Transcript Slide 1

®
&
Chase Brass
Partners With
CMX
7/10/07
Page 1
®
&
Sambo Copper “ECO BRASS ®” - a new alloy for the 21st Century
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.
7/10/07
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®
Industry Issues:
Lead legislation
• Machinability / productivity
Dezincification resistance
• Forgeability
Stress corrosion cracking resistance
• Castability
Strength characteristics
• Plating and joining
•
Cost
•
Global availability
•
Growth of copper alloys through
improved performance
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®
Eco Brass global families
INGOT
METAL
CMX
CHASE
BRASS
DIEHL
METAL
DOWA
NIPPON
OHKI
KAIMEI
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®
Examples of Green Dot and ECO BRASS machined parts, forgings and castings.
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Potential uses:
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
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®
Product Comparison
GREEN DOT Rod Properties
™
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®
™
Green Dot provides good machinability without lead by substituting silicon.
Rod Alloys
Copper
(%)
Lead
(%)
Silicon
(%)
Phos.
(%)
Zinc
(%)
C36000 (Blue Dot™)
ASTM B16
61.5
60.0 - 63.0
2.7
2.5 - 3.7
-
-
35
C37000 (Low lead)
ASTM B124
59.5
59.0 – 62.0
1.2
0.8 – 1.5
-
-
39
C37700 (Forging alloy)
ASTM B124
58.5
58.0 - 61.0
1.8
1.5 - 2.5
-
-
39
75.0
73.0 – 77.0
0.09 max.
3.0
2.7 – 3.5
0.09
0.03 – 0.16
21
ALLOY
C69300 (Green Dot™)
ASTM B371, B124, B283
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Comparison of Typical Rod Mechanical Properties For Half Hard Temper Round Rod.
120
100
80
60
40
20
0
Tensile Str.
(ksi)
Yield Str.
(ksi)
Elong. (%)
Hard. (Rb)
0.250 C360
0.250 Green Dot
0.500 C360
0.500 Green Dot
1.000 C360
1.000 Green Dot
2.000 C360
2.000 Green Dot
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Comparison of Typical Rod Mechanical Properties
120
100
80
60
40
20
0
Tensile Str.
(ksi)
Yield Str.
(ksi)
C36000 (1/2H)
C37700
Green Dot (1/2H)
303 Stainless (Annealed)
304 Stainless (Cold Drawn)
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Elong. (%) Hard. (Rb)
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Product Comparison
GREEN DOT for Forging Applications
™
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™
Forgeability of Green Dot is rated at 95% of C37700 while forging tensile strength is about 20%
higher.
C69300 Green Dot™
C37700
Hot Compression Test Results
Forging Temperature (from left). 1060F, 1150F, 1275F, 1380F, 1500F
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Forging Pressure (ksi)
Forging pressures for Green Dot are similar to C37700 forging alloy.
22
15
Green Dot™
7
C37700
0
980
1160
1340
Temperature (F)
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1520
®
Forgeability of the Green Dot water meter cap is 95% of C37700
Forgeability Data
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Production 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)
®
Machinability of the Green Dot water meter cap is 90 - 95% of C37700
Machinability Data
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Production 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
Product Comparison
®
ECO BRASS Casting Alloys
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ECO BRASS casting alloy chemistry is the same as for rod.
Copper
(%)
Lead
(%)
Silicon
(%)
Tin
(%)
Phos.
(%)
Zinc
(%)
C83600
85.0
5.0
-
5.0
-
5.0
C84400
81.0
7.0
-
3.0
C87500
82
-
4.0
-
ALLOY
9.0
-
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
88.0
1.5
-
6.0
-
4.5
76.0
74.0-78.0
0.09
max.
3.0
2.7-3.4
0.30
0.12
0.05-0.20
20
Rem.
