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.
Lost wax method 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 qualityone 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. File:Lost Wax-Model of apple in wax.jpg|A model of an apple in wax. This is the first step of the
lost-wax casting process in
bronze File:Born bronze - Bronze casts.jpg|Liquid bronze at 1200 °C is poured into the dried and empty casting mould File:Lost Wax-Apple in bronze.jpg|The sculpture of the apple, just extracted from its mould. Below is the funnel through which the bronze was poured (upside down). This is the last step of the
lost-wax casting process Creating large sculptures with a patinated bronze statue. 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.
Finishing 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. ==Gallery==