Copper Based Castings

Aero Metals is an experienced investment casting foundry with experience manufacturing copper-based castings for industrial and high-performance applications. Our team works with a wide range of copper alloys to cast near-net-shape components to tight tolerances that benefit from the alloy’s strength, conductivity, and corrosion resistance. Backed by in-house engineering expertise and proven casting processes, Aero Metals supports the production of complex copper alloy components built to meet precise performance and quality requirements.

Request a quote or contact Aero Metals for your copper-based casting needs today.

Copper Alloy Investment Castings for Complex, High-Performance Components

Copper alloys are widely used across industrial applications because they offer a unique balance of conductivity, strength, corrosion resistance, and manufacturability. By alloying copper with elements such as zinc, tin, aluminum, nickel, or beryllium, engineers can tailor material properties to meet specific mechanical, environmental, and performance requirements. Copper alloy investment casting advantages include:

• Excellent electrical and thermal conductivity
• High strength and fatigue resistance
• Superior corrosion resistance
• Excellent wear and galling resistance
• Non-sparking and non-magnetic
• Good machinability and castability
• Thermal stability and dimensional consistency

Aero Metals can work with the composition of copper-based alloys to meet the exact performance requirements for any application.

Copper-Based Alloys We Cast

Copper-based alloys are produced by combining copper with carefully selected alloying elements to enhance specific performance characteristics while retaining copper’s inherent thermal and electrical advantages. These alloy families allow engineers to balance strength, corrosion resistance, wear performance, and conductivity based on operating conditions and service requirements.

Aero Metals works with a wide range of copper alloy families to support demanding industrial applications, including:

• Brass castings – Used where good corrosion resistance, machinability, and electrical conductivity are required
• Bronze castings – Selected for applications requiring strength, wear resistance, and durability in harsh environments
• Beryllium copper castings – Ideal for high-strength, non-sparking, and high-conductivity components in critical applications
• Silicon copper castings – Chosen for strength, corrosion resistance, and improved environmental compliance

Within these families, we regularly cast aluminum bronze, silicon copper, and manganese bronze grades used in high-strength, wear-resistant, and corrosion-prone environments, with additional alloys available to meet application-specific performance criteria.

Copper Castings for Industrial Applications

Copper and copper-based alloy parts are relied upon across many industries because of their unique combination of conductivity, strength, corrosion resistance, and durability. Examples include:

• Aerospace: electrical connectors, avionic components, EMI/RFI shielding, thermal management
• Electronics: power connectors, terminals, bus bars, grounding components, switch contacts, relays
• Oil & Gas: non-sparking tools & components, valve bodies, fittings, seals, instrumentation
• Marine: propeller components, seawater valves & fittings, pump housings & bearings
• Industrial Machinery: bearings, bushings, gears, wear plates, sliding components, hydraulic & pneumatic parts
• Medical: diagnostic equipment components, precision springs & electrical contacts, instrument housings

Precision Casting Capabilities for Copper Alloys

Aero Metals is your premier source for copper alloy investment castings. Our investment castings are manufactured to tight tolerances that meet your project specifications. Our precision casting methods are backed by standards and certifications that ensure superior results.

Tight Tolerances & Precision Standards

• ISO 9001:2015 Certification
• In-house tool & die shop
• Extensive experience with complex geometries & hard-to-manufacture parts
• Consistent production repeatability supported by detailed inspection

Copper-Based Casting Engineering Support

Our engineering team collaborates closely with your product engineers to refine part designs for improved manufacturability and production efficiency. While we may not oversee every step of your product’s development, our casting expertise allows us to identify and resolve potential design challenges early in the process. These optimizations can minimize or eliminate secondary machining, reduce material usage, and ultimately lower overall production costs.

High-Volume Production Capabilities

With a 175,000-square-foot production facility, Aero Metals can provide high-volume manufacturing to ensure your production needs are always met. Our ultra-efficient workflows enable us to deliver high-volume production runs while maintaining reliable lead times.

Full-Service Copper Foundry in Indiana

Located in La Porte, Indiana, Aero Metals is the Midwest’s most trusted copper-based castings provider, offering in-house tooling, engineering, and much more.

• Contact us for copper alloy castings
• Request a quote for direct pricing information today