ALLOY•DATA•SHEET Envirobrass® (Sebiloy®) Non-Leaded* Red Brass and Yellow Brass Casting Alloys

ALLOY•DATA•SHEET EnviroBrass® (SeBiLOY®) Non-Leaded* Red Brass and Yellow Brass Casting Alloys

standard to limit the leaching of lead Sand-cast faucets and other plumbing INTRODUCTION from endpoint devices intended to components have traditionally been dispense water for human made from leaded red, semi-red and consumption. The EPA selected yellow brasses. The most common Federal regulations limit the amount of Section 9 of ANSI/NSF Standard 61: plumbing brass, C84400 (also known as lead permitted in public drinking water Drinking Water System 81 Metal or 81-3-7-9) contains nominally supplies. These regulations, in turn, es- Components–Health Effects as this 7% lead. The most popular red brass, tablished a need for reduced-lead or non- performance standard. Endpoint C83600 (85 Metal, 85-5-5-5), contains leaded plumbing alloys and EnviroBrass devices covered by the new lead nominally 5% lead. Permanent mold fills this need. limits include kitchen, bar, and and pressure die castings of plumbing lavatory faucets; drinking fountains; components are also commonly made n The U.S. Environmental Protection water coolers; residential refrigerator Agency’s Lead and Copper Rule ice makers and water dispensers; of the leaded yellow brass alloy C85800, applies to public water utilities and and supply stops and endpoint which contains nominally 1.5% lead. In establishes a framework to monitor control valves. contrast to the red brasses, which are and control water chemistry in order moderate-strength, single-phase alpha to reduce the corrosivity of water. Faucets to be certified under NSF alloys, alloy C85800 is stronger at both Utilities are required to chemically Standard 61 must pass a test in which room temperature and at elevated treat water that is sufficiently representative products are filled with a temperatures approaching the solidus, aggressive to leach excessive copper pH 8 test water. Samples of the water because of the presence of the beta or lead from the water supply are withdrawn and analyzed for lead at phase in the alpha matrix. These system. The EPA rule established a specified intervals over a 19-day period. improved mechanical properties are an lead “action level” of 15 parts per Statistical tests are applied to the data advantage not only during casting and billion (ppb), as measured at the to ensure with 90% confidence that 75% machining, but also in service. Alloy household tap in at least 90% of of the products examined leach no more C85800 has a pleasant light yellow color households, at which appropriate than 11 ppb of lead into the water. The and can be buffed to a high polish. water-treatment steps must be 11 ppb limit under NSF Standard 61 is applied. Unfortunately, not all products made lower than the 15 ppb of the Lead and from leaded brasses can qualify under n The 1996 amendments to the Safe Copper Rule because EPA assumes existing standards. Excessive lead Drinking Water Act (SDWA) required that as much as 4 ppb of lead could be leaching of cast products is usually due the EPA to establish a performance picked up from other sources. A to the segregation of lead to internal California Proposition 65 consent (i.e., cored) surfaces, where its concen- judgment has established an even lower tration is far higher than in the casting limit of 5 ppb lead in California, as as a whole. It is difficult for faucets and determined by the same NSF Standard other devices with large internal surface 61 test protocol. areas to meet the certification requirements of NSF Standard 61. Why Has Lead Been Traditionally Used in Plumbing Fixtures? Lead is added to plumbing brasses to EnviroBrass (SeBiLOY) improve machinability and ensure pressure tightness. Traditionally, cast The idea of using a combination of red and yellow brasses contain a fine bismuth and selenium as a substitute dispersion of lead particles in the for lead was originally conceived by the microstructure. Without the machinabil- ASARCO Technical Center, Salt Lake Non-leaded red brasses (EnviroBrass C89510 City, Utah. This was pursued by several and C89520) and yellow brass (C89550) cast, ity enhancement made possible by machine, polish and perform like the leaded lead, brass plumbing products could be brass equivalents. much more expensive due to very high Copper Development Association Inc. * Trace amounts up to 0.25%. machining costs. 