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Copper-Zinc-Lead Alloys, Common Defects Through Production Stages and Remedy Methods

Year 2015, Volume: 5 Issue: 2, 17 - 22, 23.07.2016

Abstract

Two types of leaded brass alloys (CuZn40Pb2 and CuZn39Pb3) as extruded rods, which use to produce pressurized gas valves were produced by a vertical semi-continuous casting, hot extrusion, cold drawing, hot forging and machining processes. The effect of lead element on machinability of these alloys was explained. The common defects of the mentioned leaded brass rods, the causes and its remedies were explained. Many defects during productions stages of leaded brass rods were occurred, such as cavities, non-metallic contaminates, lead clustering, surface cracks and zinc segregation into foundry process. In addition, surface crack, hot tearing and back defect through hot extrusion, chevron and chemical composition cracks into cold drawing with hot bursts and lap during hot forging were appeared. The machining process and in-service processes were also involved some other defects. All these defects were occurred due to no care during manufacturing process stages and using improper technological parameters and bad casting product design. To remedying the above-mentioned defects, the proper and improving technological parameters with optimal product design must be used. The current technical review of all types of defects in leaded brass alloys, have been found that, these defects can be appear and increasing in sub-sequence applications and in-service stages

References

  • Sadykov, F.A. & Barykin, N.P.& Aslanya, I.R. (1999). Wear of copper and its alloys with submicrocrystalline structure: Russian Academy of Sciences, Russian Federation.
  • PERNIS, R. & KASALA, J. & PERNIS, I. (18. - 20. 5. 2011). Surface defects of brass bars. Brno, Czech Republic, EU: Faculty of Special Technology, Slovak Republic.
  • Toulfatzis, A. I. & Besseris, G. J. & Pantazopoulos, G. A. & Stergiou, C. (2011). Characterization and comparative machinability investigation of extruded and drawn copper alloys. Int J Adv Manuf Technol, 57:811–826.
  • Pantazopoulos, G. (August, 2002). Leadeded Brass Rod C 38500 for Automatic Machining Operations: A technical Report. Journal of Materials Engineering and Performance, 402—Volume 11(4).
  • Pantazopoulos, G. & Vazdirvanidis, A. (2008). Failure Analysis of a Fractured Leaded-Brass (CuZn39Pb3) Extruded Hexagonal Rod. Journal of Failure Analysis and Prevention 8(3) 218-222.
  • Mannheim, R. & Garin, J. (2009). Hot tearing in extruded brass for machining applications. REV. METAl. MADRID, 45 (6), NOVIEMBRE-DICIEMBRE, 432-438.
  • Vilarinho, C. & Davim, J.P. & Soares, D. & Castro, F. & Barbosa, J. (2005). Influence of the chemical composition on the machinability of brasses. Journal of Materials Processing Technology 170 , 441–447, Portugal.
  • Nobel, C. & Klocke, F. & Lung, D. & Wolf, S. (2014). Machinability Enhancement of Lead-Free Brass Alloys. 6th CIRP International Conference on High Performance Cutting, HPC, Germany.
  • Wilby, A. J. & Neale, D. P. (2012). Defects introduced into Metals during Fabrication and Service. Mater. Scie. – Vol. ІІІ, UK.
  • Rajkolhe, R. & Khan, J. G. (2014, March). Defects, Causes and Their Remedies in Casting Process: A Review. International Journal of Research in Advent Technology, Vol.2, No.3.
  • Hameed, A. H. & Abed, A.T. (2014). Effect of secondary cooling configuration on microstructure of cast in semi-continuous casting of copper and brass. Applied Mechanics and Materials Vol. 575 (2014) pp 8-12, Switzerland.
  • Pantazopoulos, G. (2003, August). A review of Defects and Failure in Brass Rods and Related Components. Practical Failure Analysis, Volume 3(4).
  • Bauser, M. & Sauer, G. & Siegert, K., Translated from Germany by Castle, A. F. (2006). Extrusion. Second Edition, ASM International, Ohio.
  • NORASETHASOPON, S. (2011). Chevron Crack Initiation in Multi-Pass Drawing of Inclusion Copper ShapedWire: Journal of Metals, Materials and Minerals, Vol.21 No.1 pp.1-8, Tailand.
  • Rathi, M. G. & Jakhade, N. A. (2014, June). An Overview of Forging process with their Defects: International Journal of Scientific and Research Publications, Volume 4, Issue 6, India. Garcia, P. & Rivera, S. & Palacios, M. & Belzunce, J. (2010, June). Comparative study of the parameters influencing the machinability of leaded brasses: Engineering Failure Analysis, Volume 17, Issue 4, Pages 771–776.
  • Kondracki, M. & Gawroski, J. & Szajnar, J. (2003). The alloy additions influence on technological properties of fixture brasses: 12th International Scientific Conference, 100 Gliwice, P
Year 2015, Volume: 5 Issue: 2, 17 - 22, 23.07.2016

