Chemical formula of brass. A variety of applications of brass in everyday life and construction. The main properties of brass

Perhaps the most interesting, based on the variety of qualities, brands, characteristics and scope, is a brass alloy. And, despite the fact that its price is lower than that of, say, copper, it is used even in the manufacture of jewelry. The composition of brass is simple, but the various proportions give such varied qualities that it needs to be told in detail.

Composition and classification of brasses

The classical composition assumes the presence of copper and zinc in the alloy in a ratio of 2: 1, respectively. Such brass was known to the Ancient Romans. Skeptics will remember that pure zinc was discovered in the 16th century. But in the case of Ancient Rome, we are talking about a zinc-containing rock, which at that time was already being processed.

In those days, it was believed that it was the presence of zinc that determined the color, and only later it became known that the sunny shade of the brass alloy is due to the fact that the presence of zinc dilutes the copper redness.

  • Brass is divided into two-component (simple) and multi-component (special).

One of the markings of products, the material for which is brass, means the percentage of components. So the letter L indicates the type of alloy - brass. and the adjacent numerical index indicates the copper content in the composition. For example, L80 stands for "brass, consisting of 80% copper and 20% zinc."

Two components - not a mandatory requirement. If there are more of them, then each component introduced into the composition of brass is displayed in the marking using the corresponding letter symbol following the letter L. Tin, nickel or lead can act as additives. In this case, brass changes its properties.

Additives are introduced into the alloy to achieve certain goals. For example, brass in the classical proportion cannot be used in shipbuilding. All due to the instability of brass to the effects of saline solutions ( sea ​​water). Additives introduced into the composition of the alloy solves this problem, while maintaining the main characteristics.

  • According to the degree of processing, alloys are: wrought (brass tape, wire, pipe, brass sheet) and foundry (reinforcement, bearing, instrument parts).

Wrought Two-Piece Brasses

Wrought multi-component brasses

Cast brass

Additives in alloys

Alloying elements are used in brass. These are substances introduced into the alloy in order to change the structure, and as a result, the characteristics. These elements include:

  1. Aluminum. The presence of aluminum in the alloy reduces the volatility index. As a result of interaction with oxygen, a layer of aluminum oxide is formed on the surface of the product, which eliminates the volatility of the material.
  2. Magnesium. This additive, most often, is introduced in combination with iron and aluminum. Thus, the structure changes, and the alloy becomes stronger, wear-resistant, and corrosion-resistant.
  3. Nickel. This type of additive is introduced to neutralize the effects of oxidative processes.
  4. Lead. The presence in the composition of this alloying element provides the material with ductility. It becomes more malleable, more easily amenable to mechanical stress, including cutting. It is used for products that do not imply a bearing function during operation.
  5. Silicon. The additive is introduced to increase the strength of the metal and its rigidity. If lead is added in parallel, then the anti-friction qualities will improve. Again, alloys of copper, zinc, silicon with lead and bronze with tin become competing. The cost of the latter is higher.
  6. Tin. This metal is added to negate the risk of corrosion pockets. This is especially important in shipbuilding. With the addition of tin, salt water is not afraid of metal.

Domestic use of brass

Brass is characterized by softness and ductility during machining. At the same time, alloys characterize strength. External resemblance to gold determined its popularity in jewelry production. Brass is used to give a golden hue to orders and medals, as well as to decorate dishes. Jewelry and accessories from it has an attractive appearance at the lowest price.

Brass shades came to the service of jewelers:

  1. M 67/33 yellow;
  2. M 60/40 green;
  3. M 75/25 golden;
  4. M 90 bright yellow.

L62 and L68 are needed as simulators for students of jewelry art. This choice is due to the similarity in characteristics. But for the manufacture of insignia, brass is used, in which 15% is zinc, and 5% is aluminum. These products are durable.

Brass is characterized by durability. Jewelry from this alloy does not know old age and demolition. Knowing about this capacity Having selected the optimal composition, Zippo manufactures most models of lighters from brass. The steel facade appears due to the galvanic process (chrome plating). The presence of a brass alloy in the base serves as a distinctive feature of the original products, where brass is the main material, from a fake, where there are no brass parts.

The main application of products from a two-component alloy was found in fasteners and valves. These are bolts and screws, coils and adapters, taps and gate valves. Brass is used, the composition of which includes the maximum percentage of copper. The purpose of this composition of the brass alloy is to minimize the cost.

The use of multicomponent alloys (the composition includes more than two ingredients) is wider. This:

  • aviation;
  • shipbuilding;
  • refrigeration equipment (brass heat exchanger tubes);
  • manufacture of watch movements, etc.

All due to the fact that brass alloys are malleable, soft, but at the same time it is a durable material.

Brass is cleaned and polished with oxalic acid. It is sold in hardware stores and building materials. Before processing the alloy, the concentrated composition of the acid must be diluted at the rate of 200 ml per 10 liters of water. Only then can the product be treated with an acid composition.

Brass manufacturing technology

To get a brass alloy, you need to follow a series of steps:

  1. Put copper raw materials in an earthenware bowl, after weighing it.
  2. Send the bowl to a special furnace.
  3. Lump zinc and necessary additives are placed in molten copper.
  4. The resulting alloy is melted to a homogeneous composition.