C92200
C87850
ASTM B30, B584, B806
* C83600 version
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Comparison of Typical Sand Cast Mechanical Properties – Leaded and Lead-Free Alloys
ECO BRASS vs. Leaded Alloys
120
100
80
60
40
20
0
ECO BRASS vs. Lead Free Alloys
Tensile Yield (ksi)Elong. (%) Hard.
(ksi)
(BHN)
C83600
C84400
C92200
ECO BRASS
120
100
80
60
40
20
0
Tensile Yield (ksi) Elong.
(ksi)
(%)
C89520
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C89833
Hard.
(BHN)
ECO BRASS
ECO BRASS and Silicon Brass Typical Mechanical Properties
ECO BRASS vs. C875 Silicon Brass
Sand Cast Properties
150
100
50
0
Sand Cast and Permanent Mold
Cast ECO BRASS
Tensile Yield (ksi) Elong.
(ksi)
(%)
C87500
ECO BRASS
Hard.
(BHN)
150
100
50
0
Tensile Yield (ksi) Elong.
(ksi)
(%)
Sand Cast
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Hard.
(BHN)
Permanent Mold
Liquidus and Freezing Range Temperature Comparisons
Liquidus Temperature (F)
1900
1800
1700
1600
1500
Freezing Range (F)
1400
Alloy
ECO BRASS
C89520
C87500
C83600
C92200
C89833
C84400
400
300
200
100
0
ECO BRASS
C92200
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Alloy
C87500
C89833
C83600
C89520
C84400
The microstructure of cast ECO BRASS
ECO BRASS
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®
®
vs. C83600.
C83600
®
General Comments on ECO BRASS Casting Behavior.
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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)
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.
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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
100X
Green Dot™ Rod (C69300)
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Lead
100X
400X
7/10/07
ά
κ+γ
400X
Blue Dot™ Rod (C36000)
&
®
™
The multiple phases in Green Dot result in higher machinability (70-80%) than conventional
silicon brass (30%)
ά
κ+γ
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
C69300 Green Dot™ ROD
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C69400 Silicon Red Brass
&
®
The kappa and gamma phases in the alpha matrix create small, Type 1 chips, similar to lead in
C36000.
Green Dot™ Rod
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Free-Cutting Brass
60 Cu – 40 Zn
&
®
™
Machinability of Green Dot is 70-80% of C36000 (1)
Machinability (%)
100
80
60
40
20
0
C36000
Green Dot
CDA Published Value
TechSolve C360 Standard Machining Test Parameters
TechSolve - Sambo Recommended Machining Parameters
(1) Plunge tests: AISI T15 high speed steel, 5% Cimperial 1070 cutting fluid; drill test: high speed steel, straight oil.
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®
Ranking (1=Best)
Cutting Force, Drilling Force and Surface Finish – Relative Values.
7
6
5
4
3
2
1
0
Machining Parameters
Turning – 1575 ipm; 0.004 ipr;
0.039” cut depth
C36000
GREEN
DOT™
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303 SS
Turning - Main Force
Turning - Feed Force
Drilling - Torque
Drilling – Thrust Force
Machined Surface Roughness
7/10/07
(1)
Drilling – 0.138” dia.; 0.007 ipr;
1250 rpm
Surface Finish – 4330 ipm for
brasses; 1970 ipm for 303;
(1) Based on data from
Sambo. Relative values
calculated using best
value as denominator.
®
Compared to 303 stainless steel, Green Dot requires 60 – 70% less force to turn.
