Welcome to Calmet’s brass casting manufacturing hub, where precision meets strength. Explore our diverse range of brass casting solutions, meticulously crafted to meet industry standards and your unique specifications. From alloy selection to final inspection, we ensure the highest quality at every step. Trust us to bring your vision to life with durable, reliable, and precisely engineered brass castings. Discover the excellence that defines us – your trusted partner in brass casting innovation.
Brass Casting alloy offers popular in many domestic and industrial applications. Warm, golden color that can be polished to a high shine and is therefore a popular choice for decorative and architectural applications. Corrosion Resistance to external exposure makes it a suitable choice marine, water distribution, and architectural applications. Machinability makes it easy to produce precise and accurate parts with a good surface finish. Good Electrical Conductivity makes it a suitable choice for electrical usages.
Sand casting is a traditional and widely-used method for brass casting. In this process, a mold is created by compacting sand around a pattern of the desired brass component. Once the mold is formed, molten brass is poured into the cavity created by the pattern. After the brass solidifies, the mold is broken to reveal the brass casting. Sand casting is known for its cost-effectiveness, simplicity, and ability to produce complex shapes. Depending on the specific cast brass parts appropriate mold is chosen:
Investment casting, also known as lost-wax casting, is a precise and intricate method used for producing high-quality brass components. In this process, a wax pattern of the part is created and coated with a ceramic shell to form the mold. The wax is then melted and drained, leaving a cavity that is filled with molten brass. Once the brass solidifies, the ceramic shell is broken to retrieve the brass casting. Investment casting is favored for its ability to produce detailed and dimensionally accurate parts with excellent finish. We apply appropriate processes of Colloidal Silica, Micro Investment and Vacuum Assisted Investment Cast depending upon the intricacy, size and the production runs.
This is a method where molten brass is injected into a steel mold under high pressure. The detailed preocess is summarized with following key steps: Mould making is for basically producing a replica of the final die cast brass part required. The mold is preheated to reduce thermal shock. Injecting Molten brass into the mold under high pressure for solidification and finally taking out the brass casting from the mold. The advantages of die cast process are High production rate, Good dimensional accuracy and surface finish. The initial mold cost is high and it is limited to simple geometries.
| Composition | Brass | Bronze | Copper |
|---|---|---|---|
| Elements | Primary: Copper, Zinc. Others: Lead, Manganese, Iron, Aluminum, Silicon. |
Primary: Copper and Tin. Others: Nickel, Aluminum, Zinc, Phosphorus. |
Copper |
| Corrosion Resistance | Good Corrosion Resistance | Excellent Corrosion Resistance | Excellent Corrosion Resistance |
| Weight | 8720 kg/cu.m | 7400 – 8900 kg/cu.m | 8930 kg/cu.m |
| Durability | Highly durable | Highly durable | Durable |
| Machinability Level | Lower | Moderate | High |
| Weldability Level | Good | High | High |
| Electrical Conductivity Relative to Copper |
0.28 | 0.15 | 1 |
| Thermal Conductivity | 64 BTU/hr-ft²-°F | 229 – 1440 BTU/hr-ft²-°F | 223 BTU/hr-ft²-°F |
| Tensile Strength | 338 – 469 MPa | 350 – 635 MPa | 210 MPa |
| Yield Strength | 95 – 124 MPa | 125 – 800 MPa | 33.3 MPa |
| Melting Point | 927 °C | 913 °C | 1085 °C |
Alpha Brasses, a substitution solid solution of zinc in copper, contain 67-72% copper and 28-33% zinc. They are malleable and utilized in pressing, forging, and other related applications. Alpha brasses only have one phase and a face-centered cubic crystal structure. These brasses have a richer golden tone. It is robust, strong, and relatively difficult to machine. The best formability is achieved at 32% zinc. Corrosion-resistant can be worked cold.
Alpha-beta Brasses, also known as duplex brasses, are suitable for hot working, contain 55–65% copper and 35–45% zinc. They include both α and β’ phases. The β’-phase is ordered body-centered cubic, with zinc atoms in the centers of cubes, and is tougher and stronger than α. At 45% zinc, the alloy possesses its highest strength and because of the higher zinc content, these brasses are brighter than alpha brasses.
Beta Brasses contain 50–55% copper and 45–50% zinc. They are harder, stronger, and appropriate for casting. Because of the high zinc-low copper content, they are among the brightest and least golden of the typical brasses. Beta brasses are often used for higher–strength applications, such as valves, gears, and bearings. These brasses can only be worked hot.