Abstract

References

  • Sadykov, F.A. & Barykin, N.P.& Aslanya, I.R. (1999). Wear of copper and its alloys with submicrocrystalline structure: Russian Academy of Sciences, Russian Federation.
  • PERNIS, R. & KASALA, J. & PERNIS, I. (18. - 20. 5. 2011). Surface defects of brass bars. Brno, Czech Republic, EU: Faculty of Special Technology, Slovak Republic.
  • Toulfatzis, A. I. & Besseris, G. J. & Pantazopoulos, G. A. & Stergiou, C. (2011). Characterization and comparative machinability investigation of extruded and drawn copper alloys. Int J Adv Manuf Technol, 57:811–826.
  • Pantazopoulos, G. (August, 2002). Leadeded Brass Rod C 38500 for Automatic Machining Operations: A technical Report. Journal of Materials Engineering and Performance, 402—Volume 11(4).
  • Pantazopoulos, G. & Vazdirvanidis, A. (2008). Failure Analysis of a Fractured Leaded-Brass (CuZn39Pb3) Extruded Hexagonal Rod. Journal of Failure Analysis and Prevention 8(3) 218-222.
  • Mannheim, R. & Garin, J. (2009). Hot tearing in extruded brass for machining applications. REV. METAl. MADRID, 45 (6), NOVIEMBRE-DICIEMBRE, 432-438.
  • Vilarinho, C. & Davim, J.P. & Soares, D. & Castro, F. & Barbosa, J. (2005). Influence of the chemical composition on the machinability of brasses. Journal of Materials Processing Technology 170 , 441–447, Portugal.
  • Nobel, C. & Klocke, F. & Lung, D. & Wolf, S. (2014). Machinability Enhancement of Lead-Free Brass Alloys. 6th CIRP International Conference on High Performance Cutting, HPC, Germany.
  • Wilby, A. J. & Neale, D. P. (2012). Defects introduced into Metals during Fabrication and Service. Mater. Scie. – Vol. ІІІ, UK.
  • Rajkolhe, R. & Khan, J. G. (2014, March). Defects, Causes and Their Remedies in Casting Process: A Review. International Journal of Research in Advent Technology, Vol.2, No.3.
  • Hameed, A. H. & Abed, A.T. (2014). Effect of secondary cooling configuration on microstructure of cast in semi-continuous casting of copper and brass. Applied Mechanics and Materials Vol. 575 (2014) pp 8-12, Switzerland.
  • Pantazopoulos, G. (2003, August). A review of Defects and Failure in Brass Rods and Related Components. Practical Failure Analysis, Volume 3(4).
  • Bauser, M. & Sauer, G. & Siegert, K., Translated from Germany by Castle, A. F. (2006). Extrusion. Second Edition, ASM International, Ohio.
  • NORASETHASOPON, S. (2011). Chevron Crack Initiation in Multi-Pass Drawing of Inclusion Copper ShapedWire: Journal of Metals, Materials and Minerals, Vol.21 No.1 pp.1-8, Tailand.
  • Rathi, M. G. & Jakhade, N. A. (2014, June). An Overview of Forging process with their Defects: International Journal of Scientific and Research Publications, Volume 4, Issue 6, India. Garcia, P. & Rivera, S. & Palacios, M. & Belzunce, J. (2010, June). Comparative study of the parameters influencing the machinability of leaded brasses: Engineering Failure Analysis, Volume 17, Issue 4, Pages 771–776.
  • Kondracki, M. & Gawroski, J. & Szajnar, J. (2003). The alloy additions influence on technological properties of fixture brasses: 12th International Scientific Conference, 100 Gliwice, P
There are 16 citations in total.

Details

Other ID JA56EF64NV
Journal Section Articles
Authors

Ahmed M. M. El-bahloul This is me

M. Samuel This is me

Abdulsalam A. Fadhil This is me

Publication Date July 23, 2016
Published in Issue Year 2015 Volume: 5 Issue: 2

Cite

APA El-bahloul, A. M. M., Samuel, M., & Fadhil, A. A. (2016). Copper-Zinc-Lead Alloys, Common Defects Through Production Stages and Remedy Methods. TOJSAT, 5(2), 17-22.
AMA El-bahloul AMM, Samuel M, Fadhil AA. Copper-Zinc-Lead Alloys, Common Defects Through Production Stages and Remedy Methods. TOJSAT. July 2016;5(2):17-22.
Chicago El-bahloul, Ahmed M. M., M. Samuel, and Abdulsalam A. Fadhil. “Copper-Zinc-Lead Alloys, Common Defects Through Production Stages and Remedy Methods”. TOJSAT 5, no. 2 (July 2016): 17-22.
EndNote El-bahloul AMM, Samuel M, Fadhil AA (July 1, 2016) Copper-Zinc-Lead Alloys, Common Defects Through Production Stages and Remedy Methods. TOJSAT 5 2 17–22.
IEEE A. M. M. El-bahloul, M. Samuel, and A. A. Fadhil, “Copper-Zinc-Lead Alloys, Common Defects Through Production Stages and Remedy Methods”, TOJSAT, vol. 5, no. 2, pp. 17–22, 2016.
ISNAD El-bahloul, Ahmed M. M. et al. “Copper-Zinc-Lead Alloys, Common Defects Through Production Stages and Remedy Methods”. TOJSAT 5/2 (July 2016), 17-22.
JAMA El-bahloul AMM, Samuel M, Fadhil AA. Copper-Zinc-Lead Alloys, Common Defects Through Production Stages and Remedy Methods. TOJSAT. 2016;5:17–22.
MLA El-bahloul, Ahmed M. M. et al. “Copper-Zinc-Lead Alloys, Common Defects Through Production Stages and Remedy Methods”. TOJSAT, vol. 5, no. 2, 2016, pp. 17-22.
Vancouver El-bahloul AMM, Samuel M, Fadhil AA. Copper-Zinc-Lead Alloys, Common Defects Through Production Stages and Remedy Methods. TOJSAT. 2016;5(2):17-22.