260 Madison Avenue, New York, NY 10016 years of research by an industry continue to be used and will sometimes Why Bismuth and Selenium? consortium which included the Copper appear alone or in parenthesis following Bismuth acts very much like lead in Development Association Inc. (CDA), the term EnviroBrass. many respects. It is lead’s neighbor on the American Foundrymen’s Society However, EnviroBrass will be favored the Periodic Table of the Elements, and (AFS), the Brass and Bronze Ingot in this and subsequent publications. A its melting point is 56 C (101 F) lower Manufacturers (BBIM), the Materials high-zinc yellow brass, designated than that of lead, making its behavior Technology Laboratory of CANMET, EnviroBrass III, was also developed and during casting and solidification similar other foundries and water product designated as UNS number 89550. to that of lead. Like lead, bismuth is producers. The research shows that a EnviroBrass III contains up to 1.2% Bi nearly insoluble in copper and copper combination of bismuth and selenium and 0.1% Se, plus 0.5% Al for improved alloys. Furthermore, it causes machin- provides the same beneficial effect on fluidity (see Table I). It is suitable for ing chips to break up into small, easily machinability as does lead. In addition, both permanent mold and pressure die removed particles, similar to lead. pressure tightness and other casting castings. Unlike lead, bismuth is not known to characteristics of bismuth/selenium be toxic to humans, except in cases of brasses were found to be virtually Non-Leaded consumption of immense doses. In fact, identical to those in conventional leaded No lead is intentionally added to its most common use for many years alloys. EnviroBrasses. The stated lead content, has been as the major ingredient in Optimized red brasses developed by 0.25% max. for EnviroBrass I, popular stomach medications. the industry consortium are designated EnviroBrass II, and 0.1% max. for Selenium enhances the effect of EnviroBrass (SeBiLOY) I and EnviroBrass III, takes into account lead bismuth in red brasses; therefore, it EnviroBrass (SeBiLOY) II. They have that may be present in recycled materi- reduces the amount of bismuth needed been granted UNS numbers C89510 and als from which casting alloys are to achieve the desired improvement in C89520, respectively, and can be used commonly made. Even at maximum properties. From a health standpoint, by all foundries without restriction. permissible levels, however, the lead selenium, like copper, is one of the EnviroBrass (SeBiLOY) I contains content of EnviroBrass alloys are essential nutrient elements. Animals, nominally 1% Bi and 0.5% Se; sufficiently low enough to pass the including humans, require a minimum EnviroBrass (SeBiLOY) II contains 2% stringent lead-leach requirements of intake of selenium (as well as copper). Bi and 1% Se (see Table I). NSF Standard 61 for most plumbing The name SeBiLOY, which reflects devices. If a lower lead content is Mechanical Properties the addition of selenium and bismuth in required, this can be specified when The mechanical properties of bismuth/ these alloys is a foundry oriented name. ordering metal from an ingot supplier. However, in view of the increasing selenium-containing EnviroBrass alloys The maximum phosphorous levels are functionally equivalent to standard awareness of health and the environ- noted are usually associated with red ment, adoption of the name EnviroBrass plumbing brasses. Specifically, brass alloys. Higher levels up to about EnviroBrass I and EnviroBrass II display should achieve a high degree of accep- 0.1% P have been shown to have tance by the specifiers and purchasers mechanical properties, including benefits which include higher ultimate hardness, that are similar to the leaded of faucets, valves, water meters and tensile strength and tensile elongation. other plumbing devices. SeBiLOY will red brasses although with somewhat

Table I: Compositions of EnviroBrass I, EnviroBrass II and EnviroBrass III Alloys* Range or maximum, % Elements EnviroBrass I (C89510) EnviroBrass II (C89520) EnviroBrass III (C89550) Copper 86.0 - 88.0 85.0 - 87.0 58.0 - 64.0 Tin 4.0 - 6.0 5.0 - 6.0 1.2 Lead 0.25 0.25 0.1 Zinc 4.0 - 6.0 4.0 - 6.0 32.0 - 38.0 Bismuth 0.5 - 1.5** 1.6 - 2.2*** 0.6 - 1.2 Selenium 0.35 - 0.75** 0.8 - 1.1*** 0.01 - 0.1 Nickel (incl. Cobalt) 1.0 1.0 1.0 Iron 0.2 0.2 0.5 Antimony 0.25 0.25 0.05 Sulfur 0.08 0.08 0.05 Phosphorus 0.05 0.05 0.01 Aluminum 0.005 0.005 0.1 - 0.6 Silicon 0.005 0.005 0.25 * Cu + sum of named elements, 99.5% min. ** Experience favors Bi:Se ≥ 2:1. *** Bi:Se ≥ 2:1 Table II: Typical and Minimum Mechanical Properties of EnviroBrass Alloys compared with either UTS, 0.5% YS % Elongation Hardness, C83600 or C84400. Alloy Similarly, slightly higher ksi (MPa) ksi (MPa) (500 kg) BHN tool wear results may C83600 (Typical)* 37 (255) 17 (117) 30 60 be observed when C84400 (Typical)* 35 (241) 14 (47) 28 55 comparing the machinability of EnviroBrass III EnviroBrass I (Typical)* 