Bronze is the most popular metal for cast metal sculptures; a cast bronze sculpture is often called simply "a bronze". It can be used for statues, singly or in groups, reliefs, and small statuettes and figurines, as well as bronze elements to be fitted to other objects such as furniture. It is often gilded to give gilt-bronze or ormolu.
Common bronze alloys have the unusual and desirable property of expanding slightly just before they set, thus filling the finest details of a mould. Then, as the bronze cools, it shrinks a little, making it easier to separate from the mould. [1] Their strength and ductility (lack of brittleness) is an advantage when figures in action poses are to be created, especially when compared to various ceramic or stone materials (such as marble sculpture). These qualities allow the creation of extended figures, as in Jeté, or figures that have small cross sections in their support, such as the equestrian statue of Richard the Lionheart. [2]
But the value of the bronze for uses other than making statues is disadvantageous to the preservation of sculptures; few large ancient bronzes have survived, as many were melted down to make weapons or ammunition in times of war or to create new sculptures commemorating the victors, while far more stone and ceramic works have come through the centuries, even if only in fragments. As recently as 2007 several life sized bronze sculptures by John Waddell were stolen, probably due to the value of the metal after the work has been melted. [3]
There are many different bronze alloys. Typically modern bronze is 88% copper and 12% tin. [4] Alpha bronze consists of the alpha solid solution of tin in copper. Alpha bronze alloys of 4–5% tin are used to make coins and a number of mechanical applications. Historical bronzes are highly variable in composition, as most metalworkers probably used whatever scrap was on hand; the metal of the 12th-century English Gloucester Candlestick is bronze containing a mixture of copper, zinc, tin, lead, nickel, iron, antimony, arsenic with an unusually large amount of silver – between 22.5% in the base and 5.76% in the pan below the candle. The proportions of this mixture may suggest that the candlestick was made from a hoard of old coins. The Benin Bronzes are really brass, and the Romanesque Baptismal font at St Bartholomew's Church, Liège is described as both bronze and brass.
In the Bronze Age, two forms of bronze were commonly used: "classic bronze", about 10% tin, was used in casting; and "mild bronze", about 6% tin, was hammered from ingots to make sheets. Bladed weapons were mostly cast from classic bronze, while helmets and armour were hammered from mild bronze. According to one definition, modern "statuary bronze" is 90% copper and 10% tin. [2]
The great civilizations of the old world worked in bronze for art, from the time of the introduction of the alloy for tools and edged weapons. Dancing Girl from Mohenjo-daro, belonging to the Indus Valley Civilisation and dating back to c. 2500 BCE, is perhaps the first known bronze statue. [5] Life-sized bronze statues in Ancient Greece have been found in good condition; one is the seawater-preserved bronze Victorious Youth that required painstaking efforts to bring it to its present state for museum display. Far more Roman bronze statues have survived.
The ancient Chinese knew both lost-wax casting and section mould casting, and during the Shang dynasty created large numbers of Chinese ritual bronzes, ritual vessels covered with complex decoration, which were buried in sets of up to 200 pieces in the tombs of royalty and the nobility. Over the long creative period of Egyptian dynastic art, small lost-wax bronze figurines were made in large numbers; several thousand of them have been conserved in museum collections.
The 7th-8th century Sri Lankan Sinhalese bronze statue of Buddhist Tara, now in the British Museum, is an excellent example of Sri Lankan bronze statues.
From the ninth through the thirteenth century the Chola dynasty in South India represented the pinnacle of bronze casting in India. [6]
Making bronzes is highly skilled work, and a number of distinct casting processes may be employed, including lost-wax casting (and its modern-day spin-off investment casting), sand casting and centrifugal casting. The term "bronze" is also applied to metal sculptures made by electrotyping (or galvanoplasty), although these sculptures are typically pure copper and their fabrication does not involve metal casting. [7]
In lost-wax or investment casting, the artist starts with a full-sized model of the sculpture, most often a non-drying oil-based clay such as Plasticine model for smaller sculptures or for sculptures to be developed over an extended period (water-based clays must be protected from drying), and water-based clay for larger sculptures or for sculptures for which it is desired to capture a gestural quality –one that transmits the motion of the sculptor in addition to that of the subject. A mould is made from the clay pattern, either as a piece mould from plaster, or using flexible gel or similar rubber-like materials stabilized by a plaster jacket of several pieces. Often a plaster master will be made from this mould for further refinement. Such a plaster is a means of preserving the artwork until a patron may be found to finance a bronze casting, either from the original moulds or from a new mould made from the refined plaster positive.
