Brass Die Casting for Heavy-Duty Precision Parts
Brass Die Casting
More than 60 years of expertise in brass die casting. We process various brass alloys using the die-casting process. This enables us to meet all customer requirements regarding mechanical strength (e.g., CuZn16Si4-C) and electrical conductivity (e.g., CuZn38Al-C). We specialize in lead-free brass alloys, ensuring our operations are future-oriented and REACH-compliant.
Why Brass Die Casting Stands Out
Efficient in Series Production
Brass alloys can be processed with precision and in large quantities using the die-casting process. The high repeatability and short production cycles ensure cost-effective production. Compared to many other manufacturing processes, this results in significant cost advantages.
Robust in Use
Brass is highly resistant to corrosion, moisture, and water. Therefore, in many applications, no additional surface treatment is required. Special brass alloys are even suitable for use in saline environments and in contact with seawater.
Reliable under demanding conditions
When it comes to components subjected to heavy loads, traditional aluminum and zinc die-cast alloys often reach their limits. Brass alloys achieve tensile strengths of approximately 350 to 500 N/mm². As a result, they provide a reliable foundation for robust and sophisticated designs.
The Right Brass Alloy for Every Need
The choice of a suitable brass alloy depends on the component’s intended function, the mechanical stresses it will be subjected to, and the specific environmental conditions. We carefully coordinate the material, component geometry, and die-casting process. This results in components designed for their specific function, with the required mechanical, electrical, and corrosion-resistant properties.
Get a qouteAdditional Applications for Brass Die Casting
Brass die casting is a particularly suitable solution when:
– higher strength is required than the material currently in use can provide
– corrosion resistance needs to be improved
– hygienic or antibacterial material properties are required
Brass Die Casting as a High-Performance Alternative
Brass alloys offer great design flexibility in die-casting. Even complex component shapes, intricate structures, and thin walls can be produced with precision and reproducibility. The high dimensional and contour accuracy reduces the need for downstream machining steps, thereby contributing to cost-effective manufacturing.
The range of possible parts extends from small components weighing just a few grams to castings weighing several kilograms. At the same time, brass and special brass offer high mechanical strength: While brass achieves tensile strengths of around 350 N/mm², tombac can reach tensile strengths of around 500 N/mm². Depending on the application, this means that components made of common structural steels such as S235JR can also be replaced.
Even in corrosive environments, brass alloys stand out for their durability and long service life. Particularly in plumbing applications and water-carrying systems, additional surface treatment is often unnecessary. Tombac also exhibits very high resistance to dezincification and, due to its resistance to seawater, is also suitable for offshore applications.
Overview of Brass Alloys
Brass is an alloy of copper and zinc. Special brass alloys contain additional alloying elements.
| CUZN16SI4 | CUZN38AL | CUZN37AL1 | CUZN34MN3AL2FE1 | CUZN35MN2AL1FE1 | CUZN25AL5MN4FE3 | |
|---|---|---|---|---|---|---|
| Alternative designation | S 0600, CC761S | M 0100, CC767S | S 0100, CC766S | S 0300, CC764S | S 0340, CC765S | S 0350, CC762S |
| Tensile strength Rm in N/mm² | 500 | 380 | 450 | 600 | 475 | 750 |
| Yield strength Rp 0.2 in N/mm² | 300 | 130 | 170 | 260 | 200 | 480 |
| Elongation at break A in % | 8 | 30 | 25 | 10 | 18 | 8 |
| Hardness in HB | 130 | 75 | 105 | 140 | 110 | 180 |
| Electrical conductivity in MS/m | 3 | 12 | 8 | 8 | 8 | 7 |
| Density in kg/dm³ | 8,3 | 8,3 | 8,5 | 8,6 | 8,6 | 8,2 |
Frequently Asked Questions About Brass Die Casting
What is brass die casting?
In brass die casting, the molten brass alloy is injected into a permanent metal mold at high pressure and high speed. The material reliably fills even complex contours, thin-walled areas, and integrated functional elements. Once solidified, the component is removed and the next casting cycle begins.
This repeatable process produces dimensionally accurate mass-produced components with consistent mechanical properties and a high-quality surface finish. Holes, mounting points, reinforcing ribs, and other design features can be integrated directly into the component geometry. This reduces the effort required for subsequent machining steps.
What are the advantages of brass die casting?