30 (209) 20 (136) 12 71 with C85800. EnviroBrass I (Minimum)* 27 (185) 17 (119) 8 66 The reasons are not EnviroBrass II (Typical)* 31 (215) 21 (145) 10 73 yet fully understood. It EnviroBrass II (Minimum)* 21 (176) 18 (121) 6 68 seems to vary with the type of tooling and C85800 (Typical)** 48 (332) 28 (192) 9 60 machining operation. EnviroBrass III (Typical)** 48 (332) 29 (200) 8 63 Measurements show EnviroBrass III (Minimum)** 35 (240) 21 (140) 5 60 that machined surface * Sand Cast **Permanent Mold Cast quality and finish of lower tensile ductility. In addition, assigned a machinability rating of 85. EnviroBrass alloys are EnviroBrass III is similar in mechanical For simple drilling operations, the equal to or better than those produced properties to leaded yellow brass. nominally 2% Bi/1% Se EnviroBrass II in traditional leaded brasses. Ductility of EnviroBrass III is marginally alloy actually machines just as fast as The EnviroBrass alloys readily accept lower than leaded yellow brass. Its free-cutting red brass. EnviroBrass I is a high-luster finish by polishing and strength increases and ductility de- marginally more difficult to machine with buffing. The color of EnviroBrass I and creases with increasing zinc and a machinability rating of 75. EnviroBrass EnviroBrass II is nearly identical to that bismuth contents. That means plumbing III, with 1.1% Bi, achieves a maximum of standard red brass casting alloys. goods currently made in leaded brasses machinability rating (in drilling) of 97, The color of EnviroBrass III is also should not have to be radically rede- but the rating decreases as bismuth nearly identical to cast yellow brass, signed when cast in the EnviroBrass content decreases. At 0.7% Bi, the which is a pleasant light yellow. alloys. Mechanical properties listed in machinability rating of EnviroBrass III Platability is fully equivalent to C83600, Table II were derived from standard test falls to 75. C84400 or C85800. The substitution of bars cast according to ASTM B 208. Plumbing products cast in bismuth and selenium for lead does not Properties of traditional leaded casting EnviroBrass II, can be machined at alter the corrosion resistance of brass. brasses are included for comparison. speeds and feeds very much like those used for leaded red or semi-red brasses. Excellent Casting Properties Machinability on a Par with Some adjustment of practice may be The EnviroBrass alloys are not exotic Standard Casting Brasses required depending on part design and laboratory curiosities. They have been experience. In addition, permanent mold thoroughly tested in commercial found- All plumbing castings are machined, ries and found to have casting properties and machining operations increase plumbing products in EnviroBrass III can similar to those associated with leaded manufacturing cost. Traditional leaded be machined with essentially the same red and yellow brasses. Their casting plumbing alloys are so highly machin- practice as leaded yellow brass but with characteristics are summarized in able that cutting fluids are not always improved health benefits. The Table IV. needed. EnviroBrass alloys do not produce any significant lead-bearing airborne particu- Using Alloy C36000, which as a lates when machined dry. EnviroBrass I and EnviroBrass II: standard has a machinability rating of Some machine shops may experi- 100 based on spindle load requirements n These are long-freezing alloys, as ence slightly higher tool wear with for several machining operations (see are conventional red brasses C83600 EnviroBrass I and EnviroBrass II when and C84400, although they have Table III). EnviroBrass II has been slightly wider freezing ranges. The liquidus temperature for the 2% Bi/ Table III: Machinability Rating of EnviroBrass Alloys 1% Se alloy is nearly the same as those of the red brasses. Pouring Alloy Machinability Rating (multiple operations) temperature is, therefore, similar to C36000 (Free-Cutting Brass) 100 those of leaded alloys, although C83600 84 foundry experience indicates that about 150 F (83 C) of added C84400 90 superheat is often beneficial. The EnviroBrass I (C89510) 75 liquidus temperature for 1% Bi/0.5% Se alloy is about 30 F (17 C) higher, EnviroBrass II (C89520) 85 and a correspondingly higher pouring C85800 80 temperature should be observed. EnviroBrass III* (with 0.7% Bi) (C89550) 75 n Like leaded red brasses, EnviroBrass EnviroBrass III* (with 1.1% Bi) (C89550) 97 I and EnviroBrass II, also develop a pipe between 3.1% and 3.5% of the * Permanent Mold Cast casting’s volume. n Contraction ranges from 1.9% to n Grain refinement improves both tally friendly alloys that are able to meet 3.7%. fluidity and hot tearing resistance. the stringent requirements