Once a production mould is obtained, a wax (hollow for larger sculptures) is then cast from the mould. For a hollow sculpture, a core is then cast into the void, and is retained in its proper location (after wax melting) by pins of the same metal used for casting. One or more wax sprues are added to conduct the molten metal into the sculptures - typically directing the liquid metal from a pouring cup to the bottom of the sculpture, which is then filled from the bottom up in order to avoid splashing and turbulence. Additional sprues may be directed upward at intermediate positions, and various vents may also be added where gases could be trapped. (Vents are not needed for ceramic shell casting, allowing the sprue to be simple and direct). The complete wax structure (and core, if previously added) is then invested in another kind of mould or shell, which is heated in a kiln until the wax runs out and all free moisture is removed. The investment is then soon filled with molten bronze. The removal of all wax and moisture prevents the liquid metal from being explosively ejected from the mould by steam and vapour.
Students of bronze casting will usually work in direct wax, where the model is made in wax, possibly formed over a core, or with a core cast in place, if the piece is to be hollow. If no mould is made and the casting process fails, the artwork will also be lost. After the metal has cooled, the external ceramic or clay is chipped away, revealing an image of the wax form, including core pins, sprues, vents, and risers. All of these are removed with a saw and tool marks are polished away, and interior core material is removed to reduce the likelihood of interior corrosion. Incomplete voids created by gas pockets or investment inclusions are then corrected by welding and carving. Small defects where sprues and vents were attached are filed or ground down and polished.
For a large sculpture, the artist will usually prepare small study models until the pose and proportions are determined. An intermediate-sized model is then constructed with all of the final details. For very large works, this may again be scaled to a larger intermediate. From the final scale model, measuring devices are used to determine the dimensions of an armature for the structural support of a full-size temporary piece, which is brought to rough form by wood, cardboard, plastic foam, and/or paper to approximately fill the volume while keeping the weight low. Finally, plaster, clay or other material is used to form the full-size model, from which a mould may be constructed. Alternatively, a large refractory core may be constructed, and the direct-wax method then applied for subsequent investment. Before modern welding techniques, large sculptures were generally cast in one piece with a single pour. Welding allows a large sculpture to be cast in pieces, then joined.
After final polishing, corrosive materials may be applied to form a patina, a process that allows some control over the colour and finish.
Another form of sculptural art that uses bronze is ormolu, a finely cast soft bronze that is gilded (coated with gold) to produce a matte gold finish. Ormolu was popularized in the 18th century in France and is found in such forms as wall sconces (wall-mounted candle holders), inkstands, clocks and garnitures. Ormolu wares can be identified by a clear ring when tapped, showing that they are made of bronze, not a cheaper alloy such as spelter or pewter.
Bronze is an alloy consisting primarily of copper, commonly with about 12–12.5% tin and often with the addition of other metals and sometimes non-metals, such as phosphorus, or metalloids, such as arsenic or silicon. These additions produce a range of alloys that may be harder than copper alone, or have other useful properties, such as strength, ductility, or machinability.
In metalworking and jewelry making, casting is a process in which a liquid metal is delivered into a mold that contains a negative impression of the intended shape. The metal is poured into the mold through a hollow channel called a sprue. The metal and mold are then cooled, and the metal part is extracted. Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods.
Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter, and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.
Lost-wax casting – also called investment casting, precision casting, or cire perdue – is the process by which a duplicate sculpture is cast from an original sculpture. Intricate works can be achieved by this method.
This page describe terms and jargon related to sculpture and sculpting.
Sand casting, also known as sand molded casting, is a metal casting process characterized by using sand—known as casting sand—as the mold material. The term "sand casting" can also refer to an object produced via the sand casting process. Sand castings are produced in specialized factories called foundries. In 2003, over 60% of all metal castings were produced via sand casting.
In relief printing, a flong is a temporary negative paper mould made from an impression in a forme of set type or other relief matter, such as printing blocks. A flong is an intermediate step used to cast a metal stereotype which can be used in letterpress printing on either flat-bed or rotary press. After the flong is made, the original type can be distributed or melted-down. A flong is part of the stereotype process.
