Electrical Industry Castings

The electrical industry is responsible for generating, transmitting and distributing power for industrial businesses and the general public. Cast metal electrical boxes and other products for the electrical industry need to be highly durable and quality made to last in extreme conditions. There are many lightweight, strong metals that meet these requirements and are used for electrical products.


Our Casting Quality Standards

Common Electrical Alloys

Copper is the most common material for wires and cables in the electrical industry. It is one of the most conductive metals available, and it has high mechanical strength and low tensile strength. These properties make copper easy to work with for electrical projects. Copper alloys combine copper with other metals, so you’ll gain the benefits of copper with other engineering strengths like thermal stability and tensile strength.

Besides copper, other metal alloys used for electrical industry products include:

  • Aluminum: Aluminum is a lightweight, flexible metal common in engineering.
  • Brass: Brass is a copper and zinc alloy that offers strength and durability.
  • Bronze: Bronze is a copper and tin alloy that allows precise work and has excellent thermal and electrical conductivity.

Where Casted Metals Are Used in the Electrical Industry

Some common uses of cast metals in the electrical industry include:

  • Enclosures: Enclosures are made from alloys like aluminum and steel. These metals are strong enough to protect the electrical equipment inside from electromagnetic interference and prevent electrical shock.
  • Connectors: Connectors are simple devices made to connect and disconnect circuits, and they are made of copper alloys since they need to be conductive and malleable.
  • Switchgear: Switchgears are circuit protection structures made of steel.

Benefits of Sand Casting for the Electrical Industry

We use the sand molding method for cast metal electrical boxes and other parts. It involves creating a core out of sand, mounting a pattern designed to your specifications in the mold, and pouring molten metal into the mold to create the part.

The advantages of the sand casting process for the electrical industry are:

  • Various metal options: We can create sand castings from nearly any ferrous or non-ferrous alloy. Some alloys suit the casting process better than others.
  • Many product options: Sand casting is versatile in what parts it can make. The mold can be nearly any size, shape or weight up to 200 tons.
  • Low tooling cost: The pattern material affects the usage quantity of the part, but the sand casting process still has a low tooling cost.
  • Any quantity run: The low tooling cost also makes sand casting cost-effective for large orders, single-piece runs and any size in between.
  • Quick process: The sand casting process is quicker than similar methods, even factoring in post-casting processes like machining.

Contact Warner Brothers Foundry Company Today

Since 1955, Warner Brothers Foundry Company has created cast metal parts for our customers in the electrical industry and many others. We use primary alloys to meet or exceed their mechanical property specifications, so you know you’re getting a casting that will last. For more information about electrical industry castings, call 586-773-0858 or contact us online today.

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