Bronze Casting Process
Providing comprehensive Bronze Bearing solutions to manufacturers operating in diverse markets and industries.
Cast Bronze Bushings with Solid Lubricant Inserts
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Cast bronze bearings & bushings are ideal for maintenance-free & heavy duty applications. Available as cylindrical, spherical, flange bearings . Cast Bronze Bushings ; Plain. plain cast bronze sleeve bushings ; Grooved. grooved cast bronze sleeve bushings ; Flanged. flanged cast bronze bushings ; Cast Bronze Bushings with Solid Lubricant Inserts
- lubrication inserts
- flanged bronze bushings
- flanged bronze bearing
- bronze bushings flanged
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Self-lubricating Bearing rapid manufacturing
We specialize in cast bronze bearings and sleeve bushings, offering same-day shipping for standard parts in stock. We also provide rapid customization of bronze bearing products at competitive prices. Our self-lubricating bearing technology and precision casting enable the swift manufacture of metal parts.
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Continuous Casting & Cast Bronze Bearings
What is Continuous Casting?
Continuous casting is an advanced process where molten metal is continuously poured into a specially designed mold, solidifying as it is drawn out. This method is commonly used to produce cast bronze bearings, bronze bushings, and graphite-impregnated bearings. It offers numerous advantages in terms of material properties and manufacturing efficiency, making it ideal for high-performance applications.
Cast Bronze Bushings: Choosing the Right Casting Method
Determining the best casting method for your project depends on various factors, including the specific requirements of your bronze bushing or bearing application. To ensure you choose the most effective solution, we recommend consulting with one of our experienced sales engineers. They will evaluate each project factor and provide recommendations on the ideal casting method for your self-lubricating bearings and bronze-graphite components.
Contact Our Sales Engineers for Expert Advice
For personalized guidance, click the link below to connect with one of our knowledgeable sales engineers.
Continuous Cast Bronze Bearing Materials & Production Process
Advantages of Continuous Casting
- Improved Mechanical Properties: Continuous casting produces a bronze material with enhanced strength and durability, offering longer service life and superior load-bearing capabilities.
- Uniform Structure: The process ensures a uniform grain structure, eliminating hard spots and resulting in better machinability compared to other casting methods.
- Elimination of Waste: Continuous casting allows for the production of long rods and pipes, significantly reducing material waste caused by size restrictions in traditional casting methods.
- Preventing Segregation: Rapid cooling in continuous casting dies prevents the segregation of lead in high-lead bronze alloys, ensuring consistent material quality.
- Customizable Shapes: Continuous casting enables the production of virtually any shape that can be extruded, bringing the final product closer to its net shape. This reduces the need for extensive secondary processing and minimizes scrap losses, leading to cost savings.
VIIPLUS Continuous Cast Bronze Bearings
VIIPLUS offers a comprehensive range of stocked and custom-made continuous cast bronze bearings. Standard-stocked bearings include:
- Manganese Bronze Bearings: C86300
- Leaded Tin Bronze Bearings: C93200 (SAE 660)
- Aluminum Bronze Bearings: C95400
These continuous cast bronze bearings are available in various forms, including straight bushings, flanged bearings, washers, and plates. All products are manufactured to meet ASTM B standards and specifications.
For custom projects, we design and manufacture special alloy bronze bearings and parts based on customer requirements. Whether you need a custom bushing, special parts made to ISO, DIN, or customer specifications, or a unique alloy, VIIPLUS is committed to delivering high-quality bronze solutions tailored to your exact needs.
Let us assist you with your specific copper bronze alloy requirements and provide the right parts for your project.
Continuous Casting Bronze Bushings & Bearings
Continuous casting is an advanced manufacturing process in which molten metal is continuously poured into a specially designed mold. As the metal solidifies, the casting is drawn out from the mold, forming a continuous piece. This process has significantly improved the structure of China’s metallurgical industry, addressing issues of low efficiency and high consumption in metal production. By advancing technologies such as near-net shape continuous casting, single crystal casting, high-efficiency casting, and hot charging of billets, continuous casting is revolutionizing the production of new materials and improving product specifications.
Characteristics & Advantages
- Maintenance-Free
- Self-Lubricating
- Ideal for Applications Where Oil/Greasers Are Difficult to Apply
- Designed for Heavy Loads and Low-Speed Operations
Types of Bronze Bearings & Custom Cast Bronze Forms:
- Straight Bushings with Graphite
- Flanged Bronze Bushings
- Wear Plates
- Custom Cast Bronze Components
Applications of Bronze Bushings & Bearings
Self-lubricating bushings are widely used in various industries, including die sets, metal stamping dies, molds, special machinery, and heavy equipment. These bushings are designed for applications where maintenance-free, long-lasting lubrication is required, especially in environments where oil or grease cannot be applied.