Turning Cut into 2.000"RD Rod 1138 RPM, 0.050" Cut
800
0.125" Plunge Cut into 2.000"RD Rod 1556 RPM
600
400
200
0
0.0045 ipr
0.007 ipr
Green Dot
303 Stainless Steel
0.012 ipr
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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Force (Newtons)
Force (Newtons)
1000
1000
900
800
700
600
500
400
300
200
100
0
0.003 ipr
Green Dot
0.0045 ipr
303 Stainless
0.007 ipr
C360
Machinability Rating
(%)
Machinability Comparison Between ECO BRASS, Leaded and Lead-Free Copper Alloys
100
80
60
40
20
0
C92200
C83600
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Alloy
C87500
C89520
EcoBrass
C84400
C89833
®
&
The CuZnSi particles which improve machinability do not cause warm brittleness cracking
ImpactStrength
Strengthas
as aa Function
Function of
Impact
of Temperature
Temperature
Impact Strength (J/cm2)
Impact Strength (J/cm2)
350
350
300
300
250
250
200
200
150
150
100
100
50
50
0
0
20
150
200
250
300
20
150
200Temperature
250 (C)300
350
350
400
400
Temperature (C)
EcoBrass with
with 0.01%Pb
0.01%Pb
EcoBrass
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C36000
C36000
60Cu-38Zn-2Bi
60Cu-38Zn-2Bi
&
®
Corrosion Resistance
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™
Phosphorus and lower zinc levels in Green Dot give it measurably superior resistance to
dezincification.
Corrosion depth after
ISO6509
dezincification test
(12.7 g/l CuCl2.2H2O for
24 hrs. at 167F).
This type of
performance applies to
rod, forgings and
castings.
C69300 Green
Dot™
C36000
™
Maximum corrosion depth of C360 and C377 = 0.04" (1.0mm) while Green Dot is almost zero.
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®
Comparison of ISO 6509 test results shows ECO BRASS excellent dezincification resistance.
900
00
0
1 900
0
Cross-hatched bars
indicates dezincification
occurred. Solid bars
indicate there was general
corrosion only.
700
600
500
400
300
200
0
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80
800
17
0
12
0
20
100
7/10/07
0
90
20
10
15
5
Maximum Corrosion
0
70
5
Corrosion Depth (μm)
1000
5
5
5
Average Corrosion
C36000
C37700
Eco Brass w/o P
C87500
Green Dot Rod
Green Dot Forging
Eco Brass Casting
C83600
®
&
™
Silicon, low zinc, high strength levels: These give Green Dot high stress corrosion cracking
resistance.
Results of Stress Corrosion Cracking Tests
Hours to Appearance of
Cracks
No cracks
600
580
580
512
512
500
400
288
300
CES A Test: (Communication
Equipment Standard - Japan)
NH4Cl + NaOH (pH 10), 72 hrs.,
68F; 1500 kgf torque
290
200
72
100
0
4 32 4
Green Dot
Hex Rod
JIS A Test
7/10/07
JIS A Test: (Japanese Industrial
Standard)
NH4OH (11.8% min.),
2 hrs., 68F; 1500 kgf torque
Page 37
Green Dot
Forging
CES A Test
C360 Hex
Rod
4
4
C377 Hex
Rod
Mattsson Test
Mattsson Test: (ASTM G37-1998)
(NH4SO4 + CuSO4-5H2O + NH4OH),
no minimum time, 68F, 1500 kgf
torque
&
Maximum corrosion depth of ECO BRASS
®
®
in various corrosive environments.
Max. Corrosion
Depth (μm)
60
50
40
30
20
10
0
ISO6509
Sandy Soil - 9 Mo., 3.5pH
12 Months - Agitated Water
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Air - 9 Mo., 3.5pH
5 Months - Osaka
2 Yr. Hakui City
Clay Soil - 9 Mo., 3.5pH
12 Months - Still Water
2 Yr. Shiki City
&
Corrosion rates in hydrochloric and sulfuric acids.
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Joining and Plating
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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 Solder
Sn – 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)
Cu – 6%P – 5% Ag
(2)
(AWS A5.8, Class BCuP-3)
Cu – 6%P – 2% Ag
(2)
(AWS A5.8, Class BCuP-6)
(1) Most popular in the faucet industry
(2) Produced braze with C11000 tube that had the same breaking force as with
C36000
7/10/07
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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
7/10/07
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®
Precautionary Statement
1. 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.
Never mix Green Dot™ or ECO BRASS® scrap with leaded brass alloys.
7/10/07
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