Aluminum Bronze Casting, Aluminum Bronze Casting Foundry, AB2 Casting in India
We are one of the leading manufacturers and exporters of Aluminum Bronze Castings from India. We have been supplying C95500, CDA 955, AB1, AB2 Aluminum Bronze components to the world market for many decades. Our foundry specializes in precision-engineered non-ferrous castings produced through Green Sand Casting, Permanent Mold Casting, Shell Molding, and custom tooling designed in-house. With more than 30 years of global manufacturing experience, strong engineering capability, and the ability to customize castings for high-strength industrial applications, we supply OEMs across USA, UK, Europe, Middle East, Australia, and Canada. This page provides a complete technical overview covering grades, processes, tolerances, dimensional guidelines, finishes, industries served, and performance metrics—allowing procurement teams to make informed decisions with confidence.
Overview – Aluminum Bronze Casting
Aluminum Bronze Casting refers to the production of high-strength Bronze alloy components containing 8–12% Aluminum, often with controlled additions of Iron, Nickel, Manganese, and Silicon to enhance corrosion resistance and mechanical properties. These alloys, such as C95500, C95400, CDA 955, AB1, AB2, are widely recognized for their exceptional strength-to-weight ratio, seawater resistance, cavitation resistance, and excellent wear behaviour. Aluminum Bronze Castings are preferred in marine components, power transmission parts, electrical connectors, pump housings, valve bodies, earthing clamps, hydraulic fittings, industrial couplers, heavy-duty clamps, and defense-grade parts. Our foundry uses state-of-the-art induction furnaces, shell moulding lines, spectrometers (Fischer / Hitachi), and CNC machining centers to ensure dimensional accuracy and metallurgical consistency. Castings are supplied with full traceability to ASTM, BS, DIN, JIS, and IS international standards, along with chemical and mechanical test certificates for every batch.
Aluminum Bronze Casting
Aluminum Bronze Casting is engineered for applications requiring high tensile strength, resistance to shock loading, and long-term exposure to corrosive media. The alloy forms a protective Aluminum Oxide film on its surface, providing natural resistance to seawater, acids, industrial chemicals, and hydrogen sulfide. Our Aluminum Bronze Castings undergo controlled solidification, directional gating, and optimized riser design to eliminate porosity and shrinkage. Every casting is produced with metallurgical accuracy through spectrochemical analysis, microstructure verification, and hardness testing. Post-casting, components can be heat treated (solution annealing or stress relieving) to achieve required mechanical properties. Aluminum Bronze Castings are commonly used in heavy machinery, marine deck hardware, offshore installations, earthmoving equipment, locomotive parts, electrical connectors, and transformer fittings.
Aluminum Bronze Casting Foundry
As a specialized Aluminum Bronze Casting Foundry in India, we offer end-to-end solutions from tooling design, alloy selection, pattern development, sand simulation, shelf-life controlled binders, and full CNC machining to final inspection. Our foundry is equipped with Induction Furnaces (100–500 kg), Green Sand plants, No-Bake Moulding systems, Shell Moulding lines, and Permanent Mold Casting facilities. Advanced melting practices ensure low gas pick-up and uniform grain size. We follow stringent process control using calibrated instruments, pyrometers, coating thickness gauges, and 3-axis CMM inspection. With the ability to handle castings from 50 grams to 120 kilograms, we serve industries that demand reliability and global export-level quality. Our engineering team also provides drawing optimization, weight reduction suggestions, and manufacturability improvements.
CDA 955 Aluminum Bronze Casting
CDA 955 (also known as C95500 Nickel Aluminum Bronze) is a premium-grade alloy offering superior mechanical strength and excellent corrosion resistance, especially in marine and aerospace environments. This alloy contains approximately 10–12% Aluminum and 4–5% Nickel, significantly enhancing wear performance and thermal stability. Our CDA 955 Castings are preferred for structural components requiring high load-bearing capacity, such as marine propeller hubs, valve seats, pump impellers, heavy-duty bushings, subsea hardware, and aerospace-grade fixtures. We ensure each CDA 955 casting undergoes precise heat treatment to stabilize the microstructure and eliminate retained phases. These castings are widely used in offshore platforms, desalination plants, mining machinery, and industrial hydraulic systems.
C95500 Aluminum Bronze Casting
C95500 (ASTM B148) Aluminum Bronze is a high-strength alloy known for its excellent resistance to stress corrosion cracking, oxidation, and galling. With controlled additions of Nickel and Iron, C95500 Castings achieve tensile strength up to 800–850 MPa and exceptional fatigue resistance. We manufacture C95500 castings for bushings, bearings, valve bodies, heavy-duty clamps, hydraulic valve parts, and load-bearing connectors used across marine, industrial, and defense sectors. Our C95500 castings undergo strict metallurgical quality control using spectrometer-based chemical verification and microstructure validation. This alloy is recommended for parts exposed to seawater, brine, high-temperature steam, and pressure environments.
