Rub-a-Dub Castings
Castings often are used in light fi xtures, particularly in those that feature intricate design details. Fixtures are most commonly cast in bronze or aluminum.
Sink and bathtub faucets come in a variety of de- signs and often require thin walls (from 0.12 to 0.6 in.) and intricate cores for internal passageways. Whether a component is cast or stamped depends on the targeted audience. According to Kohler Co., Kohler, Wis., the company casts fi x- tures that are geared toward buyers of high-end, quality items because of the durability and aesthetic appeal of a cast product. Faucets requiring mass production may be diecast in zinc and given a decorative fi nish.
Most plumbing fi xtures, including the underbody for bathroom sinks, are cast in a copper-base al- loy. In the underbody casting shown (inset), three components were designed into a single casting and made via per- manent mold, saving tool- ing, manufacturing and inventory costs for the customer.
44 MetAl CAsting Design AnD PurChAsing
Cast iron tubs and sinks, which are produced in one piece, are durable enough to last the lifetime of a home. After they are cast, the tubs and sinks are coated with enamel for a glossy fi nish. Variations in wall thicknesses in the castings are exaggerated in the fi nal product, so tolerances are narrow. Additionally, the surface of the cast iron must be defect free in order for the enamel coating to provide a smooth appearance.
July/August 2010
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