Liquid hot brass is poured into molds. Furnaces for the manufacture of the alloy usually run on solid fuel - coal.

A problem with melted brass alloys is zinc evaporation. Therefore, melting plants are equipped with absorbent systems to capture it, after which it is introduced into the brass alloy again. The next feature of the alloy manufacturing technology is the need for remelting. During the primary, brass shrinks, and deflections are formed in the products.

The temperature required for melting brass cannot be lower than +800 0 C. The exact indicator is calculated for each brand of brass separately. The amount of zinc in the composition of alloys is inversely related to the melting point of brass. That's the whole technology.

The special role of the composition of brass

Brass can look like bronze in appearance, if the compositions and proportions are chosen correctly, and the surface of the brass is processed. Today, due to the lower cost, copper-zinc alloys have begun to win positions in the market. The once popular bronze chandeliers, sconces, decor items and faucets are now increasingly made of brass.

And so that outwardly it was impossible to catch differences in alloys, the surface of brass is subjected to a special chemical composition. This is how plumbing brass is made.

The conquest of the decorative metals market does not end there. Now brass is a material for headboards, candlesticks, kitchen hoods and utensils, and other interior elements. Alloys are not in vain received the status of the most important metals in the world. And even typographic fonts are brass.

How to distinguish gold from brass

Brass is a useful material not only for ordinary citizens, but also for scammers.

A trained eye can distinguish a noble metal by its characteristic shade. But if you have an ornament with you, the authenticity of which cannot be questioned, then you can compare it under a magnifying glass. The main thing is that both copies are of the same sample. The density of gold is twice as high, which means that items of identical size should weigh the same. Again, a control sample is required.

Brass is an alloy based on metals: copper and zinc. The zinc content in the alloy can be from 5 to 45%. Zinc is cheaper than copper, for this reason its addition to the alloy not only improves the mechanical, anti-friction and technological properties, but also reduces the cost of brass.

Brass can be called the most outlandish alloy of antiquity. In the Roman Empire, the production of the alloy began in the 1st century BC. Among the precious metals, brass ranked third after silver and gold. In the East, alloy has been known since the 8th century. The source of copper, lead and silver is the Anarak mine, which is located in northern Iran. There is evidence of the use of brass alloys in the VIII-IX centuries in the North-Western Caucasus. The inhabitants of the North Caucasus could buy brass from Asia Minor along the Silk Road. In England in 1781, brass was made by alloying copper with zinc.

Brass classification

Depending on the chemical composition, there are:

  • Plain (two-component) brasses. They contain only copper and zinc. Plain brass are marked with the letter "L" and a number that indicates the percentage of copper. For example: L85 contains 85% copper and 15% zinc.
  • Special (multi-component) brasses. They contain copper, zinc, lead, aluminum, iron and other elements that improve the basic properties of the material. Such elements are called alloying elements. Special brasses are marked with the letter "L", as well as letters and numbers indicating additional alloying elements and their percentage. For example: LA77-2 contains 77% copper, 2% aluminum and 21% zinc.

Special brasses are divided into classes named after the main alloying element (manganese, aluminum, silicon, tin, nickel, lead).

According to the degree of processing of brass there are:

. deformable(brass tape, wire, pipe, brass sheet);
. foundry(fittings, bearing, parts of devices).

More about brass alloys

Brass L63, Brass LS59-1

There is also a classification according to the amount of zinc in the alloy:

5-20% zinc - red brass (tompac);
. 20-36% zinc - yellow brass.

The main properties of brass

Brass lends itself well to pressure treatment. Mechanical properties are relatively high, corrosion resistance is satisfactory. If we compare brass with bronze, then their strength, corrosion resistance and anti-friction properties are less. They are not very stable in air, in salty sea water, in carbonic acid solutions and in solutions of many organic acids.

Brass has a beautiful color and, in comparison with copper, has better corrosion resistance. However, as the temperature increases, so does the rate of corrosion. This process is most noticeable in thin-walled products. Corrosion can be provoked by: humidity, traces of ammonia and sulfur dioxide in the air. To prevent this phenomenon, brass products are subjected to low-temperature firing after processing.

Almost all brass, when the temperature is lowered (to helium temperatures), remain ductile and do not become brittle, which makes it possible to use them as a good structural material. Due to more high rate recrystallization temperatures (300-370 ° C) than copper, at high temperatures the creep of brass will be less. At an average temperature (200-600°C), the phenomenon of brittleness occurs, since impurities that are insoluble at low temperatures (for example: lead, bismuth) form brittle intercrystalline layers. As the temperature rises, the impact strength of brass decreases. Compared to copper, the electrical and thermal conductivity of brass is lower.


Consider how alloying elements affect the properties of brass.

  • Tin significantly increases the anti-corrosion properties in sea water, increases the strength of the alloy. Brass with tin is often called marine.
  • Manganese increases strength, corrosion resistance. Manganese brasses are often combined with tin, iron and aluminum.
  • Nickel improves corrosion properties and strength in various environments.
  • Silicon reduces strength and hardness, and improves weldability. Brass containing silicon and lead have good anti-friction properties. Such alloys can replace more expensive ones, such as tin bronzes.
  • Lead significantly improves machinability, but at the same time degrades mechanical properties. Lead brass is called automatic, as they are processed on automatic machines. This alloy is the most common.
  • Aluminum reduces the volatility of zinc, due to the formation of molten brass on the surface protective film(aluminum oxide).

