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47-764: The Thames Ditton Foundry was a foundry in Thames Ditton , Surrey , which operated from 1874 to 1939 and which under various owners produced numerous major statues and monuments as one of the United Kingdom 's leading firms of bronze founders. Located in Summer Road in Thames Ditton , just outside the Greater London area, the Thames Ditton Foundry is believed to have been built on the site of an historic "melting house" beside

94-445: A hollow cavity of the desired shape, and then allowing it to cool and solidify. The solidified part is also known as a casting, which is ejected or broken out of the mold to complete the process. Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods. Melting is performed in a furnace . Virgin material, external scrap, internal scrap, and alloying elements are used to charge

141-500: A material. Heat treatment techniques include annealing , case-hardening , precipitation strengthening , tempering , and quenching . Although the term "heat treatment" applies only to processes where the heating and cooling are done for the specific purpose of altering properties intentionally, heating and cooling often occur incidentally during other manufacturing processes such as hot forming or welding. After degating and heat treating, sand or other molding media may remain adhered to

188-430: A mold yields leftover metal — including heads, risers, and sprue (sometimes collectively called sprue) — that can exceed 50% of the metal required to pour a full mold. Since this metal must be remelted as salvage, the yield of a particular gating configuration becomes an important economic consideration when designing various gating schemes, to minimize the cost of excess sprue, and thus overall melting costs. Heat treating

235-424: A single piece or solid pattern. More complex designs are made in two parts, called split patterns. A split pattern has a top or upper section, called a cope, and a bottom or lower section called a drag. Both solid and split patterns can have cores inserted to complete the final part shape. Cores are used to create hollow areas in the mold that would otherwise be impossible to achieve. Where the cope and drag separates

282-426: A steel foundry will use an EAF or induction furnace. Bronze or brass foundries use crucible furnaces or induction furnaces. Most aluminium foundries use either electric resistance or gas heated crucible furnaces or reverberatory furnaces. Degassing is a process that may be required to reduce the amount of hydrogen present in a batch of molten metal. Gases can form in metal castings in one of two ways: Hydrogen

329-401: Is a common contaminant for most cast metals. It forms as a result of material reactions or from water vapor or machine lubricants. If the hydrogen concentration in the melt is too high, the resulting casting will be porous; the hydrogen will exit the molten solution, leaving minuscule air pockets, as the metal cools and solidifies. Porosity often seriously deteriorates the mechanical properties of

376-416: Is a group of industrial and metalworking processes used to alter the physical, and sometimes chemical, properties of a material. The most common application is metallurgical. Heat treatments are also used in the manufacture of many other materials, such as glass. Heat treatment involves the use of heating or chilling, normally to extreme temperatures, to achieve a desired result such as hardening or softening of

423-463: Is called the parting line . When making a pattern it is best to taper the edges so that the pattern can be removed without breaking the mold. This is called draft . The opposite of draft is an undercut where there is part of the pattern under the mold material, making it impossible to remove the pattern without damaging the mold. The pattern is made of wax, wood, plastic, or metal. The molds are constructed by several different processes dependent upon

470-567: Is common to paint castings to prevent corrosion and improve visual appeal. Some foundries assemble castings into complete machines or sub-assemblies. Other foundries weld multiple castings or wrought metals together to form a finished product. More and more, finishing processes are being performed by robotic machines, which eliminate the need for a human to physically grind or break parting lines, gating material, or feeders. Machines can reduce risk of injury to workers and lower costs for consumables — while also increasing productivity. They also limit

517-546: Is dependent on the alloy system quantities produced. For ferrous materials EAFs, cupolas, and induction furnaces are commonly used. Reverberatory and crucible furnaces are common for producing aluminium, bronze, and brass castings. Furnace design is a complex process, and the design can be optimized based on multiple factors. Furnaces in foundries can be any size, ranging from small ones used to melt precious metals to furnaces weighing several tons, designed to melt hundreds of pounds of scrap at one time. They are designed according to

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564-513: Is happening inside the mold or die during the casting process. George Anderson Lawson George Anderson Lawson ( Edinburgh 1832 – 23 September 1904) was a British Victorian era sculptor who was associated with the New Sculpture movement. He was born at Edinburgh in 1832, the son of David Lawson and Anne Campbell. He was educated at George Heriot's Hospital . He trained under Alexander Handyside Ritchie , and in

