eco brass casting properties - california metal-x · pdf filegating & risering •...

Ver. 4/14/09 1

Casting C87850

Larry MullerManager, Metallurgy and Technical Services

Chase Brass & Copper Co., LLCMontpelier, OH

Ver. 4/14/09 2

C87850 Water Meter Bodies

Major Elements Rem.

Zn(%)

0.05 – 0.20

P(%)

2.7 – 3.4

Si(%)

74.0 – 78.0

Cu(%)

C87850 Chemical Requirements

0.10

Sb(%)Residual

Elements 0.20

Ni(%)

0.10

Fe(%)

0.500.100.300.09

TOEMn(%)

Sn(%)

Pb(%)

Ver. 4/14/09 3

16161680

1810 1840 1842 1850 1877

14001500

1600170018001900

Alloy

Liquidus Temperatures (F)

ECO BRASS C87500 C92200 C84400C89520 C83600 C89833

Ver. 4/14/09 4

45

170

280 291 292 305353

0

100

200

300

400

Alloy

Freezing Ranges (F)

ECO BRASS C87500 C83600 C84400C92200 C89833 C89520

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Sand Cast Water Meter Bodies

Ver. 4/14/09 6

• Foundry: Tohoku, Fukushima Japan

• Original alloy: C83600

• Current alloy: C87850

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Background

• Reason for alloy change: Pb leachate reduction from 5 ppm ►1ppm

• Year alloy changed: 2000

• Current total production: Over 9 million

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Melting

• Charge materials: Run-around scrap, ingot, turnings

• Melting furnace: High frequency crucible

• Dross generation: Less than C83600

• Fume generation: Less than yellow brass

Ver. 4/14/09 9

Pattern Design

• Pattern shrinkage: 1.2% to 1.7%

• Pattern draft: 0.5º

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Gating & Risering

• Gating ratio: 1: 2-3: 3-6

• Sprue diameter: 0.6” – 1.2”

• Casting weight: 13mm - 1.47 lb

20mm – 2.74 lb

Ver. 4/14/09 11

Molding Sand

• Sand type: No. 90-100 AFS Olivene

• Binder type: No-bake, 8.4%

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Casting Parameters

• Liquidus temperature: 1616º F

• Melt temperature: 2100º F

• Pour start temp.: 1830 - 1960º F

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Gating & Risering

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Gating & Risering

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Shakeout Parameters

• Critical temperature: Controlled for C836

• Shakeout precautions: None

• Gate & riser removal: Cut-off

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Machining

• % Machinability: 90%-105% of C836

• Coolant: Machined dry

• Tooling type: Cutting – carbide

Drilling – carbide, HSS

• Tool life: 70%

Ver. 4/14/09 17

Microstructure

C87850 C83600

Ver. 4/14/09 18

Ver. 4/14/09 19

C87850 ASTM B208 Tensile Strength Results

Tensile Strength ksi

frequ

ency

58 60 62 64 66 68(X 1000.0)

0

2

4

6

8

Ver. 4/14/09 20

C87850 ASTM B208 Yield Strength Results

Yield Strength ksi

frequ

ency

22 24 26 28 30 32(X 1000.0)

0

2

4

6

8

10

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C87850 ASTM B208 Elongation Results

Elongation %

frequ

ency

15 19 23 27 31 350

2

4

6

8

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C87850 ASTM B208 Brinell Hardness Results

Brinell Hardness 500kg

frequ

ency

99 103 107 111 115 119 1230

2

4

6

8

Ver. 4/14/09 23

Summary of Sand Casting Parameters for C87850

• Gating system: Non-pressurized or pressurized; suggest gating like silicon bronze

Tapered sprue or reverse taper + choke

Spread ingates out to prevent hot spots

• Pouring temperature: Keep it low (melting T = 1615F; suggest 1950F maximum)

• Risers: Use sufficient riser necks if risers are necessary at all

Ver. 4/14/09 24

Corrosion Resistance

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Corrosion depth after ISO6509

dezincification test(12.7 g/l CuCl2.2H2O for

24 hrs. at 167F).

Maximum corrosion depth of C360 and C377 = 0.04" (1.0mm) while ECO BRASS is almost zero.

ECO BRASS C36000

Phosphorus and lower zinc levels in ECO BRASS give it superior dezincification resistance.

Ver. 4/14/09 26

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

170

120

20 20 15

5

100

70

0.1 0.1 0.1 0.1

0

20

40

60

80

100

120

140

160

180

Maximum Average

ECO BRASS w/o P C87500 ECO BRASS Rod

ECO BRASS Forging ECO BRASS Casting C83600

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

Cor

rosi

on D

epth

(μm

) 170 μm = 0.0067”

Ver. 4/14/09 27

ECO BRASS dezincification resistance data shown in the Turner Diagram

Transition boundary for C353304

Results for ECO BRASS

Transition boundary for C3853

Layer-type dezincification2

Plug-type dezincification1

Key to the Graph

1

2

3

4

Calcium Carbonate (mmol/L)

Res

idua

l Chl

orid

e (m

l/L)

Ver. 4/14/09 28

Maximum corrosion depth of ECO BRASS® in various above and below ground environments.

0

20

40

60

Maximum Dezincification Depths (microns)

ISO6509 Air - 9 Mo., 3.5pH Clay Soil - 9 Mo., 3.5pHSandy Soil - 9 Mo., 3.5pH 5 Months - Underground (Osaka) 12 Months - Still Water12 Months - Agitated Water

Ver. 4/14/09 29

Water meter body performance in Japan shows comparable behavior with C836 and bismuth brass. 13mm and 20mm refer to water meter orifice size.

100

45

80

100

220

50

0

20

40

60

80

100

120

140

Max

imum

Dez

inci

ficat

ion

Dep

th(m

icro

ns)

3.8 Yr.(13mm)

5.2 Yr.(20mm)

7 Yr.(20mm)

8 Yr.(13mm)

C83600 ECO BRASS CAC 902

4.0-6.00.30 max4.3-6.0Tin

1.0-2.5--Bismuth

0.25 max0.09 max4.0-5.7Lead

84.5-90.074.0-78.084.0-86.0Copper

4.0-8.0Rem.4.3-6.0Zinc

-0.05-0.20-Phos.

-2.7-3.4-Silicon

CAC902ECO BRASSC83600

48020mm

44313mm

CAC902ECO BRASSC83600#

Measured

Ver. 4/14/09 3009M-0408

290

4 4

050

100150200250300

Hou

rs to

App

eara

nce

of

Cra

cks

ECO BRASS C360 Hex Rod C377 Hex Rod

Results of Stress Corrosion Cracking Tests

ECO BRASS C360 Hex Rod C377 Hex Rod

No cracks

ASTM G37NH4SO4 + CuSO4-5H2O + NH4OH 68F, 1500 kgf torque

Silicon, low zinc, high strength levels give ECO BRASS high stress corrosion cracking resistance.

Ver. 4/14/09 31

Permanent Mold Cast Water Meters

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• 13mm: High Pressure Die Cast

• 13mm production: 500,000

• 20mm: Low Pressure Permanent Mold

• 20mm production: 50,000

Ver. 4/14/09 33

Equipment

Mold

Spout

Ver. 4/14/09 34

Equipment

C17510 Mold Interior Pour Spout

Ver. 4/14/09 35

Sand Core• Silica sand with phenolic resin binder

Ver. 4/14/09 36

Casting Parameters

1571Solidus

1616Liquidus

Temperatures (F)

1830Casting

250Mold