of current n Porosity is minimal, about 0.4%. water purity regulations. The alloys have n Fluidity is identical to that of C84400 Health and Environmental Benefits good strength, excellent casting characteristics and high machinability. Their at a superheat of 135 F (75 C), but it The EnviroBrass alloys, C89510, extremely low lead content offers the is somewhat lower than that of red C89520 and C89550, were developed to possibility of reduced costs in the brasses at high superheats. provide the plumbing industry with alloys foundry as well as the machine shop. n The tendency toward hot tearing at that will perform as well or better than abrupt section changes is existing materials while meeting the Looking Ahead… dramatically reduced compared with strict requirements of current federal leaded red brasses. water quality regulations. The There is neither a royalty nor licensing EnviroBrass alloys do all of that very fee associated with any of the EnviroBrass III: well, but they also offer the following EnviroBrass alloys. EnviroBrass II n It has a short-freezing range of 60 F significant environmental, health and (C89520) is covered under ASTM (33 C), similar to that in leaded safety benefits to the foundryman and specifications B 30 and B 584. At the yellow brass. plumbing manufacturers: time of publication of this Alloy Data Sheet, ASTM action on EnviroBrass I n The piping tendency is high. n The negligible lead content of the and III were in progress. Products, such n The contraction range should be EnviroBrass alloys dramatically decreases lead levels in foundry as plumbing fixtures and faucets, made similar to that of leaded yellow brass from EnviroBrass castings, will be (not measured). sands and baghouse dust. Foundry worker exposure to airborne lead is marketed to consumers as “made of n The tendency for porosity formation is sharply lower, and sand reclamation EnviroBrass.” lower than leaded yellow brass. and disposal costs can be lower. n The drossing tendency increases n Airborne lead levels in machine shops For further information regarding with bismuth content. are reduced when EnviroBrass alloys EnviroBrass I, C89510, EnviroBrass II, n The fluidity is slightly lower than are used in place of conventional C89520; EnviroBrass III, C89550; and leaded yellow brass in similar leaded alloys. This is especially the other copper-base casting alloys, casting conditions. case when machining is performed contact: n Compositions with bismuth lower dry. Worker lead exposures are Copper Development Association Inc. than 1.2% did not show any hot reduced accordingly. 260 Madison Avenue tearing tendency in permanent mold n In all cases, special air purification New York, NY 10016 casting. This is an advantage relative equipment and worker inhalation Tel: 212/251-7200 • Fax: 212/251-7234 to conventional leaded yellow brass safeguards may no longer be Internet: www.copper.org (C85800) which is prone to hot needed, and a healthier work tearing within its nominal environmental may be reflected in composition range. lower insurance costs. This publication, based on available data, has n However, EnviroBrass III exhibits been prepared for the information and use of professionals in the castings industry. CDA severe hot tearing when superheat In Short… assumes no responsibility or liability in connec- exceeds 234 F (130 C). tion with this publication and makes no warranties EnviroBrass alloys I (C89510), II of any kind with respect to the information n Boron is used to grain refine low-tin (C89520) and III (C89550) offer the contained herein. alloys and zirconium serves the foundry industry modern, environmen- same function in high-tin alloys. Table IV: Casting Characteristics of EnviroBrass Alloys Alloy Liquidus Freezing Range, Fluidity, Relative Hot Drossing Soldering Brazing Effect of F (C) F (C) cm at 56 C Tearing Section Size on (100 F) Resistance Mechanical superheat* (lower is better)** Properties C83600 1850 (1010) 280 (156) 24 15-21 Low Excellent Good Large C84400 1840 (1004) 291 (161) 30 23-24 Medium Excellent Good Large EnviroBrass I C89510 1871 (1021) 371 (206) 24 14 Low Excellent Good Small EnviroBrass II C89520 1842 (1005) 353 (196) 25 8 Low Excellent Good Small C85800 1650 (899) 50 (28) Medium Medium Medium Good Good Medium EnviroBrass III C89550 1638 (892) 50 (32) Medium Good Medium Good Good Medium * Ragone Test, see S. Floreen & D.V. Ragone, “The Fluidity of Some Aluminum Alloys,” AFS Trans. 65, 1957, 391-393. ** Couture & Edwards Test, see A. Couture and J.O. Edwards, “The Hot Tearing of Copper Alloys,” AFS Trans., 74, 1966, 709-721. The two values given represent pouring temperatures of approximately 1170 C (2140 F) and 1225 C (2240 F), respectively. A1032-95/00