611-541: Is then removed from its mold. Where the mold is sand based, this can be done by shaking or tumbling. This frees the casting from the sand, which is still attached to the metal runners and gates — which are the channels through which the molten metal traveled to reach the component itself. Degating is the removal of the heads, runners, gates, and risers from the casting. Runners, gates, and risers may be removed using cutting torches , bandsaws , or ceramic cutoff blades. For some metal types, and with some gating system designs,

658-650: The Earl of Mayo for Calcutta (1875), Matthew Noble 's Oliver Cromwell in Manchester (1875) and his Robert Peel in Parliament Square (1876), Thomas Brock 's William Rathbone in Liverpool , George E. Ewing's Robert Burns (1876), Frederic Leighton 's An Athlete wrestling with a Python (1877), John Mossman 's David Livingstone (1877), Thomas Woolner 's John Stuart Mill (1877) on

705-888: The Victoria Embankment and Captain James Cook in Sydney , Australia (1878), Richard Belt's Lord Byron at Hyde Park (1880), Thomas Brock's Robert Raikes in the Victoria Embankment Gardens (1880) and Daniel O’Connell in Dublin (1881), William Hamo Thornycroft 's statue of General Gordon and related reliefs in the Victoria Embankment Gardens (1888) and his John Bright in Rochdale (1891). Other works by

752-873: The Wellington Arch in Hyde Park Corner (1910–11), one of the largest bronzes ever cast in Britain. Bronzes cast for Bertram Mackennal include statues in England and Australia such as the memorial statue of Edward VII in Adelaide (1920), the equestrian memorial of Edward VII in Melbourne (1920), the recumbent tomb effigy of the Duke of Norfolk in Arundel Castle (1922), various figures for

799-749: The statue of Emmeline Pankhurst in the Victoria Tower Gardens (1930), and for Alfred Gilbert the Queen Alexandra Memorial at Marlborough House (1930–1932). The Horse Memorial to the horses who died in the Boer Wars, is placed at the corner of Rink Street and Cape Road in Port Elizabeth South Africa. 51°23′36″N 0°20′00″W  /  51.3932°N 0.3332°W  / 51.3932; -0.3332 Foundry Foundries are one of

846-864: The King's Liverpool Regiment in Liverpool (1905), the figural group on the RAMC Memorial in Aldershot (1905), the equestrian statue of King Edward VII in Liverpool (1916) and the statue of General F. S. Maude in front of the British Residency in Baghdad (1922). For Adrian Jones Burton cast the equestrian statue of the Duke of Cambridge in Whitehall (1909) and the forty-ton Quadriga on

893-463: The River Thames. Its owners were: Cox & Sons (1874–80), Drew & Co. (1880–82), Moore & Co. (1882–97), Hollinshead & Burton (1897–1902) and A. B. Burton (1902–39). The foundry was established in Summer Road, Thames Ditton, in 1874 by Cox & Sons, a large firm of ecclesiastical furnishing suppliers, to cast ornaments and statues in bronze. A hand-operated gantry crane, which moved

940-645: The Shakespeare Memorial in Sydney (1924). For Thomas Brock Burton cast, among other works, two subsidiary groups for the Victoria Memorial facing Buckingham Palace (1916). For Cecil Brown he cast the Imperial Camel Corps Memorial (1920–21) in the Victoria Embankment Gardens and for John Tweed his statue of Lord Kitchener (1926) on Horse Guards Parade . For Arthur George Walker and Peter Hills he cast

987-679: The Victoria Embankment Gardens (1888), Thomas Woolner 's Bishop Dr James Fraser in Albert Square , Manchester (1888), George Anderson Lawson 's Robert Burns in Ayr (1891), Albert Toft 's Henry Richard in Tregaron (1893) and Frederick William Pomeroy 's statue of Queen Victoria in Chester Castle (1903). From 1902 to 1933 the Thames Ditton Foundry came under the sole ownership of Arthur Bryan Burton (1860 – 25 July 1933),

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1034-572: The amount of material being removed. These steps are done prior to any final machining. After grinding, any surfaces that require tight dimensional control are machined. Many castings are machined in CNC milling centers. The reason for this is that these processes have better dimensional capability and repeatability than many casting processes. However, it is not uncommon today for castings to be used without machining. A few foundries provide other services before shipping cast products to their customers. It

1081-477: The business was continued under his name by his son-in-law, Louis Tricker. In 1939 at the start of World War II Tricker closed the foundry and sold the premises rather than see it used for manufacturing munitions. It was after used by London Metal Warehouses for making industrial castings and then by Metal Centres Ltd as a metal warehouse until 1971/2 when it was sold to the District Council. The foundry

