Chase Brass CMX. Partners With. 7/10/07 Page 1
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1 & Chase Brass Partners With CMX 7/10/07 Page 1
2 & Sambo Copper ECO BRASS - a new alloy for the 21 st 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 Page 2
3 & Industry Issues: Lead legislation Dezincification resistance Stress corrosion cracking resistance Strength characteristics Cost Global availability Growth of copper alloys through improved performance Machinability / productivity Forgeability Castability Plating and joining 7/10/07 Page 3
4 Eco Brass global families CMX INGOT METAL CHASE BRASS DIEHL METAL DOWA NIPPON OHKI KAIMEI 7/10/07 Page 4
5 & Examples of Green Dot and ECO BRASS machined parts, forgings and castings. 7/10/07 Page 5
6 & 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 7/10/07 Page 6
7 Product Comparison GREEN DOT Rod Properties 7/10/07 Page 7
8 Green Dot provides good machinability without lead by substituting silicon. Rod Alloys ALLOY Copper (%) Lead (%) Silicon (%) Phos. (%) Zinc (%) C36000 (Blue Dot ) ASTM B C37000 (Low lead) ASTM B C37700 (Forging alloy) ASTM B C69300 (Green Dot ) ASTM B371, B124, B max /10/07 Page 8
9 Comparison of Typical Rod Mechanical Properties For Half Hard Temper Round Rod Tensile Str. (ksi) Yield Str. (ksi) Elong. (%) Hard. (Rb) C Green Dot C Green Dot C Green Dot C Green Dot 7/10/07 Page 9
10 Comparison of Typical Rod Mechanical Properties Tensile Str. (ksi) Yield Str. (ksi) Elong. (%) Hard. (Rb) C36000 (1/2H) Green Dot (1/2H) 304 Stainless (Cold Drawn) C Stainless (Annealed) 7/10/07 Page 10
11 Product Comparison GREEN DOT for Forging Applications 7/10/07 Page 11
12 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 7/10/07 Page 12
13 Forging pressures for Green Dot are similar to C37700 forging alloy. Forging Pressure (ksi) Green Dot C Temperature (F) 7/10/07 Page 13
14 Forgeability of the Green Dot water meter cap is 95% of C37700 Forgeability Data Production volume: 1,650,000 Forgeability rating: % Forging cracks: Forging pressure: Productivity: ~ 95 % Forging tool life: Fewer than C377 Higher than C377 No change from C377 Slugging tool life: Sharpen every 20,000 slugs Slugging productivity: 12 per minute vs. 17 for C377 (1.575 rod) 7/10/07 Page 14
15 Machinability of the Green Dot water meter cap is 90-95% of C37700 Machinability Data Production volume: 1,650,000 Machinablility rating: 90 95% ID Turning parameters: 1500 rpm, /rev Tool regrinding: 2,000 forgings Tool life: 70% of C377 7/10/07 Page 15
16 Product Comparison ECO BRASS Casting Alloys 7/10/07 Page 16
17 ECO BRASS casting alloy chemistry is the same as for rod. ALLOY Copper (%) Lead (%) Silicon (%) Tin (%) Phos. (%) Zinc (%) C C C C % Se, 1.9% Bi C % Ni, 2.2% Bi * C C87850 ASTM B30, B584, B max Rem. * C83600 version 7/10/07 Page 17
18 Comparison of Typical Sand Cast Mechanical Properties Leaded and Lead-Free Alloys ECO BRASS vs. Leaded Alloys Tensile (ksi) Yield (ksi)elong. (%) Hard. (BHN) C83600 C84400 C92200 ECO BRASS ECO BRASS vs. Lead Free Alloys Tensile (ksi) Yield (ksi) Elong. (%) Hard. (BHN) C89520 C89833 ECO BRASS 7/10/07 Page 18
19 ECO BRASS and Silicon Brass Typical Mechanical Properties ECO BRASS vs. C875 Silicon Brass Sand Cast Properties Tensile (ksi) Yield (ksi) Elong. (%) C87500 ECO BRASS Hard. (BHN) Sand Cast and Permanent Mold Cast ECO BRASS 0 Tensile (ksi) Yield (ksi) Elong. (%) Hard. (BHN) Sand Cast Permanent Mold 7/10/07 Page 19
20 Liquidus and Freezing Range Temperature Comparisons Liquidus Temperature (F) Alloy ECO BRASS C87500 C92200 C84400 C89520 C83600 C Freezing Range (F) Alloy ECO BRASS C87500 C83600 C84400 C92200 C89833 C /10/07 Page 20
21 The microstructure of cast ECO BRASS vs. C ECO BRASS C /10/07 Page 21
22 General Comments on ECO BRASS Casting Behavior. FOUNDRY PROPERTY SIMILAR TO: Permanent Mold Casting Dross Formation Leaded Yellow Brasses C87800 Fluidity - Fuming C83600 Shrinkage and Cracking Short Freezing Range Alloys Shrinkage Allowance C84400 (3/16 per foot) 7/10/07 Page 22
23 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 Page 23
24 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. 7/10/07 Page 24
25 & Machinability Information 7/10/07 Page 25
