The casings for many stage lights are diecast in aluminum to reduce weight, minimize wall thickness and provide necessary heat sinks in advanced LED systems. Additionally, the diecasting process can produce net-shape parts that eliminate costs associated with secondary machining.
drum or providing structure to a piano, metalcasting is key to the creation of a variety of components that go unno- ticed in the inner workings of musical instruments.
I
Invented in 1711, the tuning fork was a signifi cant improvement in standardizing tune. Often cast in steel, the tuning fork creates a pure tone, one with most of its energy at a fundamental frequency. Though electronic tuners are replacing tuning forks in many applications, the U-shaped castings continue to be useful in timekeeping, medical testing and instrument calibration.
They may not be the most glamorous accessory in the music hall, but music stands serve a neces- sary function. Many antique stands feature elaborate cast iron designs. The majority of today’s models, though, are diecast aluminum or sand cast in various alloys.
Cymbals T e fi ne micro-
structural properties produced by the metalcasting process means cymbals are capable of being fi nely tuned and strong enough to put up with plenty of abuse. Starting with pancake-shaped cast blanks (80% copper, 20% tin and traces of silver) the cymbals are repeatedly heated and rolled, cupped and dipped in a saline solution to improve the cast metal’s malleability. As the cymbals are ham- mered and lathed, they are heated in a rotary hearth oven to just below their melting point after each step to keep the alloy from becoming brittle. Finally, before the metal castings
are sent to drummers everywhere, from the local high school bands to the New York Philharmonic, each cymbal is put through a thorough pitch analysis to ensure quality and acoustic resonance. Cymbals can be made via several
diff erent metalworking methods, but casting has been used the longest and remains a market leader.
Drums
Aluminum may not be the fi rst material that comes to mind when you think of drums, but it plays a crucial role in keep- ing a drum in tune. Diecast aluminum components connect the drumhead (the springy surface that is struck to produce sound) to the wood body. Most drums feature top and bottom rims that are connected by threaded hardware that can be tightened or loosened to change
Sept/Oct 2014 | METAL CASTING DESIGN & PURCHASING | 21
n addition to the roles met- alcasting plays around a symphony orchestra, it also is crucial to the production of the musicians’ beautiful sounds. Whether holding together a
Two aluminum rims connect the drum- head to its body.
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