At this point it may be difficult to distinguish the actual piece of art. This encases the duplicate in a hard protective shell. Step 5: The wax duplicate with its attached wax sprue system is then heavily coated with a ceramic slurry and stucco. This is the wax duplicate that will later be melted away or "lost." Step 4: Wax bars are joined to the wax duplicate to form the "sprue system," which consists of empty channels that will direct the molten metal into the mould to form the sculpture. Molten wax is then poured into the rubber mould to make a duplicate of the original. Step 3: Once the rubber has set, the original art is removed. A liquid rubber compound is poured over the original, capturing every bit of surface texture. Step 2: A rubber mould is made of the original unless it is made of wax or styrofoam. The art can be in any material: clay, plasticine, plaster, wood, wax or styrofoam. Step 1: The artist provides the original piece of art, in actual size, that is to become a bronze sculpture. The lost-wax process of creating a sculpted piece of art gets its name from a wax duplicate of the sculpture that must be melted away in order to leave room for the molten metal to take the desired shape. Lost-Wax Technique - this is a very common technique for fabricating sculptures, but does need some explanation. Soldering is a relatively low-temperature joining process using solder filler metal. Brazing is an intermediate temperature-joining process using a nonferrous filler metal. Welding - a high-temperature and pressure - joining or bonding process involving the fusion of the base metals with, or without the addition of a filler metal. Mechanical Joining - the assembly of metal components by bolting, crimping, staking or riveting 2. Main Processes Used to Make Sculptures There are a number of ways to fabricate bronze sculptures. It should be noted that just about all cast metal sculptures are often referred to as bronzes, despite what they are actually made of. Copper and tin create bronzes, and copper and zinc create brasses. Copper alloys, or substances made by combining copper with other metals, are therefore used for sculpture. Yet copper is difficult to cast without the addition of other metals that slow its oxidation rate and improve the flow of the molten metal. Copper is a malleable red-brown metal that occurs in nature and can be refined from copper ores. Other materials do not have this wide range of properties or are as flexible when it comes to joining techniques, finishing, and colouring, important factors when fabricating a sculpture or other work of art. It has been said that copper sculpture can last for a thousand years. Copper is resistant to corrosion, weathering well, even beautifully, instead of rusting. It can be worked to show very fine surface detail. Copper can accept a wide variety of finishes to show any desired texture. Copper parts can be joined or assembled mechanically by bolting or bonded by welding, allowing for works of massive size. They can be shaped to any desired form, providing unlimited artistic possibilities. Why and How Copper Is Used Copper and copper alloys are the best materials to use for sculpture for many reasons. Main Processes Used to Make Sculptures C. This section will briefly discuss why copper and copper alloys are the best material choice for art and sculpture, as well as other technical issues regading the selection of the proper alloys, colouring techniques, and finishes.
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