Gamma Brasses contain 33–39% copper and 61–67% zinc. There are also Ag-Zn and Au-Zn gamma brasses, with Ag 30-50% and Au 41%, respectively. The gamma phase is an intermetallic compound with a cubic lattice structure, Cu5Zn8. Gamma brasses are typically used for specialized applications, including high-strength electrical contacts and fasteners.
| PROPERTIES | A260 | A280 | A360 | A385 | A464 |
|---|---|---|---|---|---|
| Density (g/cm3) | 8.53 | 8.39 | 8.49 | 8.47 | 8.41 |
| Hardness, Rockwell (F, B) | 54 F | 85 F | 78 B | 65 B | 55 B |
| Yield Strength (MPa) | 75 | 145 | 124-310 | 138 | 172-455 |
| Ultimate Tensile Strength (MPa) | 300 | 370 | 338-469 | 414 | 379-607 |
| Elongation @ Break (%) | 68 | 45 | 53 | 30 | 50 |
| Modulus of Elasticity (GPa) | 110 | 105 | 97 | — | 100 |
| Machinability (%) | 30 | 40 | 100 | 90 | 30 |
| GRADES AND APPLICATIONS | |
|---|---|
| Alloy 260 - Cartridge Brass | Another name for alloy 260 is cartridge brass. About 70% of this brass alloy is made of copper and 30% is zinc. Alloy 260 is easily cold-workable and has good hot formability. Among other things, it is utilised in fasteners, hardware, ammunition, and automobile components. |
| Alloy 280 - Muntz Metal | About 60% copper and 40% zinc make up Alloy 280. Muntz metal was frequently used as a less expensive substitute for the copper sheeting that was formerly applied to boat hulls to prevent the growth of marine life, such as barnacles. |
| Alloy 360 - Free Machining Brass | Alloy 360 comprises around 60% copper, 35.5% zinc, up to 3.7% lead, and 0.8% of iron. This is also an excellent choice for brazing and soldering applications. Designers and machinists it to create fittings, fasteners, valves & hardware components. |
| Alloy 385 - Architectural Bronze | The composition of alloy 385 is around 59% copper, 42% zinc, and up to 3.5% lead. This greatly improves its formability and machinability. This alloy is a fantastic architectural material for aluminium extrusions since it is simple to form. |
| Alloy 464 - Naval Brass | Naval brass, also known as alloy 464, is a corrosion-resistant metal composed of 40% zinc, 1% tin, and 59% copper. It is versatile in bending, soldering, welding, and cold and hot forming processes, making it ideal for various applications, including boat deck fixtures. |
Our goal is to manufacture and deliver products as per the requirements meeting your standards and specifications. It’s not about the details alone, but we also incorporate and put in our expertise to ensure superior quality products are delivered to you on time and every time!
A leading automotive manufacturer required a reliable supplier for precision brass castings to meet their stringent quality and performance requirements for the latest engine components. The customer needed components that could withstand high temperatures and harsh operating conditions while providing exceptional durability and precision fit.
Our experienced team of engineers and metallurgists worked closely with the customer to understand their specific needs and challenges. Leveraging our expertise in brass casting technologies, we recommended the use of high-quality copper-zinc alloys that offered superior strength, thermal conductivity, and corrosion resistance. Through meticulous design analysis and simulation, we optimized the casting process to ensure the parts would meet the customer’s performance expectations.
Utilizing our state-of-the-art facilities and advanced casting techniques, we delivered precision brass castings that met the customer’s exact specifications. Our quality control measures, including rigorous testing and inspection protocols, ensured that each component met the highest standards for dimensional accuracy, surface finish, and material integrity. The final brass castings exhibited excellent mechanical properties and dimensional stability, surpassing the customer’s expectations for performance and durability.
The customer was extremely satisfied with the quality and precision of the brass castings provided by our firm. The components seamlessly integrated into their engines, delivering optimal performance and reliability under demanding conditions. Our efficient production processes and responsive customer service further solidified our relationship with the automotive manufacturer, paving the way for future collaborations on additional projects.
To maintain a competitive advantage in the steel casting industry, Calmet always evaluates its unique strengths and value proposition. Here are some factors to consider while analyzing competitive advantage that Calmet offers:
Sustainable manufacturing focuses on minimizing the environmental impact and maximizing resource efficiency throughout the manufacturing process using the below commonly used techniques:
Innovative technologies can revolutionize the brass casting manufacturing industry, enhancing efficiency, quality, and customization capabilities. Some notable advancements at Calmet include:
The brass casting manufacturing industry is subject to various regulations, which ensure safety, quality, and environmental compliance. Key regulations may include:
