal force. Hence, how it got its name. 

Now used in so many industries, centrifugal casting has been mass-produced on a large scale to meet the need. What makes it so popular? Perhaps it is its high level of reliability and material soundness or maybe it is because these products are created with a high level of accuracy. 

Whatever the reason, centrifugal casting isn’t going anywhere - so let’s learn about it. 

What is Centrifugal Casting? 

Sometimes referred to as roto casting, centrifugal casting is a metal casting process that begins with molten metal being poured into a die mold that has been heated and is spinning at a rapid rate. The die mold will be oriented and designed in any type of configuration so that it can yield the desired outcome. For instance, the mold could be horizontal or it could be vertical. 

As the molten metal is poured into the spinning die, inertia carries the metal throughout the walls of the mold at high pressures. Between the spinning and this added pressure, you get a piece of metal that has been created under controlled solidification. 

The result is a metal lacking in impurities without any unwanted pockets or inclusions. 

Types of Centrifugal Casting

There are many different applications that rely on centrifugal casting. A few of the most common include sewage and water pipes, engine cylinders, brake drums, bushings and rings, gas pipes, street lamp posts, and industrial equipment. 

To meet the needs of so many different industries, there are three main types of centrifugal casting. 

• True centrifugal casting. True centrifugal casting is the basic process mentioned above. The downfall is that it is limited to cylindrical and otherwise circular dies. 
• Semi-centrifugal casting. The product of semi-centrifugal casting is solid instead of tubular. 
• Centrifuging. Centrifuging works to create asymmetrical products using high pressure. These molds are typically small in size. 

Benefits of Centrifugal Casting

Are you interested in the benefits of centrifugal casting for your applications? Are you curious whether or not it will make a difference? Those who rely on it do so because it has proven to be beneficial, high-performing, and high-quality. 

Below are a few of the benefits of centrifugal casting. 

• The molten metal solidifies from the outside to the inside. This is what allows it to get rid of any impurities and cavities 
• Affordable manufacturing
• Easily mass-produce symmetrical products
• Mechanical soundness
• Can be used with different types of metal
• Very minimal waste

With all of the advantages it brings, the life and endurance of the resulting product are increased. And that makes it a reliable option. 

Atlas Bronze For All Your Metal Needs

Whether you are interested in learning more about centrifugal casting or you have other metal needs, such as forgings, sand castings, plates, or castings - the team at Atlas Bronze is here for you. Our made-to-order items are not only convenient, but they help to make your processes flow much more efficiently. 

Contact us today at (800) 478-0887.

How Continuous Casting Machine Works

 

Continuous casting is a cost-efficient metallurgic process that is regularly used with steel, aluminum, or copper. It breaks these metals down into high-quality sections using prefabricated molds. 

The result? 

A strong, continuous length of metal in specified shapes is used as raw material to fit many different applications.

Let’s take a look at how the continuous casting process works.

What is Continuous Casting? 

With continuous casting, you can melt and shape metals and metal alloys without stopping. In other words, the metal is melted and poured into a mold where it takes on a new shape. Water is used to cool it as the machine continues to work with the metal and get it in the right shape. 

Thanks to this technology that has been around since the 1950s, all types of metals used in various industries are created from continuous castings, such as bars, tubes, slabs, and stripes. Squares and rectangles, too. 

Benefits of Continuous Casting

Continuous casting provides many advantages over other types of metalwork, including other types of casting methods. A few of the benefits of continuous casting over other casting methods include: 

• It does not waste metal 
• Ability to cast metal into larger forms
• The end product is always the same - very consistent
• More efficient and more cost-effective

And that’s just to name a few. 

The Continuous Casting Process

There are a few main steps that are involved in the continuous casting process. Below is an overview. 

Step one: The metal is heated at a high temperature to liquefy it.

Step two: Using a ladle, the molten metal is poured into a tundish (similar to a funnel) that leads directly into a mold that sits underneath it. Depending on the setup, it could flow into one mold or multiple molds at the same time. 

Prefabricated molds that are used during the continuous casting process will vary based on the project. They can either be expendable molds that are usable for a one-time casting process or non-expendable molds that can be used a number of times. 

A continuous casting machine makes this process flow smoothly and efficiently - and produces a greater output. 

Step three: Cool water surrounds the molds to lower the temperature of the exterior edges of the metal in the mold so that it can easier maintain its shape. As it is removed from the mold, it is surrounded by even more cool water which further drops the surface temperature - and helps it to maintain its shape. 

The molded metal flows down a slope, cooling as it travels. 

Step four: The semi-solid metal will be sent through a guide that stretches it into a desired thickness and straightens it to fulfill the dimensions. The final product can be cut as needed. 

The continuous casting process is relatively standard throughout the industry. And all of these parts to create it are referred to as the continuous casting machine. 

Learn More About Metals at Atlas Bronze

In many different industries, continuous casting can prove to be beneficial and keep businesses moving. It can also benefit those who are looking for metal of specific dimensions. To learn more about how this can benefit your application - or to get answers to any questions you may have - the experts at Atlas Bronze can help. 

Contact us today at (800) 478-0887.