26 & The microstructure of Green Dot results in excellent machinability and surface finish. ά κ+γ ά Lead 100X 100X 400X Green Dot Rod (C69300) 400X Blue Dot Rod (C36000) 7/10/07 Page 26
27 & 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 , Si , Zn , Fe 0.20, Pb 0.30 Approximate magnification of both micrographs is 400X C69300 Green Dot ROD C69400 Silicon Red Brass 7/10/07 Page 27
28 & The kappa and gamma phases in the alpha matrix create small, Type 1 chips, similar to lead in C Green Dot Rod Free-Cutting Brass 60 Cu 40 Zn 7/10/07 Page 28
29 & Machinability of Green Dot is 70-80% of C36000 (1) 100 Machinability (%) 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. 7/10/07 Page 29
30 Cutting Force, Drilling Force and Surface Finish Relative Values. (1) Ranking (1=Best) C36000 Turning - Main Force Drilling - Torque GREEN DOT Machined Surface Roughness 303 SS Turning - Feed Force Drilling Thrust Force Machining Parameters Turning 1575 ipm; ipr; cut depth Drilling dia.; 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. 7/10/07 Page 30
31 Compared to 303 stainless steel, Green Dot requires 60 70% less force to turn Turning Cut into 2.000"RD Rod RPM, 0.050" Cut Force (Newtons) ipr ipr ipr Green Dot 303 Stainless Steel C360 Coolant: Blasocut 40NF Top rake: 18º: lead angle: +2º; side clearance 5º Force (Newtons) " Plunge Cut into 2.000"RD Rod RPM ipr ipr ipr Insert: Manchester Tool MTC-PT (M43 with TiAlN coating) Green Dot 303 Stainless C360 7/10/07 Page 31
32 Machinability Comparison Between ECO BRASS, Leaded and Lead-Free Copper Alloys Machinability Rating (%) Alloy C92200 C87500 EcoBrass C89833 C83600 C89520 C /10/07 Page 32
33 & The CuZnSi particles which improve machinability do not cause warm brittleness cracking Impact Strength as a Function of Temperature Impact Strength (J/cm2) Impact Strength (J/cm2) Temperature 250 (C) Temperature (C) EcoBrass E B with i h 0.01%Pb0 01%Pb C Cu-38Zn-2Bi 7/10/07 Page 33
34 & Corrosion Resistance 7/10/07 Page 34
35 & 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 CuCl 2. 2H 2 O 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. 7/10/07 Page 35
36 Comparison of ISO 6509 test results shows ECO BRASS excellent dezincification resistance. Corrosion Depth (μm) Maximum Corrosion Average Corrosion C36000 C37700 Eco Brass w/o P C87500 Green Dot Rod Green Dot Forging Eco Brass Casting C83600 Cross-hatched bars indicates dezincification occurred. Solid bars indicate there was general corrosion only /10/07 Page 36
37 & Silicon, low zinc, high strength levels: These give Green Dot high stress corrosion cracking resistance. Hours to Appearance of Cracks Results of Stress Corrosion Cracking Tests Green Dot Hex Rod No cracks Green Dot Forging C360 Hex Rod JIS A Test CES A Test Mattsson Test 72 4 C377 Hex Rod JIS A Test: (Japanese Industrial Standard) NH 4 OH (11.8% min.), 2 hrs., 68F; 1500 kgf torque CES A Test: (Communication Equipment Standard - Japan) NH 4 Cl + NaOH (ph 10), 72 hrs., 68F; 1500 kgf torque Mattsson Test: (ASTM G ) (NH 4 SO 4 + CuSO 4-5H 2 O + NH 4 OH), no minimum time, 68F, 1500 kgf torque 7/10/07 Page 37
38 & Maximum corrosion depth of ECO BRASS in various corrosive environments. 60 Max. Corrosion Depth (μm) ISO6509 Air - 9 Mo., 3.5pH Clay Soil - 9 Mo., 3.5pH Sandy Soil - 9 Mo., 3.5pH 5 Months - Osaka 12 Months - Still Water 12 Months - Agitated Water 2 Yr. Hakui City 2 Yr. Shiki City 7/10/07 Page 38
39 & Corrosion rates in hydrochloric and sulfuric acids. 7/10/07 Page 39
40 & Joining and Plating 7/10/07 Page 40
41 & 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 7/10/07 Page 41
42 & Brazing tests proved that Green Dot and ECO BRASS can be brazed using commercial brazing alloys BRAZING ALLOY TYPE 30% Cu 28% Zn - 40% Ag 2% Sn Cu 5%P 15% Ag American Welding Society Designation (AWS A5.8, Class BAg-28) (AWS A5.8, Class BCuP-5) Cu 7%P 6% Ag Cu 6%P 5% Ag Cu 6%P 2% Ag (1) (2) (2) (AWS A5.8, Class BCuP-4) (AWS A5.8, Class BCuP-3) (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 C /10/07 Page 42
43 & 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 Page 43
44 & 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 Page 44
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