Ceramic forming techniques are ways of forming ceramics, which are used to make everything from tableware such as teapots to engineering ceramics such as computer parts. Pottery techniques include the potter's wheel, slip casting and many others.
A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal into a mold, and removing the mold material after the metal has solidified as it cools. The most common metals processed are aluminum and cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed.
Electrotyping is a chemical method for forming metal parts that exactly reproduce a model. The method was invented by Moritz von Jacobi in Russia in 1838, and was immediately adopted for applications in printing and several other fields. As described in an 1890 treatise, electrotyping produces "an exact facsimile of any object having an irregular surface, whether it be an engraved steel- or copper-plate, a wood-cut, or a form of set-up type, to be used for printing; or a medal, medallion, statue, bust, or even a natural object, for art purposes."
Bellfounding is the casting and tuning of large bronze bells in a foundry for use such as in churches, clock towers and public buildings, either to signify the time or an event, or as a musical carillon or chime. Large bells are made by casting bell metal in moulds designed for their intended musical pitches. Further fine tuning is then performed using a lathe to shave metal from the bell to produce a distinctive bell tone by sounding the correct musical harmonics.
In printing, a stereotype, stereoplate or simply a stereo, is a solid plate of type metal, cast from a papier-mâché or plaster mould taken from the surface of a forme of type. The mould was known as a flong.
Investment casting is an industrial process based on lost-wax casting, one of the oldest known metal-forming techniques. The term "lost-wax casting" can also refer to modern investment casting processes.
In casting, a pattern is a replica of the object to be cast, used to form the sand mould cavity into which molten metal is poured during the casting process. Once the pattern has been used to form the sand mould cavity, the pattern is then removed, molten metal is then poured into the sand mould cavity to produce the casting. The pattern is non consumable and can be reused to produce further sand moulds almost indefinitely.
Glass casting is the process in which glass objects are cast by directing molten glass into a mould where it solidifies. The technique has been used since the 15th century BCE in both Ancient Egypt and Mesopotamia. Modern cast glass is formed by a variety of processes such as kiln casting or casting into sand, graphite or metal moulds.
Dhokra is non–ferrous metal casting using the lost-wax casting technique. This sort of metal casting has been used in India for over 4,000 years and is still used. One of the earliest known lost wax artefacts is the dancing girl of Mohenjo-daro. The product of dhokra artisans are in great demand in domestic and foreign markets because of primitive simplicity, enchanting folk motifs and forceful form. Dhokra horses, elephants, peacocks, owls, religious images, measuring bowls, and lamp caskets etc., are highly appreciated. The lost wax technique for casting of copper based alloys has also been found in China, Egypt, Malaysia, Nigeria, Central America, and other places.
Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting materials are usually metals or various time setting materials that cure after mixing two or more components together; examples are epoxy, concrete, plaster and clay. Casting is most often used for making complex shapes that would be otherwise difficult or uneconomical to make by other methods. Heavy equipment like machine tool beds, ships' propellers, etc. can be cast easily in the required size, rather than fabricating by joining several small pieces. Casting is a 7,000-year-old process. The oldest surviving casting is a copper frog from 3200 BC.
Nonferrous archaeometallurgy in the southern Levant is the archaeological study of non-iron-related metal technology in the region of the Southern Levant during the Chalcolithic period and Bronze Age from approximately 4500BC to 1000BC.
Art in bronze and brass dates from remote antiquity. These important metals are alloys, bronze composed of copper and tin and brass of copper and zinc.
Swamimalai Bronze Icons refers to bronze idols and statues manufactured in Swamimalai, Tamil Nadu. It has been recognized as a Geographical indication by the Government of India in 2008–09.
Some extremely important commissions were made in electrotypes, such as the "bronzes" that adorn the Opéra in Paris, and the 320 cm high statue of Prince Albert and four accompanying figures, erected behind the Albert Hall in London as a memorial to the Great Exhibition of 1851. The Prince Albert statue was electrotyped by Elkington & Company of Birmingham, England, in 1861 and has recently been restored.Note that the Memorial to the Great Exhibition was originally erected in the garden of the Royal Horticultural Society, and moved to its present location around 1890.