Bronze casting is the process of molding an alloy composed of copper and tin with small amounts of lead and zinc. When headstones are made from bronze, a mold of the bronze plaque (complete with lettering and dates) is prepared for pouring. Bronze blocks or bars are placed in a crucible and melted under intense heat, usually about 2000 degrees. The molten bronze is then poured into the mold.
The next phase in the bronze casting process is called "chasing." The phase involves removing imperfections by lightly grinding the bronze until the desired surface texture and shape has been achieved. It's a process similar to fine sanding wood. After chasing, a craftsman will define any areas of detail that may not have transferred during the casting process.
A craftsman will next apply several coats of paint to the bronze headstone plaque. Once the paint dries, he or she will use a solvent to rub areas of the bronze plaque. This will remove the paint and expose the top edge of both the letters and the sculpted design features. This process brings out the beautiful contrast between the natural bronze coloring and the painted background. Finally, a lacquer coating is applied to provide the finish.
Bronze is often used in commemorative plaques and awards as well. Many companies use bronze plaques to honor employees or donors that have made significant contributions to the company. Small bronze plaques can be used as awards for distinguished employees as well.