VIIPLUS: A Leading Supplier of Self-Lubricating Bronze Bearings
VIIPLUS is a China-approved, limited liability company specializing in the production and sales of self-lubricating bearings, cast bronze bearings, and graphite bronze bushings. The company is a key player in the stamping and injection molding industries, supplying guide parts, die ramp mechanisms, and wear-resistant materials for continuous casting machines. Over the years, VIIPLUS has built a solid reputation in both domestic and international markets, with over 80% of its products exported to high-end markets abroad.
The company prides itself on its long-term strategic partnerships with renowned international enterprises, which have contributed to its excellent market visibility and strong customer loyalty. VIIPLUS continues to grow, embracing its entrepreneurial spirit and striving to provide customers with reliable products and exceptional service.
Advanced Casting Technologies and Processes
VIIPLUS utilizes various casting methods such as sand casting, centrifugal casting, metal casting, and investment casting to meet customer requirements. The company is committed to selecting the most appropriate casting process based on the material and specifications of the workpiece. With a robust quality management system, VIIPLUS ensures that all components undergo rigorous testing, including mechanical property assessments, to guarantee the highest standards of quality.
Production Processes:
- Sand Mold Casting
- Metal Mold Casting
- Centrifugal Casting
Through these advanced casting techniques and a focus on customer satisfaction, VIIPLUS continues to lead the way in delivering high-quality, self-lubricating, and maintenance-free bronze bushings and bearings.
Machined Cast Bronze Bushing Overview
Manufacturing Process:
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Cast Bronze Bushings: These are formed from solid or hollow cast bronze bars through a machining process to achieve precise shapes. The bronze is cast continuously or centrifugally into bars before machining.
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Comparison with Oil-Impregnated Bronze Bushings: Unlike oil-impregnated bushings, which are made from powdered bronze, cast bronze bushings are made from solid or hollow bars, offering different mechanical properties and performance characteristics.
Applications:
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Machinery and Equipment: Widely used in machinery, earth-moving equipment, hydraulic cylinders, and more due to their high hardness and impact resistance.
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Wear Resistance: Ideal for sacrificial bushings and wear pads due to their long lifespan and resistance to wear.
Commonly Used Cast Bronze Bushing Materials
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ZCuSn10Pb1 (C52400):
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Properties: High hardness, excellent wear resistance, good casting and cutting performance, corrosion resistance in atmospheric and freshwater environments.
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Applications: High-load and high-speed wear-resistant parts like connecting rods, bushings, gears, and worm gears.
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QSn6.5-0.1, QSn6.5-0.4, QSn7-0.2, QSn8-0.3 (C51900, C52100):
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Properties: High strength, elasticity, wear resistance, anti-magnetic properties, good machinability, and corrosion resistance.
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Applications: Elastic components, wear-resistant parts, and anti-magnetic parts in precision instruments.
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ZCuZn25Al6Mn3Fe3 (C86300):
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Properties: High strength, hardness, wear resistance, moderate plasticity, and good corrosion resistance.
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Applications: Heavy machinery bushings, oil-free self-lubricating bearings.
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QSn6-6-3, QSn5-5-5 (C83600, C93200, C54400):
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Properties: Medium strength, good wear and corrosion resistance, excellent cutting performance.
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Applications: Higher load, medium-speed wear-resistant parts like shaft tiles, bushings, and cylinder liners.
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QAl9-4, QAl10-3-1.5, QAl10-4-4, CuAl10Fe3, ZCuAl9Fe4Ni4Mn2 (C95400, C61900, C95800):
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Properties: High strength, good cutting and grinding performance, weldability, and hot workability.
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Applications: High-strength bushings, gears, nuts, and connecting rods.
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ZCuPb10Sn10, ZCuPb15Sn8 (C93700, C93800):
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Properties: Good lubrication, wear resistance, and corrosion resistance.
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Applications: High-pressure sliding bearings, bimetallic shaft tiles, and piston pin bushings.
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Frequently Asked Questions (FAQ)
1. What are the raw materials used?
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Answer: Primarily materials meeting U.S. and international standards. Custom designs are available.
2. Can I inspect the factory?
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Answer: Yes, you can visit or hire a third-party agency to inspect the factory.
3. What are the packaging details?
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Answer: Products are packed in plastic film or export plywood boxes, with auxiliary products in thick cartons.
4. What are the characteristics of self-lubricating bronze bearings?
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Answer: Customizable based on your requirements, offering tailored solutions.
5. What are the benefits of bronze bushings from China?
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Answer: Competitive pricing, superior quality, and excellent service due to a well-established industry chain.
