eco brass general properties - california metal-x plating and joining. 7/10/07 page 4. diehl. metal....

7/10/07

Chase BrassPartners With

®

&

CMX

7/10/07

Green Dot™ and ECO BRASS® is a lead-free brass alloy developed by Sambo Copper Alloy Company. The alloy has superior performance and properties compared to existing silicon brasses or leaded yellow brasses.

Chase Brass has the exclusive license for the distribution and production of Green Dot™ and ECO BRASS® in North America including the United States, Canada and Mexico. It markets the products under the brand names Green Dot™ for rod products and ECO BRASS ® for ingot products. Chase Brass is proud to announce that we have chosen California Metal-X along with Ingot Metal Company to be the sole manufacturers licensed to produce ECO BRASS ®

ingot in the North America.

Sambo Copper “ECO BRASS ®” - a new alloy for the 21st Century

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7/10/07

Industry Issues:Lead legislation

Dezincification resistance

Stress corrosion cracking resistance

Strength characteristics

• Cost

• Global availability

• Growth of copper alloys through

improved performance

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• Machinability / productivity

• Forgeability

• Castability

• Plating and joining

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DIEHLMETAL DOWA

NIPPON

OHKI

INGOTMETAL

KAIMEI

CMXCHASE BRASS

®

Eco Brass global families

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Examples of Green Dot and ECO BRASS machined parts, forgings and castings.

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7/10/07

Drinking water applications – rod, forgings and castings

Fire protection devices

Forgings or castings for ball valves (no-lead and stainless applications)

Forgings for shower valve

Water meter body castings

Automotive parts: lead-free requirements

European electrical/electronic parts: lead-free requirements

Substitute for free-machining stainless steel in general applications

Potential uses:

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Product Comparison

GREEN DOT™ Rod Properties

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Green Dot™ provides good machinability without lead by substituting silicon.

ALLOYCopper

(%)Lead(%)

Silicon(%)

Phos.(%)

Zinc(%)

C36000 (Blue Dot™)ASTM B16

61.560.0 - 63.0

2.72.5 - 3.7

- - 35

C37000 (Low lead)ASTM B124

59.559.0 – 62.0

1.20.8 – 1.5

- - 39

C37700 (Forging alloy)ASTM B124

58.558.0 - 61.0

1.81.5 - 2.5

- - 39

C69300 (Green Dot™)ASTM B371, B124, B283

75.073.0 – 77.0

-0.09 max.

3.02.7 – 3.5

0.090.03 – 0.16

21

Rod Alloys

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Comparison of Typical Rod Mechanical Properties For Half Hard Temper Round Rod.

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0

20

40

60

80

100

120

Tensile Str.(ksi)

Yield Str.(ksi)

Elong. (%) Hard. (Rb)

0.250 C360 0.250 Green Dot 0.500 C360 0.500 Green Dot1.000 C360 1.000 Green Dot 2.000 C360 2.000 Green Dot

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Comparison of Typical Rod Mechanical Properties

®

0

20

40

60

80

100

120

Tensile Str.(ksi)

Yield Str.(ksi)

Elong. (%) Hard. (Rb)

C36000 (1/2H) C37700Green Dot (1/2H) 303 Stainless (Annealed)304 Stainless (Cold Drawn)

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Product Comparison

GREEN DOT™ for Forging Applications

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Hot Compression Test ResultsForging Temperature (from left). 1060F, 1150F, 1275F, 1380F, 1500F

Forgeability of Green Dot™ is rated at 95% of C37700 while forging tensile strength is about 20% higher.

C69300 Green Dot™ C37700

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0

7

15

22

980 1160 1340 1520Temperature (F)

Forg

ing

Pres

sure

(ks

i)

Green Dot™

C37700

Forging pressures for Green Dot™ are similar to C37700 forging alloy.