1128-436: The casting surface. Numerous materials may be used to clean cast surfaces, including steel, iron, other metal alloys, aluminium oxides, glass beads, walnut shells, baking powder, and many others. The blasting media is selected to develop the color and reflectance of the cast surface. Terms used to describe this process include cleaning, bead blasting, and sand blasting . Shot peening may be used to further work-harden and finish

1175-423: The casting. To remove any mold remnants, the surface is cleaned using a blasting process. This means a granular media will be propelled against the surface of the casting to mechanically knock away the adhering sand. The media may be blown with compressed air, or may be hurled using a shot wheel. The cleaning media strikes the casting surface at high velocity to dislodge the mold remnants (for example, sand, slag) from

1222-415: The daughter of the foundry’s then owner, James John Moore. Button's daughter, also named Florence, married Louis Richard Tricker (1884–1963) in 1913. A younger daughter, Dorothy "Dolly" Frances Victoria Burton (1893–1908) died aged 14. Following the death of his partner Arthur John Hollinshead in 1902, Burton became the sole owner of the Thames Ditton Foundry. He served as a councillor on Surbiton Council and

1269-778: The end of William Brown Street . He also created the relief sculpture depicting Wellington's major victory at Waterloo. The monument was completed "towards the end of 1865 when George Lawson's relief panel of the final battle at Waterloo was fixed in place on the pedestal". He moved to London in 1866. He later created the memorial to Robert Burns in Ayr , inaugurated in 1892. Other versions were circulated to Dublin, Melbourne, Montreal, Winnipeg, Halifax and elsewhere. Other memorials include those to James Arthur ( Glasgow ), Joseph Pease ( Darlington ), John Vaughan ( Middlesbrough ) and John Biggs ( Leicester ). In New Zealand, he commemorated William Sefton Moorhouse in Christchurch. He

1316-491: The entire casting manufacturing route. Casting process simulation was initially developed at universities starting from the early ' 70s , mainly in Europe and in the U.S. , and is regarded as the most important innovation in casting technology over the last 50 years. Since the late ' 80s , commercial programs (such as PoligonSoft, AutoCAST and Magma) are available which make it possible for foundries to gain new insight into what

1363-682: The entire foundry floor to facilitate all major lifting work, was an integral part of the building constructed for this work. When the factory was demolished in 1976 this crane was preserved by the Surrey Archaeological Society . The foundry was a leader in its field and produced fine bronze statues which it exported worldwide, including Matthew Noble 's statue of the Earl of Derby in Parliament Square , Westminster (1874), Thomas Thornycroft 's equestrian statue of

1410-433: The facility. The process includes melting the charge, refining the melt, adjusting the melt chemistry and tapping into a transport vessel. Refining is done to remove harmful gases and elements from the molten metal to avoid casting defects. Material is added during the melting process to bring the final chemistry within a specific range specified by industry and/or internal standards. Certain fluxes may be used to separate

1457-622: The foundry include Joseph Edgar Boehm 's statues of Lord Lawrence in Waterloo Place (1882), Francis Drake in Tavistock (1882–83), William Tyndale in the Victoria Embankment Gardens (1884), the Duke of Wellington in Hyde Park Corner (1884–1888), Queen Victoria in Sydney (1885–1888), and the equestrian Prince Albert in Windsor Great Park (1890), among others. They cast Thomas Brock ’s Sir Bartle Frere in

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1504-401: The furnace must be designed for temperatures over 1,600 °C (2,910 °F). The fuel used to reach these high temperatures can be electricity (as employed in electric arc furnaces ) or coke . The majority of foundries specialize in a particular metal and have furnaces dedicated to these metals. For example, an iron foundry (for cast iron) may use a cupola , induction furnace, or EAF, while

1551-505: The furnace. Virgin material refers to commercially pure forms of the primary metal used to form a particular alloy . Alloying elements are either pure forms of an alloying element, like electrolytic nickel , or alloys of limited composition, such as ferroalloys or master alloys. External scrap is material from other forming processes such as punching , forging , or machining . Internal scrap consists of gates , risers , defective castings, and other extraneous metal oddments produced within

1598-403: The largest contributors to the manufacturing recycling movement, melting and recasting millions of tons of scrap metal every year to create new durable goods. Moreover, many foundries use sand in their molding process. These foundries often use, recondition, and reuse sand, which is another form of recycling. In metalworking , casting involves pouring liquid metal into a mold , which contains