6. Do you offer custom bearing bushing services?
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Answer: Yes, we design bushings based on your specifications and provide professional guidance.
7. Which products are popular?
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Answer: All products are popular, but market preferences vary. Consult with our experts for tailored recommendations.
8. What is your guarantee or warranty?
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Answer: Lifetime technical support, with assistance tailored to different industry needs.
9. Do you have certificates?
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Answer: Yes, we are certified by reputable bodies. Certificates can be provided upon request.
10. What are your delivery terms?
– Answer: We offer EXW, FOB, CFR, CIF, and other delivery terms.
11. How do you test bronze bushings before shipment?
– Answer: Multiple inspections including raw material checks, process inspections, finished product inspections, and strength tests.
12. What if you can’t provide what I want?
– Answer: We handle complex requirements, including special oil sumps, oversized parts, and unique raw materials.
Conclusion
Cast bronze bushings are versatile, durable, and suitable for a wide range of applications. With a variety of materials and customization options, they meet the needs of different industries. The manufacturing process ensures precision and quality, supported by comprehensive testing and inspection protocols. Whether you need standard or custom bushings, the options and support available make it easy to find the right solution for your requirements.
The bronze casting process for producing bronze bearing bushings involves several steps to ensure the final product has the desired mechanical properties, dimensional accuracy, and surface finish. Below is an outline of the typical process:
1. Material Selection
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Bronze alloys commonly used for bearing bushings include:
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Tin Bronze (e.g., C93200, C93700): High strength, good wear resistance, and excellent corrosion resistance.
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Aluminum Bronze (e.g., C95400): High strength and excellent wear resistance.
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Lead Bronze (e.g., C94300): Good machinability and anti-friction properties.
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The alloy is selected based on the application requirements, such as load capacity, speed, and operating environment.
2. Pattern Making
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A pattern (typically made of wood, plastic, or metal) is created to form the shape of the bearing bushing.
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The pattern accounts for shrinkage allowances and machining allowances.
3. Mold Preparation
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Sand Casting: A common method for bronze bushings. The pattern is pressed into sand to create a mold cavity.
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The mold is typically made of green sand (a mixture of sand, clay, and water) or resin-bonded sand.
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Investment Casting: Used for high-precision bushings. A wax pattern is coated with ceramic slurry, dried, and then melted out to form the mold.
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The mold is designed with gating systems to allow molten bronze to flow into the cavity and for gases to escape.
4. Melting and Pouring
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The bronze alloy is melted in a furnace (e.g., induction furnace or crucible furnace) at temperatures ranging from 1,800°F to 2,100°F (982°C to 1,149°C), depending on the alloy.
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The molten bronze is poured into the mold cavity through the gating system.
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Care is taken to avoid turbulence and oxidation during pouring.
5. Solidification and Cooling
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The molten bronze solidifies inside the mold, taking the shape of the bearing bushing.
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Cooling rates are controlled to prevent defects like porosity or cracks.
6. Mold Removal
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After solidification, the mold is broken away to retrieve the casting.
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In sand casting, the sand is shaken off or blasted away.
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In investment casting, the ceramic shell is broken or dissolved.
7. Cleaning and Finishing
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The casting is cleaned to remove any residual sand, oxide scale, or other impurities.
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Excess material (e.g., gates, risers) is removed using cutting or grinding tools.
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Surface finishing processes, such as sandblasting or polishing, may be applied.
8. Machining
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The rough casting is machined to achieve the final dimensions and tolerances.
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Key machining operations include:
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Turning the outer and inner diameters.
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Facing the ends.
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Drilling oil holes or grooves (if required).
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Precision machining ensures proper fit and functionality in the final application.
9. Inspection and Testing
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The finished bearing bushing is inspected for dimensional accuracy, surface finish, and defects.
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Non-destructive testing (e.g., ultrasonic or X-ray) may be used to check for internal defects.
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Mechanical properties (e.g., hardness, wear resistance) may also be tested.
10. Surface Treatment (Optional)
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Depending on the application, surface treatments such as:
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Lubricant impregnation: To enhance self-lubricating properties.
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Plating or coating: To improve corrosion resistance or reduce friction.
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11. Packaging and Shipping
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The finished bronze bearing bushings are packaged to prevent damage during transportation.
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They are then shipped to the customer or assembly line.
Key Considerations:
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Dimensional Accuracy: Critical for proper fit and function in the final application.
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Material Properties: Ensure the bronze alloy meets the required mechanical and tribological properties.
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Defect Prevention: Proper mold design, pouring techniques, and cooling rates are essential to avoid defects like porosity, shrinkage, or inclusions.
This process can be adapted based on the specific requirements of the bearing bushing and the production scale.
