Brass
Brass
Brasses are copper alloys in which the principal alloying constituent is zinc. Their properties depend primarily upon the proportion of zinc present but can be usefully modified by the introduction of additional elements to further improve specific characteristics such as strength, machinability or resistance to particular forms of corrosion. The principal wrought and cast brass compositions in commercial use are listed in Tables 19 and 20 on pages 24 - 26 with an indication of the forms in which they are available. The tables include two groups of alloys not commonly described as brasses: the nickel silvers (which, except for the 20% nickel versions, contain more zinc than nickel) and the so-called bronzewelding filler alloys. In the USA an alloy containing 5% each of zinc, tin and lead is known as red brass, but in the UK this alloy is classified as a leaded gunmetal with the EN designation CC491K (LG2). Gunmetals are not covered in this publication. and the alloy has better corrosion resistance than the brasses with a higher zinc content. For long production runs of deep-drawn components it is essential to keep the process well monitored. The tooling and lubrication must be well maintained and arrangements made to ensure a consistent supply of feedstock. Deep drawing properties are controlled by alloy composition and trace impurities (lead and iron) and mechanical and thermal history during manufacture. Good agreement should be reached with reputable suppliers regarding quality assurance. Tubes for heat exchangers are frequently manufactured from the alpha brasses, normally of 70/30 composition but often containing alloying additions which enhance corrosion resistance. Substantial quantities of alpha alloys are also used for the manufacture of fasteners such as wood screws, rivets and zip fasteners. For less demanding fabrications such as spring contacts in a domestic electrical socket, an alloy with a higher zinc content (and hence lower price) can be used, such as CuZn33 (2/1 brass), CuZn36 and CuZn37 (common brass). These alloys are not quite as ductile as CuZn30, although other mechanical properties are similar. They are perfectly adequate for all but the most severe cold working operations.
Duplex brasses
The alpha-beta brasses, duplex brasses or hot working brasses usually contain between 38% and 42% zinc. In contrast to the alloys of the first group, their ability to be deformed at room temperature is more limited. They are, however, significantly more workable than the alpha brasses at elevated temperatures and can be extruded into bars of complex section, either solid or hollow, and hot forged in closed dies (hot stamped) to complex shapes. The ideal hot working temperature range is whilst the brass is cooling, between 750C and 650C, during which the alpha phase is being deposited (see Figure 4). The mechanical working process breaks down the alpha phase into small particles as it is deposited, resulting in good mechanical properties.
Alpha brasses
The range of alloys, termed alpha brasses, or cold working brasses, contain a minimum 63% of copper. They are characterised by their ductility at room temperature, and can be extensively deformed by rolling, drawing, bending, spinning, deep drawing, cold heading and thread rolling. The best known material in this group contains 30% zinc and is often known as 70/30 or cartridge brass, CuZn30 - due to the ease with which the alloy can be deep drawn for the manufacture of cartridge cases. The cases (up to 100mm diameter) start as flat discs blanked from strip or plate and are successively formed to the final shape by a series of operations, carried out at room temperature, which progressively elongate the sidewalls and reduce their thickness. CuZn30 possesses the optimum combination of properties of strength, ductility and minimal directionality which make it capable of being severely cold drawn. Its ductility allows cold manipulation
35
Note the need for careful control of annealing temperature and cooling rate if it is required to obtain a single-phase alpha structure in a brass of high zinc content such as common brass and dezincification-resistant brass. Current use of continuous annealing techniques for sheet, strip, wire and tube gives a much quicker cooling rate than previous batch annealing in controlled atmosphere bell furnaces. For brasses of the CuZn37 type this resulted in a greater tendency to retain some of the beta phase and the standard composition has therefore now been adjusted to CuZn36. These brasses are available as extruded rods, bars and sections, which in turn are the starting stock for the manufacture of a vast range of engineering components and accessories (see page 44). Hot stampings are used in virtually every industry: pipe fittings,
domestic taps, radiator valves, gas appliances, window and door furniture being merely a few typical examples of the products which can be manufactured by this process (see page 59). Good tolerances are maintained during manufacture, minimising the need for machining during the final component production. The addition of lead to these alloys aids chip breakage during machining, producing short broken chips which are easily cleared from the cutting area to improve machinability. Since the cost of zinc is lower than that of copper, brasses of higher zinc content have a lower first cost. This may be significant in assessing manufacturing and total-lifetime costs.
10
20
30 LIQUID
40
Atomic % Zn
+ LIQUID 902C
+ LIQUID
Temperature C
800
low hot formability
+ +
1
200
Cu
CAP COPPER
10
GILDING METALS
20
40
DUPLEX BRASSES
50 Weight % Zn
DZR BRASS
36
where A = sum of (zinc equivalent factor x % of each alloying element) + zinc and B = A + % copper This method gives good accuracy for high tensile brasses provided that alloying elements do not exceed 2% each.
FREE-MACHINING BRASSES
Typically, free-machining brass contains about 58% copper and 39% zinc. Lead is added to improve machinability; other alloys, required to be free-machining and yet having sufficient ductility for riveting or other cold work, contain less lead and more copper. Additions of other elements such as manganese, tin, aluminium, iron, silicon and arsenic may be used to improve strength and corrosion resistance. This gives rise to a very wide selection of alloys, see Table 19 on pages 24 & 25. The choice of alloy to use for an application depends on balancing the range of properties required including machinability, extrudability of shape and cold ductility for post forming after machining. There are many standard materials suited to specific end uses. The EN standards recognise categories of material classified by copper, zinc and lead content. The effects are summarised in Figure 5 and the materials now available shown in Figure 6.
Tin
1% tin is included in the composition of Admiralty brass CW706R (CZ111) and Naval brass CZ112 (nearest CW712R). As their names indicate, these brasses were developed originally for seawater service, the tin being added to provide improved corrosion resistance. Nowadays Aluminium brass CW702R (CZ110) has replaced Admiralty brass for marine service but Admiralty brass is used for fresh water. Naval brass retains some important applications in seawater service.
Silicon
Silicon increases the strength and wear resistance of brass and is also sometimes included in die casting brasses and in filler alloys for gas welding to reduce oxidation of the zinc and to assist fluidity. Its principal effect from the corrosion point of view is to increase the beta phase content.
Arsenic
Arsenic is often added in small amounts to alpha brass alloys to provide protection against dezincification corrosion as discussed in Section 3. FIGURE 5 Effect of copper and lead content on free-machining brass
5
IN CR
Nickel silvers
The range of copper-nickel-zinc alloys containing from 10 to 20% nickel and known as nickel silvers can be regarded as special brasses. They have a silvery appearance rather than the typical brassy colour. In most respects they show similar corrosion characteristics to alpha brasses but the higher nickel versions have superior tarnish resistance and resistance to stress corrosion cracking.
4 3 2
EA
IN
SI
CR
NG
EA
CO
SI
NG
LD
FO
% Pb
AC
RM
HI
AB
NA
ILI
BI
TY
LI
TY
54
55
56
57
58
59 % Cu
60
61
62
63
37
Shape memory effect brass (SME alloy) Some copper alloys, including certain copper-zinc-aluminium compositions, exhibit a metallurgical transformation which is temperature dependent and reversible. Great use can be made of the forces available during consequent dimensional changes in suitably designed components for temperature sensitive actuators. This type of material can be produced to a primary shape such as a spring or torsion rod. It is heat treated to give the required metallurgical condition and then strained beyond its elastic limit to a secondary shape. Warming the component through its transition temperature will cause it to regain the original shape and it will revert to the secondary shape upon cooling.
If the alloy composition, fabrication and heat treatment are all closely controlled, then the component can be used as a temperature sensitive actuator to give a predictable mechanical performance. The force produced can be up to 200 times that of a bimetallic element of similar size. A variety of materials are available with controlled transition temperatures between 70C and +150C.
5 4 3
CuZn43Pb2 CuZn39Pb3 CuZn36Pb3
% Pb
2 1
CuZn40Pb2
CuZn35Pb2
CuZn35Pb1
CuZn39Pb0.5
54
55
56
57
58 59 % Cu
60
61
62
63
64
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PRIMARY COPPER
PRIMARY ZINC
MELT
MILL SURFACE
COLD ROLL
ANNEAL
HOT STAMP
MACHINE
FINISHED COMPONENTS
The strength of most of the commercially available brasses cannot be improved by heat treatment. Any improvement in properties over the soft, annealed condition is obtained by cold working. In the case of extruded products such as rods, bars, sections, tubes and wire, the cold reduction is applied by drawing through dies, while in the case of sheet and strip it is applied by cold rolling.
Temper Grade
Progressive amounts of cold working increase the tensile strength, proof strength and hardness of the alloy, with a consequent reduction in ductility, as measured by elongation. Material available from manufacturers has been subjected to various amounts of cold reduction; referred to as the temper grade and designated in the old BS for sheet, strip and wire as 1 4 H, 12 H, H, extra hard, spring hard and extra spring hard. These terms are not used in the EN standards but are included for information purposes to allow comparison with BS standards. In EN standards alloys are supplied to a material condition (see page 22), namely H for a minimum hardness value or R for a minimum tensile strength value. Example: brass wire CW508L (CZ108) in EN 12166 material condition R560 (tensile strength 560-700 N/mm2) or H160 (hardness 160-190 HV) Both these conditions are approximately equivalent to the half hard/hard condition in the old BS 2873 Standard. Note - It is much easier to measure tensile strength in wire than hardness. Not all brasses or forms are available in all temper conditions. Hard rolled brasses have better ductility longitudinally in line with the rolling direction rather than in the transverse direction. Advantage of this can be taken when designing springs or other flexible parts.
The temper grade specified when ordering material must be based on the degree of forming necessary to produce the finished component. With experience, alpha brasses can be temper-annealed within a wide variety of combinations of properties such as hardness and grain size suitable for differing end-uses. Hardnesses may vary from about 55HV up to about 100HV with corresponding grain sizes from 0.08 down to 0.01 mm. The softer the brass, the better the ductility, but a small grain size is needed for the good surface finish required after deep-drawing operations (see Figure 12 on page 42).
1000
% Elongation T.S. (N/mm2)
ire Hard W xtra E f o gth ren t eS
60
Ty pic al
750
s il en
Modulus of Elasticity
500
40
T y pic
al
Values ion ga t
250
20
Modulus of Rigidity
90 10
80 20
70 30
% Cu % Zn
Heading Limit
5 4 3 2 1
Electrical Resistivity
90 10
80 20
70 30
% Cu % Zn
Thermal Conductivity
stampings, forgings, sand castings, shell moulded castings, gravity and pressure diecastings, and investment castings. The availability of these items to specific composition and size specifications may be dependent on quantity requirements. Dimensional tolerances suitable for most general engineering applications are quoted in the relevant EN Standards for the wrought products. Any special requirements should be discussed with manufacturers.
80 20
70 30
% Cu % Zn
CASTABILITY
All brasses can be readily cast for a wide variety of end uses giving strong, sound castings (see examples page 43). The EN 1982 specification covers a selection of the most frequently used alloys, some with additions of lead to improve machinability, and tin to improve corrosion resistance and strength (see Table 20 on page 26). Manganese is a useful deoxidant, as little as 0.02% present giving stronger, sound castings. For diecasting the 60/40 type alloys are used. The higher zinc content lowers the casting temperature and gives essential hot ductility. Aluminium is added to form a protective oxide film to keep the molten metal clean and reduce the attack on the die materials. This type of alloy with a suitably controlled composition may also be used for castings required to be resistant to dezincification. The high tensile brasses can be sand cast and CC765S (HTB1) is also used for gravity diecasting. The casting process is ideal for the production of complex shapes. End uses range from pipeline valves and electrical switchgear components, which require high soundness and strength, a long operating life and, in the case of components for mines and the petrochemical industry, spark-resistant characteristics, to non-critical ornamental applications where the requirement is for a good surface finish as well as a long service life.
Brass compositions and product forms are included in various EN Standards, detailed in Tables 19 and 20 on pages 2426. Also included are typical mechanical properties of the brasses for the product forms covered by the Standards. For more detailed information on composition limits, minimum mechanical properties, tolerances and other requirements, the relevant standards should be consulted. For castings, relatively wide ranges of properties are shown because of the variations due to casting design, section thickness and foundry variables. Close collaboration between designer and founders can help minimise the influence of casting variables. The commonly used brasses are available from manufacturers and stockists in the size ranges shown in Table 22 on page 42. The EN Standards introduce a wider range of available tolerances than previously included in British Standards and are shown in Table 23 on page 42.
TABLE 22 Common size ranges of wrought and cast brasses (UK) Form Up to 127mm diameter for rod Up to 90mm across flats for square section Up to 110mm across flats for hexagons Shape that falls within a 127mm diameter circumscribing circle Up to 127mm diameter, 110mm across flats for hexagons, etc. Up to 22kg weight Up to 750kg weight Up to 2500 x 1250mm Up to 125mm thick, 2m x 1m From 0.05mm to 4mm thickness in widths from 3mm to 400mm From 0.02 to 6mm diameter From grammes up to several tonnes, dependent on casting technique Size Range
Rod and Bar Sections Hollows Hot Stampings Forgings Sheet Plate Foil and Strip Wire Castings
TABLE 23 Tolerance classifications in EN specifications Note: A is the widest tolerance in each standard. Product Type Rod for Free-machining A and B for round rods A, B and C for outside dimension A and B for inside dimension A and B for wall thickness A and B for eccentricity A, B and C for round products A, B and C A, B, C, D and E for round products A, B and C for regular polygons A and B for round and polygonal products Tolerance Classes in EN Standards
Forging Stock Rectangular Bar Wire for General Engineering Purposes Rod for General Purposes
FIGURE 12 Hardness v grain size for annealed CuZn30 brass sheet and strip
110 100 90 Hardness (HV) 80 70 60 50 0 0.02 0.04 0.06 Grain Size (mm)
42
0.08
Castings examples
Adjusting nut for a rolling mill cast in high tensile brass to EN 1982 CC7625 (HTB3)
This brass is relatively easily cast and machined to close tolerances to give a strong component resistant to wear and shock.
Clarinet keys
Clarinet keys are now precision cast (right) to a near-net-shape that needs little finishing beyond fettling, polishing and decorative plating. Even the pivot holes are cored into place. Previously these keys were made from a silver-soldered assembly of several components (left). This economy in production methods has enabled the manufacturer to meet stiff competition from elsewhere.
(J W Singer Ltd)