How to get

The technology for producing brass involves the processes of the copper and zinc industries, as well as recycling. Raw materials for the production of alloys are blanks of copper, zinc and other metals for the production of multicomponent alloys. We also use our own production waste and secondary raw materials. All blanks are made in accordance with GOST.

Used to melt brass different kinds melting furnaces used for melting copper alloys. The most efficient are low-frequency electric induction furnaces with a magnetic core. Melting is carried out under exhaust ventilation, since some elements of the alloy evaporate intensively and can harm human health. It is undesirable to overheat the alloy, because of the likelihood of some components igniting in air. Pure and recycled metals are used as charges for melting brass.

Raw materials are preliminarily prepared, and the ovens are cleaned. Copper heated to red heat is placed in a furnace, and then lumpy billets of zinc are added. During the melting of copper-zinc alloys, the significant oxidizability of zinc is taken into account. To reduce oxidation, a number of measures are taken. For the manufacture of multicomponent alloys, copper is added first, and then the remaining components with care.


A homogeneous mass is poured into molds to obtain foundry brass. As a result, flat and round ingots are obtained. Wrought alloys after casting are subjected to a deformation procedure. The resulting products differ in the degree of hardening and aging, as well as the hardness of the material. Preliminary heat treatment of blanks significantly increases the strength and corrosion resistance of brass.

Application

Brass produces cooling systems for motors, a variety of bushings, adapters. The alloy is used in the construction industry. For example, for the manufacture of sanitary equipment and design elements. Fasteners such as bolts and nuts are also made from brass. This alloy is used in shipbuilding and in the manufacture of ammunition.

There are several types of brass rolled products:

BRASS and ROLLED BRASS

Brass classification

Brass is an alloy based on copper and zinc. By chemical composition, they are divided into simple (only copper and zinc) and special (along with copper and zinc, they contain Pb, Fe, Al, Sn and other elements). The chemical composition of brass is defined in GOST 15527-2004.

Plain brass marked with a letter L and a number indicating the percentage of copper: L96, L90, L85, L80, L75, L68, L63. The zinc content is determined by the remainder of 100%.

For example, L63 contains 63% copper and 37% zinc. Plain brasses are also called double brasses (two main components).

Special brass In addition to zinc, they contain other alloying elements. Their marking includes additional letters and numbers indicating alloying elements and their content in%. The zinc content is determined by the remainder of 100%. For example LS59-1 contains 59% copper, 1% lead and 40% zinc. Multicomponent brasses are divided into classes, which are named after the main (except zinc) alloying element.

The table shows the main brands of brass. They are used both for casting (casting) and for the production of rolled products (wrought). Some brass are used for welding and soldering (GOST 16130-90). They are highlighted in yellow in the table.

SIMPLE ALUMINUM SILICIAN TIN LEAD
L96 LA85-0.5 LK80-3 LO90-1 LS74-3
L90 LA77-2 LK62-0.5 LO70-1 LS64-2
L85 LA67-2.5 LKS65-1.5-3 LO62-1 LS63-3
L80 LAZH60-1-1 LO60-1 LS59-1
L75 LAN59-3-2 MANGANESE LOK59-1-0.3 LS59-2
L70 LZhMts59-1-1 LS58-2
L68 LANKMts 75-2-2.5-0.5-0.5 LMts58-2 NICKEL LS58-3
L63 LMtsA57-3-1 LN65-5 LZhS58-1-1
Brass structure.

Depending on the chemical composition brass can be single-phase, two-phase and multi-phase.

Most plain brasses and some specialty brasses are about single-phase ( ? -brass) and are a solid solution of zinc in copper (? -phase). They have good ductility over the entire temperature range, so single-phase? - brass, for example L68, are well processed by pressure at high and low temperatures.

Duplex Brassescontain inclusions of hard and brittle phases, for example ? -phase . ( ? + ? ) Brass and other two-phase brass are subject to limited pressure treatment (for example, only at high temperatures).

WITH screw brass have a structure (? +Pb) or ( ? + ? +Pb).Practically insoluble in brass, lead is present as an independent phase,which provides excellent machinability.

With an increase in the content of alloying elements, additional hard and brittle phases can appear. Therefore, doping with an additional component usually does not exceed 0.5 - 3% (see the table of brass grades).

The phase composition determines belonging to the class of cast or wrought brass, the possibility of producing various semi-finished products and their properties. More about the structure of brass - Structure and properties of alloys .

General properties of brasses

Plain brass .

The hardness, yield strength, tensile strength and ductility of simple brass are higher than those of copper. In general, these figures increase with increasing zinc content. L68 has the best plasticity (the largest drawing depth for sheets, the largest number of kinks for wire). In L63 quantity? -phase is insignificant and it has little effect on the plasticity of L63 and its ability to be processed by pressure at low temperatures, but requires strict adherence to the cooling regime.

All types of rolled products are made from simple brass. All simple brasses have good casting properties and can be used to produce castings. Plain brass, like copper, do not have anti-friction properties.

Special brass .

Special brasses have greater strength, better corrosion resistance to a greater number of media than simple brasses. Most special brasses have good anti-friction properties.