Aluminum Bronze Sand Casting
Aluminum Bronze Sand Casting is the most versatile and economical process for producing complex geometries. We utilize Green Sand, No-Bake Sand, and Shell Sand depending on dimensional accuracy and casting size. Our sand casting process includes precise pattern development, gating optimization through simulation software, controlled green sand properties (GCS, moisture, permeability), and strict moulding process control. Sand Cast Aluminum Bronze components are suitable for medium-to-heavy parts such as flanges, couplings, clamps, housings, support brackets, and transformer hardware. After casting, components undergo shot blasting, fettling, stress-relieving, and precision CNC machining to ensure tolerance consistency. Sand cast parts can achieve dimensional tolerances of ±0.3 mm to ±0.8 mm depending on size.
Aluminum Bronze Hotline Clamp Casting
We manufacture high-strength Aluminum Bronze Hotline Clamp Castings used in power transmission and distribution systems. These clamps require precise conductivity, mechanical reliability, and consistent alloy composition. Our Hotline Clamps are produced using C95400, C95500, and AB2 Bronze depending on customer specifications. The castings are optimized for grain refinement, uniform solidification, and high mechanical integrity to withstand thermal cycling and line vibrations. Typical applications include dead-end clamps, hotline connectors, tension clamps, and power line accessories. All castings are machined to achieve burr-free surfaces and accurate fitment.
Aluminum Bronze Vise Connector Casting
Aluminum Bronze Vise Connector Castings require high clamping force tolerance, dimensional precision, and resistance to galling. We produce Vise Connectors using C95500 and AB2 Aluminum Bronze alloys due to their exceptional tensile strength and durability. Each connector undergoes controlled sand moulding, robust gating design, and NDT inspection (dye penetrant test or radiography as required). These castings are widely used in electrical transmission networks, mechanical locking systems, industrial tightening devices, and rail infrastructure. The final machined surfaces provide smooth gripping without deformation even under high torque loads.
AB1 Bronze Casting
AB1 Aluminum Bronze (BS EN 1982 AB1) contains approximately 9–12% Aluminum and exhibits excellent corrosion and abrasion resistance. It is widely used for general engineering castings such as valve components, pump housings, bearings, couplers, and heavy-duty hardware. Our AB1 Bronze Castings are produced under controlled melting conditions, with full spectrometer-based chemical analysis, ensuring uniformity and mechanical consistency. AB1 is suitable for moderate load-bearing parts and industrial fittings requiring cost-effective performance.
AB2 Bronze Casting
AB2 Aluminum Bronze offers higher strength and hardness compared to AB1 due to additional Iron and Nickel. AB2 castings are ideal for marine hardware, high-load mechanisms, bushings, industrial clamps, and corrosion-resistant mechanical parts. We manufacture AB2 Bronze Castings using calibrated furnaces, sand testing equipment, and precision pattern tooling. These castings provide long service life under high temperature, abrasive, and corrosive conditions. Each batch is validated with tensile, hardness, and microstructure testing for end-use assurance.
Green Sand Casting of Aluminum Bronze
Green Sand Casting is preferred for producing economical and repeatable Aluminum Bronze parts. Our process includes moisture-controlled sand, active clay binder systems, proper ramming, and mould hardness testing to avoid defects. Green Sand is suitable for low-to-medium complexity components, ensuring fast turnaround and cost-effective production. We use hand moulding, semi-automatic, and fully automatic moulding lines depending on casting volume. Green Sand produces excellent surface finish, good dimensional stability, and robust characteristics for heavy engineering use.
Aluminum Bronze Permanent Mold Casting
Permanent Mold Casting (Gravity Die Casting) of Aluminum Bronze provides superior surface finish, directional solidification, and enhanced strength. This process uses reusable metal dies that allow faster cooling and uniform grain structure. We manufacture Permanent Mold Aluminum Bronze parts for aerospace, electrical systems, defense applications, and marine equipment. The method ensures dimensional accuracy, reduced porosity, and fine metallurgical properties ideal for premium-grade components.