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Forgeability of the Green Dot water meter cap is 95% of C37700

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Forgeability DataProduction volume: 1,650,000

Forgeability rating: 95 – 100%

Forging cracks: Fewer than C377

Forging pressure: Higher than C377

Productivity: ~ 95 %

Forging tool life: No change from C377

Slugging tool life: Sharpen every 20,000 slugs

Slugging productivity: 12 per minute vs. 17 for C377 (1.575” rod)

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Machinability of the Green Dot water meter cap is 90 - 95% of C37700

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Machinability DataProduction volume: 1,650,000

Machinablility rating: 90 – 95%

ID Turning parameters: 1500 rpm, 0.005”/rev

Tool regrinding: 2,000 forgings

Tool life: 70% of C377

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Product Comparison

ECO BRASS® Casting Alloys

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ECO BRASS® casting alloy chemistry is the same as for rod.

ALLOYCopper

(%)Lead(%)

Silicon(%)

Tin(%)

Phos.(%)

Zinc(%)

C83600 85.0 5.0 - 5.0 - 5.0

C84400 81.0 7.0 - 3.0 9.0

C87500 82 - 4.0 - - 14.0

C89520 0.9% Se, 1.9% Bi 86.0 - - 5.5

C89833 0.75% Ni, 2.2% Bi * 89.0 - - 5.0 - 3.0

C92200 88.0 1.5 - 6.0 - 4.5

C87850ASTM B30, B584, B806

76.074.0-78.0

-0.09 max.

3.02.7-3.4

-0.30

0.120.05-0.20

20Rem.

* C83600 version

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Comparison of Typical Sand Cast Mechanical Properties – Leaded and Lead-Free Alloys

020406080

100120

Tensile(ksi)

Yield (ksi)Elong. (%) Hard.(BHN)

ECO BRASS vs. Leaded Alloys

C83600 C84400 C92200 ECO BRASS

020406080

100120

Tensile(ksi)

Yield (ksi) Elong.(%)

Hard.(BHN)

ECO BRASS vs. Lead Free Alloys

C89520 C89833 ECO BRASS

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ECO BRASS and Silicon Brass Typical Mechanical Properties

0

50

100

150

Tensile(ksi)


Hard.(BHN)

ECO BRASS vs. C875 Silicon Brass Sand Cast Properties

C87500 ECO BRASS

0

50

100

150

Tensile(ksi)


Hard.(BHN)

Sand Cast and Permanent Mold Cast ECO BRASS

Sand Cast Permanent Mold

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Liquidus and Freezing Range Temperature Comparisons

14001500

1600170018001900

Alloy

Liquidus Temperature (F)

ECO BRASS C87500 C92200 C84400C89520 C83600 C89833

0

100

200

300

400

Alloy

Freezing Range (F)

ECO BRASS C87500 C83600 C84400C92200 C89833 C89520

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The microstructure of cast ECO BRASS® vs. C83600.

ECO BRASS® C83600

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FOUNDRY PROPERTY SIMILAR TO:

Permanent Mold Casting Leaded Yellow Brasses

Dross Formation C87800

Fluidity -

Fuming C83600

Shrinkage and Cracking Short Freezing Range Alloys

Shrinkage Allowance C84400 (3/16” per foot)

General Comments on ECO BRASS® Casting Behavior.

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Samples of ECO BRASS castings

Low Pressure Permanent Mold Casting Green Sand Casting

Since 2000, over five million ECO BRASS water meter bodies have been cast and put into service in Japan. No leaking or corrosion defects have been experienced.

7/10/07

Chase Brass & Copper Co. Inc signed sub-license agreements with California Metal-X of Los Angeles, CA and Ingot Metal Company of Toronto to produce and sell ECO BRASS Ingots for the North American marketplace.

CMX has been a manufacturer of brass and bronze ingots for over 25 years. They have a monthly capacity of over 4+ million pounds producing over 30 alloys including silicon brasses.

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Machinability Information

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The microstructure of Green Dot™ results in excellent machinability and surface finish.

ά

Green Dot™

Rod (C69300) Blue Dot™

Rod (C36000)

ά Lead

100X

400X

100X

400X

κ+γ

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C69300 Green Dot™ ROD C69400 Silicon Red Brass

ά

The C69400 microstructure is from the Copper Dev. Assoc. Website.