Many of them are resistant to sea water (tin, aluminum, silica, manganese), superheated steam (manganese brass), etc. Some of them combine excellent corrosion properties with good antifriction properties (LK65-1.5-3, LO90-1, LZhMts59-1-1). The special resistance of individual brasses to specific media under specific operating conditions determines the scope of their preferential application. For example, pewter brasses are called "marine brasses".

The most common are lead brass. Their main property is excellent machinability. This is manifested in the possibility of high-speed processing of workpieces with low tool wear. In this case, small loose chips are formed, which determines the cleanliness of the machined surface and the minimum work hardening during cutting. This determines the use of lead brass for the manufacture of small parts for precision mechanics.Their negative side is low impact strength, low bending strength in the presence of a notch. The most common lead brass is LS59-1.

LS63-3 brass has the best machinability. In relation to it, the machinability of non-ferrous metals and carbon steels is evaluated (as a percentage).

Almost all brass is a good structural material at low temperatures. Like copper, they retain ductility and do not become brittle when cooled down to helium temperatures.

Due to higher recrystallization temperatures (300-370 o C) the creep of brass at high temperatures is less than that of copper. In the zone of medium temperatures (200-600 ° C ) in brass, the phenomenon of brittleness is observed. It is associated with the formation of brittle intercrystalline interlayers from impurities insoluble at low temperatures (lead, bismuth). With increasing temperature, the impact strength of brass decreases.

The electrical and thermal conductivity of brass is noticeably lower than that of copper.

Some parameters of the physical and mechanical properties of the most common brasses (in comparison with copper) are given in the table:

MATERIAL
COPPER
L68
L63
LS59-1
LZhMts59-1-1
SPECIFIC ELECTRICAL RESISTANCE
0.018 0.064
0.065
0.065
0.093
THERMAL CONDUCTIVITY 0.925 0.28 0.25 0.25 0.18
IMPACT VISCOSITY
17 17 14 5 12
CUTTING STRENGTH, MPa
210 200 240 260 300
PROCESSIBILITY. %
18 30 40 80 25

Mechanical properties of brass rolled products

Almost all types of rolled metal are produced from brass.

Brass bars(round, hexagonal and square) are produced in accordance with GOST2060-2006. The ratings and states of bars of various grades are shown in the table.

State

bar

Brand of brass and bar diameters in mm

L63

L63-3

LS59-1

LS58-3

LZHS

58-1-1

LO62-1

LMts

58-2

PLWMC

59-1-1

LAJ

60-1-1

Solid

3 - 12

3 - 20

3 - 12

Polutv.

3 - 40

10 - 20

3 - 40

3 - 50

Soft

3 - 50

3 - 50

Pressed.

10 -180

10 - 180

The figure shows the values ​​of the main parameters of mechanical properties for bars made of several grades of brass and, for comparison, of copper (right side of the figure).

The figure clearly shows how much brass is harder and stronger than copper.

Among the semi-solid bars, the bars made of LZhMts59-1-1 and LMts58-2 have the maximum hardness and tensile strength. They combine excellent mechanical properties with good antifriction properties and increased corrosion resistance in atmospheric conditions and in sea water. LS63-3 brass in the solid state has the highest strength and hardness, but it is very brittle. Like most brasses, they have a relatively narrow application, based on a combination of specific mechanical, corrosion or processing properties of a particular brand of brass. They are produced to order and are practically not found on free sale.

Pressed, solid and semi-solid bars from cheap brass LS59-1 (circles and hexagons) and circles from L63 are mass-produced.

Flat brass general purpose is produced in the form of foil, tape, sheets and plates in accordance with GOST 2208-2007 from brass of a dozen different grades in various states of delivery (hot-rolled and cold-formed products). However, out of all the possible variety, only flat products from L63 and, to a lesser extent, from LS59-1 are on free sale. Other brands are available on request.

Below are histograms that give a general idea of ​​the mechanical properties of sheets from L63, LS59-1 and, for comparison, from copper.

In terms of strength and hardness, L63 noticeably surpasses copper, while stepping on LS59-1. The high hardness of work-hardened sheets from LS59-1 with good wear resistance determines their use for guides in machine tools.

The histogram does not show the parameter values ​​for L68, since they almost coincide with those for L63. Nevertheless, L68 sheets and tapes have better ductility. Sheets and tapes of this brand are used for the manufacture of parts by cold stamping and deep upsetting, incl. for the manufacture of cartridge cases, so it is often called cartridge brass.

Plasticity is determined not so much by the relative elongation in tension (this indicator is the same for L68 and L63), but by technological tests. Based on their results, the number of bends (for wire), the minimum bending radius, and the depth of extrusion by a punch (for tapes and sheets) are determined, at which the sample is not yet destroyed.

In terms of the depth of extrusion of tapes (without the appearance of tears and cracks), L68 is superior to both L63 and, moreover, copper. This difference increases with increasing tape thickness. For these brasses, extrusion is possible not only in soft, but also in deformed states.

brass pipes general purpose produce cold-formed (L63, L68) and pressed (L63, LS59-1, LZhMts59-1-1) according to GOST 494-90. From many grades of brass, pipes for special purposes are produced according to various specifications. Boiler pipes from L63 or from L68 are widely used, the latter being preferable because of the better corrosion resistance of L68. The method of continuous casting from LS59-1 produces cheap pipe blanks.

brass wire made of L80, L68, L63 and LS59-1 (GOST 1066-90). Mass-produced wire from L63 (in soft, hard and semi-hard states) with a diameter of 0.1 to 12 mm. Wire from L63 is used for rivets and as a solder. L63 wire of increased accuracy is used as electrodes in electroerosive machines.

The availability of brass products in stock can be found on the page "Brass bars, sheets. wire"

Corrosion properties of brasses

Brasses in general have better corrosion resistance than copper. However, semi-finished products in the cold-formed state (including after machining) from simple and many special brasses are subject to stress corrosion cracking. The most sensitive to stress corrosion cracking are L68 and L63. The rate of corrosion increases sharply with increasing temperature. This type of corrosion is most detrimental in thin-walled products.

The main cause of corrosion cracking is the residual tensile stresses in the metal, and the provoking factors are the presence of moisture, traces of ammonia and sulfur dioxide in the atmosphere. This phenomenon is called seasonal, because. it depends on humidity and its intensity is not the same in different seasons. To prevent this phenomenon, semi-finished products and products after processing are subjected to low-temperature annealing atwhich relieves internal stress.

Naturally, different brasses have different degrees of corrosion resistance in the same environments. The special resistance of individual brasses to specific media and operating conditions (quiet state or flow, aeration, impact environment) determines the scope of their application.

The general characteristic of the corrosion resistance of brass is as follows:

Brass resistant in the following environments (at normal temperatures):

Air, incl. nautical

Dry steam at low speeds (oxygen, carbon dioxide and ammonia accelerate corrosion)

Fresh water (ammonia, hydrogen sulfide, chlorides, acids accelerate corrosion)

In sea water at low water velocities

Dry halogen gases

Antifreezes, alcohols, freons

Relatively stable:

Alkalis without stirring

Brass unstable in the following environments:

Wet saturated steam at high speeds

Mine water

Oxidizing solutions, chlorides

mineral acids

hydrogen sulfide

Fatty acid

contact corrosion: brass should not be used in contact with iron, aluminum, zinc, because. it will rapidly deteriorate.

Comparison of properties of L63 and LS59-1

Practice shows that many consumers do not know what the differences are between the two most common brands of brass - LS59-1 and L63. So here are the answers to the most frequently asked questions.

1 . The electrical and thermal conductivity of these brasses is the same.

2 . These brasses differ from each other not because they have different copper content, but because lead is present in LS59-1. Thanks to lead, LS59-1 is perfectly sharpened with the formation of small loose chips.

3 . L63 is processed by cutting worse than LS59-1, but better than most bronzes, duralumin-mini and copper, i.e. it lends itself to turning without problems, it just has a different chip.

4 . In comparable states, rods from LS59-1 are not much harder and stronger than L63. However, in the presence of notches, bars from LS59-1 are easily subjected to brittle fracture under transverse loading. Impact strength LS59-1 (5-6) is much smaller than for L63 (14) . For these reasons, under certain operating conditions, parts from L63 may be more reliable than from LS59-1.

5 . L63 is easy to work with cold pressure. The difference in plasticity is clearly illustrated by a simple experiment: the wire from L63 is easily flattened, and the wire from LS59-1 cracks after 2-3 blows with a hammer. This favorably distinguishes L63 from LS59-1 and determines the use of L63 for the manufacture of parts that require, in addition to turning and milling, additional shaping by pressure.

6 . High ductility allows the use of L63 wire for the manufacture of rivets.

7 . Bars and wires from L63 are used as solder.

8. LS59-1 has good antifriction properties and can be used in plain bearings operating at low specific pressures and high speeds.

9 . Cold-formed sheets from LS59-1 have high hardness. combined with high wear resistance, this allows them to be used as guides in machine tools.

Brass is denoted by the letter “L”, and bronze “Br”, then there are letters indicating alloying elements: O - tin, C - zinc, Mts - manganese, F - iron, F - phosphorus, B - beryllium, X - chromium, C - lead, A - aluminum, H - nickel, Su - antimony, etc. Both bronzes and brasses are divided into wrought and cast, which is reflected in the marking.

In simple (unalloyed) wrought brass, the number following the letter "L" means% Cu. For example, L80 - 80% Cu, Zn - the rest (20%). If the wrought brass is multicomponent, the letter “L” is followed by the designations of all alloying elements in a row. For example, LAN59-3-2 (A - aluminum, H - nickel). The first digit in the brand is the percentage of copper, the subsequent ones are the percentage of the alloying element in the same order as the letters, zinc is the rest. Thus, LAN59-3-2 stands for: wrought brass with 59% Cu, 3% Al, 2% Ni, Zn - the rest. Wrought bronzes are also marked, only the amount of copper is not indicated, for example, BrOTsS8-4-3 stands for: wrought tin bronze containing 8% Sn, 4% Zn, 3% Pb, the rest Cu.

The marking of foundry brasses and bronzes is identical: after each letter, which means an alloying element, there is a number - the percentage of this alloying element. For example, LTs35N2ZhA cast brass, Zn 35%, Ni 2%, Fe up to 1%, Al - up to 1%, Cu - rest. BrA9Mts2 - cast aluminum bronze containing Al 9%? Mn 2%, Cu - rest. BrA9Mts2 - cast aluminum bronze containing Al 9%, Mn 2%, Cu - rest.

Brass.

On fig. 12.1 shows the Cu-Zn diagram, which shows that up to 39% Zn dissolves in copper. On fig. 12.2 shows how the properties change depending on the zinc content in brass. It can be seen that when Zn is dissolved, not only the strength but also the ductility of brass increases (the maximum passes at 30% Zn), thus, single-phase α-brasses are more ductile than pure copper. Such brasses (L96, L90 - tompak, L80 - semi-tompak, L68 - cartridge (sleeve), etc.) - are subjected to pressure treatment. Sheets, pipes, wire, bellows, musical instruments, pipes for heat exchangers, etc.

Rice. 12.1 Cu-Zn diagram

Rice. 12.2 Influence of Zn on the mechanical properties of brasses.

With a Zn content of more than 39%, a brittle "-phase" appears in brasses, while the strength of brasses becomes the highest, and ductility decreases. Upon transition to a single-phase "-region, both strength and ductility drop sharply, therefore brasses are not made with a Zn content of more than 45% (see fig. 12.2). Two-phase brasses are processed by pressure at temperatures above 700 0, when the "-phase is disordered and becomes sufficiently ductile.

Two-phase brasses are often alloyed, while the strength increases, and the ductility decreases.

Lead improves machinability (brasses LS60-1 and LS59-1 are automatic), tin, nickel, aluminum and manganese increase corrosion resistance. For example, LO70-1, LO62-1 are called "marine" brasses, LN65-5 for condenser tubes.

Parts can be made from brass not only by pressure, but also by casting: they have good fluidity, are little prone to segregation, which is explained by the small temperature range of crystallization (the liquidus and solidus lines are very close (see Fig. 12.1). Usually foundry brasses are multicomponent, and additives improve casting properties, as well as strength and give special properties (anti-corrosion, anti-friction, heat-resistant, etc.) For example, parts for shipbuilding and mechanical engineering are made from brass LTS30A3, fittings for automobile hydraulic systems are made from brass LTS25S2, critical parts are made from LTS23A6ZHZMts and anti-friction parts.

Bronzes.

Tin bronzes are the oldest metal alloys(Bronze Age). Now tin bronzes are used less and less due to the scarcity of tin.

Bronzes containing up to 4-5% Sn are usually single-phase, and with a higher content of Sn they are two-phase and have a + eutectoid ( + Cu 31 Sn 8) structure. The chemical compound Cu 31 Sn 8 (-phase) is very brittle. In practice, only bronzes with a Sn content of up to 10-12% are used; at a higher content, the alloys become very brittle.

Bronzes are alloyed: Zn - to reduce the cost, P - improves casting properties, Ni - increases mechanical properties, corrosion resistance and density of castings, reduces segregation, lead - increases the density of castings, improves machinability and imparts anti-corrosion and anti-friction properties.

Wrought bronzes are usually single-phase and are used to make bars, strips, wires, springs, or other elements. For example, flat and round springs are made from BrOTs4-3, BrOF7-0.2 - bars with high corrosion resistance and wear resistance, as well as with good spring properties.

Tin bronzes have a diffuse shrinkage shell, while at the same time, the external outlines very accurately copy the shape, so they are used for parts of a very complex configuration, as well as artistic casting.

a) - Cu-Al diagram

b) - influence of concentration

aluminum for mechanical

properties of aluminum bronzes

a) - Cu-Be diagram

b) - the effect of concentration

beryllium for mechanical

properties of beryllium bronzes

Two-phase bronzes have very high anti-friction properties, so bearing shells, worm gears, etc. are made from them. For example, plain bearings are cast from bronze BrO10S10, reinforcement, bearing shells are cast from BrO5Ts5S5 bronze.

Aluminum bronzes. Due to the fact that Al is not a scarce metal, aluminum bronzes are most widely used. Al in copper dissolves up to 9% (see Fig. 12.3), with a content of more than 9% Al, a eutectoid appears in the alloy ("), where" is the chemical compound Cu 32 Al 9. Single-phase aluminum bronze BrA5 is plastic, used for making coins, medals and has high corrosion resistance.

Two-phase aluminum bronzes have reduced ductility but high strength, which can be increased heat treatment. When heated, the eutectoid transforms into a -phase, which, when cooled at a critical rate, transforms into martensite (an acicular structure similar to hardened steel). In addition, at certain cooling rates, a ground eutectoid mixture can be obtained (similar to troostite and sorbitol in steel).

At a content of more than 11% Al, the strength decreases (Fig. 12.3, b) due to brittleness, so more than 11% Al is not added. Two-phase bronzes are usually alloyed: iron refines the grain and improves mechanical and anti-friction properties: nickel improves mechanical properties and wear resistance at both low and high temperatures. Bronzes BrAZhN10-4-4 and BrAZhN11-6-6 are the most durable of all aluminum bronzes, while they have good anti-friction properties, chemical resistance, therefore, parts of chemical and Food Industry, rubbing parts.

The casting properties of aluminum bronzes are lower than those of tin bronzes, but they provide a high density of castings and are more durable.

Beryllium bronzes (BrB2, BrBNT1, 9, etc.) contain up to 2% beryllium. The limiting solubility of beryllium (see Fig. 12.4) in copper is 2.7%, and at 300 0 C - 0.2%. When bronze is heated to a hardening temperature of 760-780 0 C, a single-phase solution is formed, and when cooled in water, a supersaturated solution of beryllium in copper is obtained. When aging 300-350 0 C for 3 hours. dispersed particles of the -phase (Cu Be) are released from the supersaturated solution, which greatly increases the strength (Fig. 12.4, b) and hardness (= 1250 MPa, = 3-5%, HB375). Beryllium is an expensive and rare metal, but the complex of properties of these bronzes is so high that their production is economically justified.

Beryllium bronzes are used in instrumentation for the manufacture of critical springs, membranes and other spring parts. It has chemical resistance, good weldability and machinability with cutting tools.

Beryllium bronze is non-sparking, so it is made from electrical contacts and impact tool for work in explosive atmospheres.

Lead bronzes (BrS30, BrS60N2, 5, etc.) are used for the manufacture of bushings for plain bearings. Lead practically does not dissolve in liquid copper, therefore, no eutectic is formed, and the crystallization interval is more than 600 0, which leads to segregation. To prevent it, the alloy must be rapidly cooled or alloyed. After hardening, the alloy consists of copper crystals and lead inclusions. Compared to tin bronzes, the thermal conductivity of Br30 is 4 times higher, so it well removes the heat that occurs during friction.

Due to low mechanical properties (=60MPa, =4%), lead bronze is deposited in a thin layer on steel pipes (tapes).

Such bimetallic bearings are easy to manufacture, easy to replace when worn, and cheaper. To harden crystallites of copper BrS30 doped with Sn and Ni.

In addition to tin, lead, aluminum and beryllium bronzes, silicon, manganese, antimony, cadmium, and other bronzes are used.

Metals and alloys are literally the basis of human civilization. Pure metals are not often used in national economy, but alloys are used everywhere. This is not surprising, since the alloy combines the properties of several substances in the best possible proportion. This article talks about the production and processing of the melt, material preparation, composition, properties and.

Structure and chem. The composition of brass is a very important issue. Brass is a two- or multi-component solid solution - an alloy based on and zinc. Brass has been known for an extremely long time, over time ancient rome, and is still in use today. Its properties depend on the quantitative composition.

The traditional composition of brass is 70% copper and 30% zinc. Zinc improves the mechanical and technological qualities of the alloy, and at the same time reduces its cost, since it is a more affordable metal. In practice, the use of solutions with more than 50% zinc is rare.

Brass has a very beautiful golden color. However, without a protective layer - varnish, for example, darkens rather quickly. In pretty in large numbers cases, this property is not considered a disadvantage.

The alloy is marked depending on the composition. Brass is denoted by the letter "L", followed by a number indicating the proportion of copper - 70, for example. If the alloy was alloyed, then all additives are indicated by decreasing their proportion, and then the composition is also indicated. For example, LAZh60-1-1 means that there is 60% copper in brass, and that the alloy is alloyed with aluminum - 1%, and iron - 1%.

This video will tell you how brass burns and how the material of the house is melted:

Classifications by zinc content

The compositions are classified according to the proportion of zinc:

  • if its content is 5-20%, brass is called red - tompak;
  • if the proportion of zinc fluctuates in the range of 20–36%, the alloy is called yellow brass;
  • an alloy with a zinc content of 48–50% is called technical.

In the production of brass, more than 50% of zinc is obtained from the processing of secondary raw materials, so the alloy can be attributed to a fairly environmentally friendly product.

Separation by quality of additional ingredients

Alloys are divided according to the quantity and quality of additional ingredients.

Two-component

Two-component include only copper and zinc. Here, the properties of the alloy are strongly affected by the phase composition. Copper can dissolve no more than 39% of zinc. Moreover, with an increase in temperature, the solubility decreases, and only a single-phase solution is formed - the α-phase. Such alloys are called α-brass, they are highly ductile and strong enough if the proportion of zinc reaches 30%.

With an increase in the proportion of zinc, part of the metal no longer dissolves and a two-phase solution is formed - α+β'-brass. β'- phase is harder, but also more brittle, so this alloy is stronger, but loses ductility.

This feature also determines an unusual processing method. So, for cold working - figured profiles, wire, only α-brass is used, since its ductility is high at low temperatures, and in the temperature range from +300 to +700 C it drops sharply, so it is useless to deform brass when heated. But α + β’-solutions are processed at a high temperature.

Multicomponent

Multicomponent additives may contain:

  • nickel - increases corrosion resistance;
  • - reduces strength, but together with lead gives antifriction properties;
  • lead - no more than 4%, reduces strength, but facilitates machining. Such brasses are often called automatic;
  • iron - reduces grain growth, which improves the mechanical properties of the alloy;
  • - no more than a share. Otherwise, the alloy turns into one of the varieties. Tin gives the alloy resistance to the action of sea water, for which such brass was called marine;
  • manganese - increases resistance to corrosion, contributes to strength.

Metal production

Since the main component of brass is copper, the material is classified as a copper alloy. The production scheme is quite simple. However, from a technological point of view, the process turns out to be difficult, since it requires very strict adherence to temperature conditions and processing of raw materials and workpieces.

IN general view getting the alloy looks like this:

  • melting copper in special crucibles;
  • the introduction of zinc;
  • the introduction of additional components - iron, nickel;
  • pouring into molds;
  • hardening - by stamping or drawing.