Brass die casting combines high strength, good corrosion resistance, and precise shaping in a cost-effective mass-production process. Even complex geometries can be produced with consistent repeatability. Functional elements such as ribs, mounting holes, openings, and fastening points can be integrated directly into the casting.
Depending on the alloy, the components also offer high hardness, good wear resistance, or increased electrical conductivity. Because the parts are manufactured close to their final shape, less material is removed than in machining from solid stock. This reduces machining effort and enables the efficient production of durable precision parts.
For what production quantities is brass die casting suitable?
Since each component requires its own permanent mold, brass die-casting is particularly well-suited for recurring production runs. However, cost-effectiveness does not depend solely on the quantity produced. Component size, weight, complexity, alloy, tooling costs, and post-processing also influence the costs. An assessment is therefore always made on a per-component basis.
For prototypes and small-batch production, we offer our innovative rapidSitomb® solution:
When is brass die casting a viable alternative to aluminum or zinc die casting?
Brass die casting is used when the mechanical or thermal requirements exceed the capabilities of many aluminum and zinc alloys. Brass alloys offer high strength, hardness, and wear resistance. They are therefore suitable for components that are continuously exposed to high forces, friction, or demanding environmental conditions.
In addition, brass offers good corrosion resistance and—depending on the alloy—high electrical conductivity. This makes brass die casting particularly suitable for high-stress housings, fasteners, electrical components, and water-carrying parts. The advantages of the die-casting process—such as short cycle times, high dimensional accuracy, and the ability to produce complex shapes—are preserved.
When is brass die casting a viable alternative to steel or stainless steel?
Brass die casting can replace steel or stainless steel structures when complex components have previously been manufactured from multiple individual parts, welded, or extensively machined. In die casting, many functions can be integrated directly into a single component. This reduces assembly effort, the number of parts, and the amount of machining required.
The high strength and corrosion resistance of selected brass alloys allow them to be used even in mechanically demanding applications. At the same time, brass has good sliding and wear properties and can be precisely machined as needed. Particularly for recurring production runs, a die-cast part manufactured close to the final contour can be a technically and economically compelling alternative to milled, forged, or welded steel components.
What brass alloys does Breuckmann GmbH & Co. KG process?
We process a variety of lead-free brass and special brass alloys. Our range of materials covers applications with high requirements for strength, hardness, corrosion resistance, and electrical conductivity.
CuZn16Si4-C, for example, is suitable for components subjected to high mechanical loads and combines high strength with good corrosion resistance. CuZn38Al-C offers advantages in applications that require increased electrical conductivity. In addition, other alloys are available for components subject to particularly high wear or requiring high strength. The material is selected based on the function, load, and operating conditions of the respective component.
How do you choose the right brass alloy?
The decisive factors are the component’s intended function, the mechanical loads it will be subjected to, and the environmental conditions. In addition, electrical conductivity, corrosion resistance, wear behavior, and any required post-processing steps may play a role. The material, component geometry, and die-casting process are therefore specifically matched to one another.
If you need assistance in selecting the right brass alloy, we would be happy to advise you and support you throughout your project, from material selection to implementation.
How strong are die-cast brass components?
Die-cast brass parts are characterized by high mechanical strength and are suitable for structural components with medium to very high strength requirements. Depending on the alloy, tensile strengths ranging from approximately 380 to 750 N/mm² can be achieved. CuZn16Si4-C, for example, offers a tensile strength of around 500 N/mm², while high-strength specialty brass alloys can reach values of up to 750 N/mm ².
In addition to their tensile strength, these materials offer high hardness, wear resistance, and good resistance to mechanical stress. As a result, die-cast brass is suitable for applications such as high-stress housings, levers, gear components, clamping pieces, and fittings. The combination of high strength and precise shaping makes this process a high-performance alternative when aluminum or zinc die casting fails to meet the required mechanical properties.
Can die-cast brass parts be machined?
Brass die-cast parts can be machined to specific requirements after casting. Depending on the component’s requirements, processes such as drilling, milling, turning, thread cutting, grinding, and polishing are possible. This allows for the production of parts with tight tolerances, precise functional surfaces, and connections ready for assembly.
Various surface treatments and coatings can also be applied. These serve, for example, to enhance the appearance, provide additional corrosion protection, or tailor functional surface properties. Because many contours are already formed in the die-casting mold, post-processing is usually limited to the areas that are actually relevant to function. This reduces processing time and material consumption.