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Sand Casting, Production Capacity, and Specializations

Employing a full range of non-leaded bronze and copper alloys, Erie Bronze produces superior quality sand castings up to 100 pounds. The automated high-capacity molding line along with the ability to alloy metals and our proprietary degassing processes ensure customers receive the same high quality casting with every pour. Our modern 65,000 square foot foundry is home to the latest technology. Every investment in people, technology and equipment has been made to ensure consistent product quality, reduced lead times and increased efficiency. Focus and flexibility are hallmarks of Erie Bronze and Aluminum. A relentless focus on quality and production speed with quick change flexibility positions Erie Bronze to meet the most demanding requirements, all at a very competitive price.

Erie Bronze & Aluminum Co.
What is sand casting?
Sand casting is a manufacturing process that utilizes sand as the molding material to create a metal component “casting”. The sand is mixed with a bonding agent and water so it will hold its shape during the manufacturing process.
How is a sand casting made?
The sand casting process begins with a pattern. The pattern includes a physical replica of the casting and a gating system, which is the delivery channels for the molten metal. The pattern is comprised of two halves called a cope (top half) and drag (bottom half). Sand is pressed molded around the cope or drag patterns separately. The patterns are removed from the molds, creating negatives of the pattern equipment. The cope and drag molds are placed together and then molten metal is poured down a hole called a sprue to fill the negative areas created by the pattern.
What are the advantages of sand casting?
  • Less expensive than other manufacturing processes such as the investment casting process.
  • Sand castings can conform to final shapes, reducing the amount of excess material.
  • Shorter lead times due to the manufacturing process of sand castings.
  • Pattern equipment is typically less expensive than the other methods of manufacture.
What is the largest size casting you can make?
The largest size casting we can generally manufacture must fit into a 26″ x 26″ square.
What is your typical lead time?
Lead times for initial first-run products can range from 3 to 9 weeks depending on a number of factors such as; the complexity of pattern construction, the use of cores, auxiliary services such as machining, NDT testing, or heat treating. Lead times for production run items typically range from as little as 1 to 6 weeks also dependent on the auxiliary services.
What are the benefits of aluminum bronze casting?
Aluminum bronze is known for being a heavy-duty alloy with incredible resistance to everyday corrosion and wears in various weather conditions. The alloy is made up of 10% aluminum, as well as small percentages of nickel and iron. Aluminum bronze is resistant to tarnishing and corrosion from seawater, making it a staple for sleeve bearings and for the shaft and pumping parts in marine environments.

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What kind of aluminum alloys do you specialize in pouring?

Our proprietary process utilizes three rare aluminum alloys: AL850, AL852, and AL443. These alloys provide both greater machinability and lubricity when compared to the common AL6061.

What are the benefits of manganese bronze casting?

Manganese bronze is an alloy with a high load-carrying capacity, capable of operating at comparatively high speeds. While it is known to require lubrication, the alloy also contains excellent mechanical properties and high resistance to corrosion, often being utilized for bearings, bushings, and gears within a number of industries, including oil and gas, aviation, aerospace, and more. The alloy is composed of varying percentages of aluminum, copper, manganese, and iron.

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What are the benefits of tin bronze casting?
Tin bronze is noted for its strength and hardness, with a tensile strength of 44 KSI and a minimum hardness of 70 Bhn on the Brinell hardness scale. The alloy contains a low content of lead, increased ductility, and a large load-carrying capacity. Despite a relatively low resistance to friction, tin bronze is highly resistant to impact and wear. For these reasons, it is commonly used for gears, bearings, fillings, cylindrical linings, and is compatible with seawater.
What are the benefits of silicon bronze casting?
The silicon bronze alloy is made up of 96% copper and a 4% mixture of silicon and low-lead brass alloys, including iron, tin, manganese, and zinc. Silicon bronze has a clean surface finish and is known to have a high resistance to corrosion. For this reason, it commonly appears in the chemical and aerospace industries, as well as metal TIG welding processes.

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