The matter is further complicated by the fact that the conditions for producing alloys largely depend on the composition of the alloy and its purpose.

Below is a video about melting brass at home.

The video below shows how to make and melt brass at home:

Technologies

The production of brass should begin with the production of copper from copper ore. In fact, this is a complex polymetallic raw material, in which the proportion of copper is just small. The main components are waste ore, iron and copper, and the first step in obtaining brass is to separate copper from other components.

Getting raw materials

This process is extremely complex, since its goal is to transfer raw materials from a single multicomponent mixture into a heterogeneous system consisting of several phases with different compositions and different properties. Only then can the phases be separated from each other and formulations suitable for further use can be obtained. A variety of methods are used for this: in some cases, the extracted phase is additionally enriched in the “main” metal, in others, on the contrary, it is depleted, in others, mechanical separation methods are used when the phases, for example, differ in solubility, and so on.

The following two methods are most commonly used.

  • pyrometallurgical the technology involves the processing of copper ore with subsequent refining of blister copper. Includes smelting, converting copper matte, fire refining - in fact, cleaning from large impurities, and electrolytic. The latter allows not only deep purification of copper, but also the extraction of any related components, if they are of value.
  • hydrometallurgical the method is applied when using poor copper ore. Its essence boils down to leaching - the effects of sulfuric acid, iron sulfate. To do this, the ore is crushed and dissolved in solvents, and then copper is mined either by cementation - the deposition of pure copper on iron, for which ordinary sheet and wire trimmings are used, or by electrolysis.

Thus, it is possible to completely extract copper even from the poorest ore.

Obtaining zinc also has its own characteristics, but, in general, is a simpler process.

About whether it is possible to weld brass at home and how it is produced at the factory, we will tell below.

Alloy production method

The smelting of brass depends on the composition of the alloy. Here it is necessary to take into account both the different boiling point of metals and the different ability to oxidize.

  • Smelting with pure metal- when using turnaround metals, the charge can be loaded in any order. If there is pure metal in the charge, then copper is melted first, and then turnaround metals. Zinc and, if present, are introduced into the melt last, preheated to 100–120 C. Melting is carried out under a layer of charcoal, which is loaded with the first batch of charge.
  • Silicon brass melting- such a composition tends to absorb reducing gases, so charcoal is not used here. Melting is carried out under a cover flux - glass or borax, to prevent interaction with oxygen. Copper is loaded into the furnace first, then waste and copper-silicon ligature. Zinc is loaded into the melt last, after the slag is removed.
  • Smelting Manganese Brass- carried out under charcoal or glass flux. In this case, manganese is introduced last, along with ligatures, after all other ingredients are melted.

Sheet manufacturing

The usual form of brass production is sheets and wire. In general, the process goes like this.

  1. The ingots from the melting shop go to the rolling shop, where they are heated in a furnace to a deformation temperature of –790–830 C.
  2. On the mill, the ingots are deformed to the size and thickness of the billet.
  3. The workpiece in the form of a roll is supplied for welding, and then subjected to double-sided milling.
  4. Then the semi-finished product is returned to the rolling shop, where it is rolled on a three-stand rolling mill until the desired sheet thickness is obtained.
  5. The finished strip is cut into measured lengths.
  6. The sheets are annealed in chamber furnaces and then pickled in pickling baths.
  7. The material is again deformed to the final thickness and pickled again.

Read about the equipment for casting brass at the factory for its manufacture.

Necessary equipment and raw materials

Since copper is a metal in demand, methods for extracting copper from both rich and very poor ores are implemented in production. So almost any ore containing at least some fraction of the metal can act as a raw material.

Obtaining brass is a multi-stage and technologically complex process. So the equipment here includes both the latest production lines and the most traditional casting tools.

  • For melting brass the best option is an induction channel furnace or crucible electric resistance. This equipment consumes the minimum amount of electricity based on the production of 1 kg of alloy and allows you to achieve minimal overheating of metals. The worst choice are electric arc furnaces.
  • To warm up the ingots before deformation, a methodical furnace is used - heating from 650 to 1200 C is possible here.
  • Hot rolling mill - the working module is the working stand, in which hot rolling is carried out. The equipment can also be used for cold rolling of sheets and strips.
  • Welding line - equipment depends on the parameters of the workpieces and finished products.
  • Milling machine - for double-sided milling of the welded strip.
  • The cold rolling mill is usually three-stand. For its maintenance, a hoist is also needed - it feeds rolls to the mill, an accumulative roller table - with its help they complete a batch of strips of the same brand, and an input section - an unwinder, a bender, a straightening machine, and so on.

In addition, the line should include equipment - from a trolley to a loading crane, which ensures the movement of ingots, billets, coils and sheets between technological units.

At the stage of obtaining alloys, you will also need a mechanical tool:

  • bell - a device for cleaning and degassing alloys, perfect for introducing refining fluxes;
  • slag - a tool for removing slag from the surface of the alloy;
  • pouring spoon;
  • two-handled ladle - a device for pouring non-ferrous alloys.

The production of brass, or rather, sheets and wires required for the manufacture of finished products, is a technologically complex and time-consuming process. It is possible to obtain an alloy that meets the requirements of GOST only at large non-ferrous metallurgy enterprises.

The video below shows the casting of brass into a mold: