Brass Component Manufacturing Process
The usage of brass objects dates back centuries ago. Today, the material is used for making various tools and decorative objects, lighting fixtures, and many other things. This strong and flexible metal is obtained from both zinc and copper. Brass component manufacturers use it for a wide number of applications across various industries. The manufacturing process of the brass components is distinctive in nature and herein we’ll explain the same.
The production process of brass involves the combination of the correct raw materials into a molten metal that is then allowed to solidify. With various carefully controlled steps, the shape and properties of the solidified metal are then altered in order to produce the desired brass stock.
The brass stock produced are available in a number of forms or shapes, such as sheet, bar, foil, wire, plate, rod, and billet, depending on the concluding application. As an example, we can see and understand how brass screws are cut from rods or how zigzag fins that are used in the radiators of vehicles are bent from strips.
The overall size, as well as the thickness of the material, is the difference maker between the sheet, strip, plate and foil forms. The manufacturing process of the brass components directly depends upon the desired properties and shape of the brass stock. It also depends upon the particular machinery used and the practices across different brass plants. Here we explain how brass component manufacturers go about with the manufacturing process to produce brass strip and sheet:
• A precise amount of suitable copper alloy scrap is weighed down and moved into an electric furnace, wherein it is melted at a temperature of about 1,920°F. Following this, an approximate amount of zinc is poured in after the copper melts down.
• The melted down metal is then poured into the molds and is allowed to be solidified into the slabs, which are called as cakes.
• As the cakes cool down, it is dumped out of the molds and is then moved into the rolling area, the place where they’re stored.
• The cakes are once again heated after being placed in the furnace to the extent it reaches the desired temperature.
• Next, the breakdown rolling process is applied, wherein the heated up cakes are fed through a series of differing steel rollers that help curb down the thickness of the brass.
• The cooled down brass is then passed through a scalper, which is milling machinery.
Annealing and Cold Rolling
• Now, the brass is heated to relive its hardness and to make it more ductile. The process is named as annealing.
• The annealed down pieces of brass are led towards another series of rollers to further curb down the thickness of the material, which is why the process is named as cold rolling.
• The last two steps are repeated multiple times to achieve the desired thickness, durability, and a degree of hardness.
• The sheets are given a final cold rolling, depending upon the requirement, in order to tighten its tolerance on the thickness and to attain a smooth surface finish.
• It can be given a final rolling before being cut to a length, coiled, and moved down to the warehouse.
There may be some specific changes in the steps when it comes to various other forms of brass components. However, the above was the overall process that is followed by brass component manufacturers in the manufacturing process.