Nominal Composition of Sample:

Cu 80.0-83.0, Si 3.4-5.4, Zn 12.0-13.0, Fe 0.20, Pb 0.30

Approximate magnification of both micrographs is 400X

The multiple phases in Green Dot™ result in higher machinability (70-80%) than conventional silicon brass (30%)

κ+γ

ά

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Green Dot™ Rod Free-Cutting Brass 60 Cu – 40 Zn

The kappa and gamma phases in the alpha matrix create small, Type 1 chips, similar to lead in C36000.

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Machinability of Green Dot™ is 70-80% of C36000 (1)

(1) Plunge tests: AISI T15 high speed steel, 5% Cimperial 1070 cutting fluid; drill test: high speed steel, straight oil.

0

20

40

60

80

100

Mac

hina

bilit

y (%

)

C36000 Green Dot

CDA Published ValueTechSolve C360 Standard Machining Test ParametersTechSolve - Sambo Recommended Machining Parameters

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Cutting Force, Drilling Force and Surface Finish – Relative Values. (1)

(1) Based on data from Sambo. Relative values calculated using best value as denominator.

®

01234567

Ran

king

(1=

Bes

t)

C36000 GREENDOT™

303 SS

Turning - Main Force Turning - Feed ForceDrilling - Torque Drilling – Thrust ForceMachined Surface Roughness

Machining Parameters

Turning – 1575 ipm; 0.004 ipr; 0.039” cut depth

Drilling – 0.138” dia.; 0.007 ipr; 1250 rpm

Surface Finish – 4330 ipm for brasses; 1970 ipm for 303;

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Compared to 303 stainless steel, Green Dot requires 60 – 70% less force to turn.

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Turning Cut into 2.000"RD Rod -1138 RPM, 0.050" Cut

0

200

400

600

800

1000

0.0045 ipr 0.007 ipr 0.012 ipr

Forc

e (N

ewto

ns)

Green Dot 303 Stainless Steel C360

0.125" Plunge Cut into 2.000"RD Rod - 1556 RPM

0100200300400500600700800900

1000

0.003 ipr 0.0045 ipr 0.007 ipr

Forc

e (N

ewto

ns)

Green Dot 303 Stainless C360

Coolant: Blasocut 40NF

Top rake: 18º: lead angle: +2º; side clearance 5º

Insert: Manchester Tool MTC-PT (M43 with TiAlN coating)

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Machinability Comparison Between ECO BRASS, Leaded and Lead-Free Copper Alloys

0

20

40

60

80

100

Mac

hina

bilit

y R

atin

g(%

)

Alloy

C92200 C87500 EcoBrass C89833C83600 C89520 C84400

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The CuZnSi particles which improve machinability do not cause warm brittleness cracking

Impact Strength as a Function of Temperature

0

50

100

150

200

250

300

350

20 150 200 250 300 350 400Temperature (C)

Impa

ct S

tren

gth

(J/c

m2)

E B i h 0 01%Pb C36000 60C 38Z 2Bi

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Impact Strength as a Function of Temperature

050

100150200250300350

20 150 200 250 300 350 400Temperature (C)

Impa

ct S

tren

gth

(J/

cm2)

EcoBrass with 0.01%Pb C36000 60Cu-38Zn-2Bi

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Corrosion Resistance

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Corrosion depth after ISO6509

dezincification test(12.7 g/l CuCl2.2H2 O for

24 hrs. at 167F).

Maximum corrosion depth of C360 and C377 = 0.04" (1.0mm) while Green Dot™ is almost zero.

C69300 Green Dot™

C36000

This type of performance applies to

rod, forgings and castings.

Phosphorus and lower zinc levels in Green Dot™ give it measurably superior resistance to dezincification.

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Comparison of ISO 6509 test results shows ECO BRASS excellent dezincification resistance.

