Casting
the Bronze:The process of manufacturing bronze sculpture has changed very little in essence since it's earliest
days some more 3000 years ago in China
. In this section we explain the surprising procedures involved in manufacture, each of which requires a very high degree of hand making.
1. From original
sculpture model to rubber mould: usually the original model is made
in a variety of material including clay、wax and types of plasticize;
from the model a mould is taken using specific grades of silicon rubber
depending on the degree of strength required.
2. Remolding: Liquid wax is poured into the mould and allowed
to set hard. Once this is achieved, the wax model can be drawn from
the mould. Care has to be taken to ensure the wax is not broken. Where
the mould joins, a seam is created which has to be removed using a
knife or scalpel.
3. Ceramic Mix: Times ago the actual casting of bronze was
done in sand pits but this tried and trusted method has been replaced
by encasing the model in layers of liquid ceramic. When a sculpture
has been covered by layers of ceramic mix and is ready for bronze
casting. The wax rods seen attached to the model facilitate the flow
of bronze and help the air and gas to escape. Detailed knowledge is
required to know where to position the rods.
4. Removal of Wax and bronze dispensing: The wax inside the
mould now has to be heated and removed to allow a cavity to be formed
into which the liquid bronze can be poured. Bronze is an alloy of
copper and smaller quantities of tin. It is heated to 1300c and poured
into the handling vessel illustrated. At this stage the heat is intense
and two operatives are required to take the vessel to the moulds.
5. Casting the mould then mould filled: The moulds are placed
in a sand filled container to prevent the ceramic container injuring
the operatives in the unlikely event of a shattering. The vessel then
fills the moulds to the required depth. The liquid bronze can just
be seen in the moulds which will be left for 24 hours to cool. Patience
is required to prevent the process being hurried and the model damaged.
6. Breaking open ceramic mould and metal chasing: Once the
ceramic case is cool the operator can break it. The bronze inside
is extremely hard and not usually marked in this process. The bronze
sculpture once removed from the case requires chasing, the removal
of any seams, lines or blemishes. It takes time and skill to reinstate
the model to the sculptors original. A high speed drill and selection
of chasing tools can be seen on the worktable.
7. Patina and finished: The procedure finishes the bronze to
the required colour and is considered to be one of the most skillful
jobs in the foundry. The process of applying the appropriate acids
and subsequently burnishing them takes much training since the effects
can only be seen when the whole process is complete. Final waxing
of the model enhances the colour and produces the reflective sheen.
With care and skill many finishes and colours can be achieved.
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