Design For Manufacture in Cost-Effective and Recyclable Brass

Design for Manufacture in Costeffective and Recyclable Brass
Copper Development Association
Introduction
About Copper Development Association Introduction to brass The properties of brass Brass manufacturing processes Case studies Summary

Incorporated in September 1933 Sponsored by the copper producers and fabricators Encourages the correct and efficient use of copper and copper alloys Produces technical publications, software, website and a technical help-line Maintains close links with other copper centres throughout the world
Market for Brass

European consumption of semi-finished brass last year (1999)
exceeded
1,000,000 tonnes*
* World Bureau Metal Statistics
Market Growth
European brass consumption has grown at 2.7% per annum over last 20 years*
* IZA
Italian Market has growth 20% in 5 years

World Bureau Metal Statistics
What is Brass?
An alloy of copper and zinc Plus additions of other metals to enhance different properties
Types of Brass
Alloys - (up to 35% Zn) - single phase
Cold working alloys
+ Alloys - (35 - 40% Zn) - two phase (duplex brasses)

Hot working alloys
Other Alloying Elements Added to Brass

ELEMENT MATERIAL PROPERTY IMPROVED Lead 1.0 to 4.0% High-speed Machining Brass Machinability
Manganese Aluminium Silicon Nickel Iron
0.75 to 2.5%
High Tensile Brasses
Yield strength up to 500MN/m
Aluminium Arsenic Tin
0.4 to 1.5%
Aluminium Brasses Corrosion resistance Dezincification-resistant Brass especially in sea water Naval Brasses
Important Properties of Brass

Excellent Machinability
Sets the standard by which other materials are judged Slight reduction in ductility when lead is present
Comparisons of Machinability
METAL BS NUMBER EN12164 4300Pt.5 1474 970 Pt. 3 970 Pt. 3 Brass (4% Lead) Aluminium Aluminium Mild Steel Stainless Steel SPECIFICATION METAL REMOVAL DESIGNATION RATE CM/MIN CW609N 133 2001 6082 230M07 304S15 80 44 36 6
Important Properties of Brass

Excellent Machinability
Sets the standard by which other materials are judged Slight reduction in ductility when lead is present
Good Strength Good Strength
Yield Strength 250 to 500MPa Yield Strength 250 to 500MPa
Corrosion Resistance
No plating or painting required
Further Properties of Brass

Conductivity
Electrical Thermal
Conductivity
Electrical
Brass components from a 13 amp plug
Thermal
Car radiator

Conductivity
Electrical Thermal
Non sparking
Non-Sparking
Courtesy of Conflow Ltd
Underground Emulsion Mixer


Conductivity
Electrical Thermal
Non sparking Attractive colours
Attractive Colours
CuZn5 CuZn10 4-6 % Zn 9-11% Zn
CuZn15 14-16% Zn CuZn20 19-20% Zn
CuZn30 29-31% Zn CuZn33 32-34% Zn

CuZn36 34.5-36.5% Zn CuZn37 36-38% Zn CuZn40 39.5-41.5% Zn
Courtesy of EIP Ltd

Conductivity
Electrical Thermal
Non sparking Attractive colours Strength at cryogenic temperatures

Conductivity
Electrical Thermal
Non sparking Attractive colours Strength at cryogenic temperatures Wear Resistance
Wear Resistant
Courtesy of Samuel Heath & Sons plc
Concealed Hydraulic Door Closer


Conductivity
Electrical Thermal
Non sparking Attractive colours Strength at cryogenic temperatures Wear Resistance Readily Recycled
Readily Recycled
Brass is recycled without loss of properties Almost 100% of brass manufactured in the UK is made from recycled copper and brass Process scrap has a high value approximately 40% of the virgin alloy
Brass swarf & scrap awaiting recycling
Courtesy of Boliden MKM Ltd

Hygienic
No loss of properties at temperatures up to 200C Good impact resistance (toughness)

Brass Manufacturing Processes

Readily cast Good hot and cold formability Easily machined Joining
Casting
Sand & Shell
Casting
Sand & Shell Permanent Die
Gravity Pressure
Pressure Die Casting
Courtesy of Regon Ltd
Pressure Casting Dies

Pressure Die Casting
Courtesy of Regon Ltd
Cold Chamber Diecasting Machine

Casting
Gravity Pressure
Investment
Casting
Gravity Pressure
Investment Centrifugal
Casting
Gravity Pressure
Investment Centrifugal Continuous (Logs for extrusion/slabs for rolling)

Typical Castings
Courtesy of The Enfield Foundry Co Ltd
Courtesy of Saunders Valve Co Ltd
Courtesy of J W Singer Ltd
Courtesy of Boosey and Hawkes Ltd
Hot Forming
Extrusion
The Extrusion Process
Courtesy of Boliden MKM Ltd
Direct Extrusion
Indirect Extrusion
Typical Extrusions
Courtesy of Cerro Extruded Metals Ltd
Hot Forming
Extrusion Hot stamping/forging
Hot Stamping
Open Die Stamping
Closed Die Stamping
Examples of Hot Stampings
Hot Forming
Extrusion Hot stamping/forging Hot rolling
Cold Forming
Drawing (Sections, Wire, Tube)
Cold Drawing
Extruded bar
Drawn bar
Draw die
Courtesy of Cerro Extruded Metals Ltd
Tube Drawing
Courtesy of Dorset Tube Company
Wire and Tube Examples
Courtesy of Cerro Extruded Materials
Courtesy of Dorset Tube Company
Cold Forming
Drawing (Sections, Wire, Tube) Heading and Thread Rolling
Example of Cold Heading & Thread Rolling
The TIMco Brass Woodscrew
Courtesy of T I Midwood
Cold Forming
Drawing (Sections, Wire, Tube) Heading Rolling
Cold Forming
Drawing (Sections, Wire, Tube) Heading Rolling Stamping/Pressing
Cold Forming
Drawing (Sections, Wire, Tube) Heading Rolling Stamping/Pressing Deep Drawing
Deep Drawing
Courtesy of Trevelyans (Birmingham) Ltd
Courtesy ofLamp Caps Ltd
Cold Forming
Drawing (Sections, Wire, Tube) Heading Rolling Stamping/Pressing Deep Drawing Spinning
Spinning
Courtesy of Metal Spinners (Newcastle) Ltd
Cold Forming
Drawing (Sections, Wire, Tube) Heading Rolling Stamping/Pressing Deep Drawing Spinning Machining
Machining
Free Machining Brass
Fine chips of swarf No lubricant Minimal wear on cutting and Machine tool
Non-Free Machining Metal

