CASTINGS: Copper-tin alloys

Specialists in bronze castings for industrial and cryogenic valves

Valfond is specialized in casting of copper-tin alloys (non-ferrous alloys).
Only ingots from leading national and European suppliers are used, accompanied by Certificates of Analysis 3.1.

Meticulous tests are performed on the incoming materials during Acceptance Phase. Especially, for the ingots, the composition and parameters of the elements are checked, in accordance with the EN1982 standard. The various incoming alloys are catalogued, stored and managed through a recognition system with an identification tag.

The main alloys used in Valfond are:
CB491K – CB499K – CB493K – CB480K – CB492K – CB482K

We also supply certified castings for CRYOGENIC valves suitable for low temperatures applications (-197°C) and subjected to high pressures (PN 50).

Foundry INSTALLATIONS

A complete control of the process
from the preventive analysis of the castings with dedicated simulation software, to the certified casting process.

Production capacity

Three in-line ovens of 10 quintals each realise a daily production capacity of 15t. Production is diversified according to requirements and weights (100 g – 50 kg).

Shell Moulding and Green sand

We carry out castings with a shell-moulding plant equipped with 450 x 300 mm brackets and we offer also green sand castings.

The organisation of the production area

The production process

Design

We define the best technical solution in agreement with the Customer.

Innovation takes shape on a daily basis in research and co-design activities, which are central to Valfond’s activities.
Our technical office intervenes right from the design phase of the item, supporting the Customer in choosing the most effective and efficient solutions.

Casting process

Raw materials are loaded into the melting furnace, where they are heated to melting temperature. Careful and scrupulous temperature monitoring is performed by specific tools. A continuous detection of the temperature of liquid metal ensures that a high-precision, and high-quality casting are obtained.

Forming process


Pattern making, shell and core realization.

The shell reproduces in negative the geometry of the casting item to be made and into which the molten metal is poured.
Customer’s patterns are handled with experience, subjected to routine maintenance after each use and carefully stored in a dedicated area.

Pouring process


Filling of the shells, cooling and solidification and extraction of the casting parts from the shell.

The molten bronze is transferred into shells placed on a casting carousel. The transfer phase of the liquid bronze from the oven into the shells takes place with the assistance of ladles, which are moved by electrically controlled hoists. After the time required for the solidification and cooling of the casting obtained has elapsed, the casting is removed from the shell by dethatching, separating it from the sand.

Finishing process


Subsequent processing of the paw parts.

Once extracted from the shell, the casting is sent to finishing operations (removal of the casting device, surface cleaning, removal of any burrs). During the deburring or shearing stages, the casting is separated from the metal parts constituting the casting system (casting channels and couplings). This step is followed by shot-blasting operations to remove sand residues remaining attached to the casting, and deburring and grinding to remove any metal burrs from the casting.

Quality controls conclude the casting production cycle, before sending the items to the Customer.