1645-498: The metal from slag and/or dross and degassers are used to remove dissolved gas from metals that readily dissolve in gasses. During the tap, final chemistry adjustments are made. Several specialised furnaces are used to heat the metal. Furnaces are refractory-lined vessels that contain the material to be melted and provide the energy to melt it. Modern furnace types include electric arc furnaces (EAF), induction furnaces , cupolas , reverberatory , and crucible furnaces. Furnace choice

1692-430: The metal. An efficient way of removing hydrogen from the melt is to bubble a dry, insoluble gas through the melt by purging or agitation. When the bubbles go up in the melt, they catch the dissolved hydrogen and bring it to the surface. Chlorine, nitrogen, helium and argon are often used to degas non-ferrous metals. Carbon monoxide is typically used for iron and steel. There are various types of equipment that can measure

1739-489: The potential for human error and increase repeatability in the quality of grinding. Casting processes simulation uses numerical methods to calculate cast component quality considering mold filling, solidification and cooling, and provides a quantitative prediction of casting mechanical properties, thermal stresses and distortion. Simulation accurately describes a cast component's quality up-front before production starts. The casting rigging can be designed with respect to

1786-400: The presence of hydrogen. Alternatively, the presence of hydrogen can be measured by determining the density of a metal sample. In cases where porosity still remains present after the degassing process, porosity sealing can be accomplished through a process called metal impregnating . In the casting process, a pattern is made in the shape of the desired part. Simple designs can be made in

1833-413: The required component properties. This has benefits beyond a reduction in pre-production sampling, as the precise layout of the complete casting system also leads to energy , material, and tooling savings. The software supports the user in component design, the determination of melting practice and casting methoding through to pattern and mold making, heat treatment , and finishing. This saves costs along

1880-542: The schools of the Royal Scottish Academy . Lawson travelled to study in Rome, becoming an admirer of John Gibson . Back in England, he lived initially in Liverpool, making work in terracotta. His reputation was established through the creation of statues of distinguished citizens. His first major work was the statue of the Duke of Wellington at the top of Wellington's Column in the centre of Liverpool at

1927-526: The son of Eliza and Frederick Burton, a carpenter and joiner. Born in Surbiton , Burton was apprenticed at the age of 16 to the bronze foundry of Cox & Sons in Thames Ditton . Burton later opened his own foundry in Southsea Road, Kingston, before buying into the Thames Ditton Foundry in 1897, becoming the co-owner with Arthur John Hollinshead. In 1887 he married Florence Louisa Moore (1859–1932),

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1974-444: The sprue, runners, and gates can be removed by breaking them away from the casting with a sledge hammer or specially designed knockout machinery. Risers must usually be removed using a cutting method (see above) but some newer methods of riser removal use knockoff machinery with special designs incorporated into the riser neck geometry that allow the riser to break off at the right place. The gating system required to produce castings in

2021-408: The surface. The final step in the process of casting usually involves grinding, sanding, or machining the component in order to achieve the desired dimensional accuracies, physical shape, and surface finish. Removing the remaining gate material, called a gate stub, is usually done using a grinder or sander . These processes are used because their material removal rates are slow enough to control

2068-482: The type of foundry, metal to be poured, quantity of parts to be produced, size of the casting, and complexity of the casting. These mold processes include: In a foundry, molten metal is poured into molds . Pouring can be accomplished with gravity, or it may be assisted with a vacuum or pressurized gas. Many modern foundries use robots or automatic pouring machines to pour molten metal. Traditionally, molds were poured by hand using ladles . The solidified metal component

2115-414: The type of metals that are to be melted. Furnaces must also be designed based on the fuel being used to produce the desired temperature. For low temperature melting point alloys, such as zinc or tin, melting furnaces may reach around 500 °C (932 °F). Electricity, propane, or natural gas are usually used to achieve these temperatures. For high melting point alloys such as steel or nickel-based alloys,

2162-652: Was a deacon of Surbiton Park Congregational Church, a Sunday school teacher and a benefactor of the Scout Movement . He was a Special Constable during World War I . On his death in 1933 Burton was buried with his daughter Dolly and his wife Florence in Bonner Hill Cemetery. Above their grave, atop a granite plinth, is a statue in bronze of a winged angel with arms outstretched reaching up. This had been cast in Burton's own foundry. After Burton's death

2209-578: Was demolished in 1976 and the crane removed for preservation by the Surrey Archaeological Society . Today Burton Court stands on the site. Works from this period include Frederick William Pomeroy 's relief of Archbishop Frederick Temple in St Paul's Cathedral (1905), George Frederic Watts 's Physical Energy in Kensington Gardens (1907), Goscombe John 's figures for the Monument to

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