Spirals of swarf slow to clear Excessive Lubricants
Examples of Machined Components
Joining
Brass can be joined by
Mechanical Fasteners e.g. rivets, screws etc. Adhesive Bonding Soldering Brazing
Brazing
The flux protects the brass component during heating. 100-200C The silver brazing alloy melts and flows as it is touched onto the joint area. 700-750C
The flux goes clear and watery as the component reaches brazing temperature 550-600C
Text and Photographs courtesy of Johnson Matthey
Joining
Brass can be joined by
Mechanical Fasteners e.g. rivets, screws etc. Adhesive Bonding Soldering Brazing Welding
Brass Case Studies Illustrating the cost-effectiveness & recyclability of
Brass
MECO International Heavy Duty Valve Chest
High Tensile Brass versus Steel

Working pressure (bar) Non sparking for mining application
HTB 350 Yes
Steel 350 No
MECO International
High-Tensile Brass Raw Material Cost Pre machining cost Milling Drilling & threading Plating Total Total Saving 6.22 0.00 0.00 7.90 0.00 14.12 7.34 Steel 2.35 3.50 2.50 11.70 1.41 21.46
Vickers Systems Division

Process with no special dies required
Machining ideal
Courtesy of Vickers Systems Division, Trinova Ltd
Easily machined materials to be identified Corrosion resistant a requirement Good wear properties also required Brass was most costeffective material
Vickers Valve Costing Analysis

Brass Raw Material Cost (Extruded Bar) Machining Cost Finishing Cost (Hard Anodising) Sub Total Minus scrap value of machining swarf Total Cost 45% 63% 0% 108% (8%) 100% Aluminium 21% 66% 29% 116% (1%) 115%
Linic
Mild steel replaced by brass Plating eliminated Cost reduced Lubricant eliminated Increased perceived value
Courtesy of Linic Plastics Ltd
KeyMed Rigid Borescope

Brass was chosen for its
Machinability
low tool wear high accuracy
Courtesy of KeyMed
Corrosion resistance Strength Inherent lubricity

elimination of bearings
Tungum
Good corrosion resistance Good mechanical properties Good ductility Non sparking COST-EFFECTIVE
Courtesy of Tungum Hydraulics Ltd
SPC
Mild Steel replaced by brass Improved corrosion resistance Increased life Improved aesthetics
Courtesy of SPC Ltd
ERA Concealed Security Bolt

Good corrosion resistance No machining burrs Attractive self colour Readily joined cold riveting Productivity increase of 300%
Courtesy of J E Reynolds & Co Ltd
Summary
Brass is cost-effective
Close tolerance manufacturing processes give near-net shapes High-speed machining Swarf/scrap commands premium price No plating or painting required
Brass is recyclable
Without loss of properties The recycling infrastructure is already in place

Design For Manufacture in Cost-Effective and Recyclable Brass

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Design for Manufacture in Costeffective and Recyclable Brass

Copper Development Association

Copper Development Association

Copper Development Association

Market for Brass

Italian Market has growth 20% in 5 years

Copper Development Association

Copper Development Association

+ Alloys - (35 - 40% Zn) - two phase (duplex brasses)

Copper Development Association

Other Alloying Elements Added to Brass

Manganese Aluminium Silicon Nickel Iron

High Tensile Brasses

Yield strength up to 500MN/m

Aluminium Arsenic Tin

Copper Development Association

Important Properties of Brass

Copper Development Association

Copper Development Association

Important Properties of Brass

Good Strength Good Strength

Yield Strength 250 to 500MPa Yield Strength 250 to 500MPa

Further Properties of Brass

Copper Development Association

Copper Development Association

Further Properties of Brass

Copper Development Association

Courtesy of Conflow Ltd

Underground Emulsion Mixer

Further Properties of Brass

Non sparking Attractive colours

Copper Development Association

CuZn15 14-16% Zn CuZn20 19-20% Zn

CuZn30 29-31% Zn CuZn33 32-34% Zn

Copper Development Association

Further Properties of Brass

Non sparking Attractive colours Strength at cryogenic temperatures

Copper Development Association

Further Properties of Brass

Non sparking Attractive colours Strength at cryogenic temperatures Wear Resistance

Copper Development Association

Courtesy of Samuel Heath & Sons plc

Concealed Hydraulic Door Closer

Further Properties of Brass

Copper Development Association

Brass swarf & scrap awaiting recycling

Courtesy of Boliden MKM Ltd

Copper Development Association

Further Properties of Brass

No loss of properties at temperatures up to 200C Good impact resistance (toughness)

Brass Manufacturing Processes

Copper Development Association

Copper Development Association

Pressure Die Casting

Courtesy of Regon Ltd

Pressure Casting Dies

Pressure Die Casting

Courtesy of Regon Ltd

Cold Chamber Diecasting Machine