1000

900

170

120

20 20 15 5

900

800

100

70

5 5 5 5

0

100

200

300

400

500

600

700

800

900

1000

Maximum Corrosion Average Corrosion

C36000 C37700 Eco Brass w/o PC87500 Green Dot Rod Green Dot ForgingEco Brass Casting C83600

®

Cross-hatched bars indicates dezincification occurred. Solid bars indicate there was general corrosion only.

Cor

rosi

on D

epth

(μm

)

7/10/07

Silicon, low zinc, high strength levels: These give Green Dot™ high stress corrosion cracking resistance.

JIS A Test: (Japanese Industrial Standard)NH4 OH (11.8% min.), 2 hrs., 68F; 1500 kgf torque

CES A Test: (Communication Equipment Standard - Japan) NH4 Cl + NaOH (pH 10), 72 hrs., 68F; 1500 kgf torque

Mattsson Test: (ASTM G37-1998) (NH4 SO4 + CuSO4 -5H2 O + NH4 OH), no minimum time, 68F, 1500 kgf torque

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512580

288

512

580

290

4 32 4 472

40

100200300400500600

Hou

rs to

App

eara

nce

of

Cra

cks

Green DotHex Rod

Green DotForging

C360 HexRod

C377 HexRod

Results of Stress Corrosion Cracking Tests

JIS A Test CES A Test Mattsson Test

No cracks

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Maximum corrosion depth of ECO BRASS® in various corrosive environments.

0

10

20

30

40

50

60

Max

. Cor

rosi

onD

epth

(μm

)

ISO6509 Air - 9 Mo., 3.5pH Clay Soil - 9 Mo., 3.5pHSandy Soil - 9 Mo., 3.5pH 5 Months - Osaka 12 Months - Still Water12 Months - Agitated Water 2 Yr. Hakui City 2 Yr. Shiki City

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Corrosion rates in hydrochloric and sulfuric acids.

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Joining and Plating

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7/10/07

Resin fluxes and solder pastes containing chlorine compounds are required for the best solderability.

SOLDER TYPE

97 Sn – 3 Sb

95 Sn – 5 Sb

Bridgit SolderSn – 5 Sb – 3 Cu – 0.2 Ni

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Brazing tests proved that Green Dot and ECO BRASS can be brazed using commercial brazing alloys

BRAZING ALLOY TYPE American Welding Society Designation

30% Cu – 28% Zn - 40% Ag – 2% Sn

(AWS A5.8, Class BAg-28)

Cu – 5%P – 15% Ag (AWS A5.8, Class BCuP-5)

Cu – 7%P – 6% Ag (1) (AWS A5.8, Class BCuP-4)



(1) Most popular in the faucet industry

(2) Produced braze with C11000 tube that had the same breaking force as with C36000

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Polishing, buffing and plating characteristics of this alloy are excellent

Green Dot machined parts & forgings and ECO BRASS castings have been:

1) Polished and buffed

2) Chrome or nickel plated

3) Teflon coated

Pre-cleaning: acid or caustic systems work well.

A copper strike helps pass more stringent corrosion tests, e.g. 96 hour CASS (ASTM B368-97) but is not required for cosmetic plating

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Never mix Green Dot™ or ECO BRASS® scrap with leaded brass alloys.

Precautionary Statement1. Green Dot™ and ECO BRASS® uses silicon instead of lead to attain good

machinability and excellent mechanical and physical properties.

2. Because of its silicon content, Green Dot™ and ECO BRASS® scrap must never be mixed with leaded brass scrap because of contamination and safety problems. If silicon is found in leaded brass scrap, the load will be immediately rejected and will jeopardize the total scrap stream.

3. To highlight its difference from leaded brass rod, a special, green tag will be attached to every bundle of Green Dot™ and ECO BRASS® with a precautionary statement, disposal and recycling information.

4. We are in the process of establishing sources which will buy your Green Dot™ and ECO BRASS ® scrap.

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eco brass general properties - california metal-x plating and joining. 7/10/07 page 4. diehl. metal....

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