International Material Grade Equivalents – Table
| Alloy | USA (ASTM) | Europe (EN) | UK (BS) | India (IS) | Germany (DIN) | Japan (JIS) | China (GB/T) |
|---|---|---|---|---|---|---|---|
| C95400 | ASTM B148 | EN CC331G | BS 1400 AB1 | IS 305 | DIN CuAl10Fe3 | JIS ACu10 | GB YAl10Fe3 |
| C95500 | ASTM B148 | EN CC333G | BS 1400 AB2 | IS 305 | DIN CuAl10Ni5Fe4 | JIS AB2 | GB YAl10Ni5Fe4 |
| CDA 955 | ASTM B505 | EN 1982 NA | BS AB2 | IS 305 | CuAl12Ni | JIS 955 | GB CuAl12Ni |
Mechanical Properties – Aluminum Bronze (Typical)
| Property | C95400 | C95500 | CDA 955 |
|---|---|---|---|
| Tensile Strength | 620–690 MPa | 780–850 MPa | 650–760 MPa |
| Yield Strength | 300–350 MPa | 400–450 MPa | 350–420 MPa |
| Hardness | 170–190 HB | 200–230 HB | 180–210 HB |
| Elongation | 12–18% | 10–15% | 10–14% |
Process Flow Diagram (ASCII Line Drawing)
Typical Dimensions Table
| Component | Length (mm) | Width (mm) | Height (mm) | Weight (kg) |
|---|---|---|---|---|
| Clamp Body | 50–200 | 20–90 | 15–70 | 0.25–4.0 |
| Vise Connector | 40–150 | 15–75 | 10–60 | 0.2–2.5 |
| Brackets | 60–250 | 20–120 | 15–80 | 0.5–8.0 |
| Bushings | OD 25–150 | ID 10–120 | Length 20–150 | 0.05–6.0 |
Industries Using Aluminum Bronze Castings
Marine, Offshore, Aerospace, Railway, Power Transmission, Electrical Distribution, Earthmoving, Agricultural Machinery, Automotive, Mining, Hydraulic Equipment, Defense Hardware.
Surface Treatments / Plating Finishes
Shot Blasting
Sand Blasting
Tumbling
Electro-Polishing
Passivation
Chromate Coating
Anodic Film Treatment (for corrosion resistance)
Tolerances
Sand Casting: ±0.3 to ±0.8 mm
Permanent Mold: ±0.15 to ±0.5 mm
Machined Surfaces: ±0.05 to ±0.10 mm
Turnaround Time
4–6 weeks depending on pattern development and order volume.
Performance Metrics
High load-bearing capability
Excellent corrosion resistance
Cavitation resistance
Superior fatigue strength
High electrical continuity (for clamps & connectors)
Why Choose Us? (USPs)
30+ years global manufacturing experience
Strong engineering capability
Ability to redesign drawings for weight optimization
Customized packaging with customer logos
Timely communication & technical support
Export-quality inspection & documentation
Flexible batch sizes from prototypes to bulk
Customer Testimonials
John R. (USA)
“Your Aluminum Bronze Castings are the most consistent we’ve received. Zero rejection in the last six shipments. Communication and documentation are top-class.”
Mark Thompson (UK)
“The machining accuracy and finish quality exceeded our expectations. Very responsive team and excellent packaging for export.”
Glossary of Terms
Gating System: Flow channel design used in Aluminum Bronze Casting.
Riser: Reservoir that compensates for shrinkage during solidification.
C95500: High-strength Nickel Aluminum Bronze alloy.
Spectrometer Report: Chemical composition certification of Bronze alloys.
Green Sand: Moist sand used for economical Bronze casting.
Permanent Mold: Reusable die used for precise Bronze casting.
Aluminum Bronze – A family of copper-based alloys containing 5-11% aluminum, offering excellent corrosion resistance, high strength, and good castability.
Pattern – A replica of the final part used to create the mold cavity, typically made from wood, metal, or plastic.
Core – A preformed sand shape placed inside the mold to create internal cavities or hollow sections in the casting.
Sprue – The vertical channel through which molten metal is poured into the mold.
Riser – A reservoir that supplies additional molten metal to the casting as it solidifies and shrinks, preventing defects.
Gating System – The network of channels (sprue, runner, gates) that directs molten metal from the pouring basin into the mold cavity.
Sand Casting – A casting process using sand molds, commonly used for aluminum bronze due to its versatility and cost-effectiveness.
Investment Casting – A precision casting method using a wax pattern and ceramic shell mold, ideal for complex aluminum bronze parts.
Degassing – The process of removing dissolved gases from molten metal to prevent porosity defects.
Pouring Temperature – The temperature at which molten aluminum bronze is poured into the mold, typically 1100-1200°C depending on alloy composition.
Solidification – The process of molten metal cooling and transforming into solid state within the mold.
Shrinkage – The volumetric reduction that occurs as aluminum bronze cools from liquid to solid state, requiring compensation through risers.
Porosity – Gas or shrinkage voids within the casting that can weaken mechanical properties.
Hot Tear – A crack formed during solidification due to thermal stresses and restrained contraction.
Fettling – The finishing process of removing gates, risers, flash, and surface imperfections from the casting.
Related parts:
Aluminum Bronze Manufacturer, C95400 Casting Supplier, AB2 Bronze Exporter India, Aluminum Bronze Electrical Connectors, Nickel Aluminum Bronze Casting, Marine Bronze Hardware, High Strength Bronze Castings.
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