Custom Online Copper Brass Die Casting Service

Explore our Custom Online Copper Brass Die Casting Service, offering high-quality metal casting, rapid prototyping, and post-process services. We provide a wide range of casting materials to meet your specific requirements and deliver precision-engineered solutions for your projects.

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What Is Copper/Brass Die Casting?

Copper/Brass die casting is a manufacturing process where molten copper or brass alloys are injected into molds under high pressure to create precise, durable parts. It's widely used in industries such as electrical, automotive, and plumbing due to its strength and conductivity.

Steps	Description
Mold Preparation	High-strength steel molds are designed with cavities to shape the molten copper or brass alloy. Molds are coated with a release agent for easy part removal.
Copper/Brass Alloy Melting	Copper or brass alloys are heated in a furnace to temperatures around 900°C-1100°C. The molten alloy is then ready for injection into the die-casting machine.
Copper/Brass Injection	The molten copper or brass alloy is injected into the mold under high pressure, filling all cavities quickly and precisely to form the desired part.
Cooling and Solidification	The molten alloy cools rapidly and solidifies inside the mold, forming a solid part. Cooling time varies depending on part size and complexity.
Trimming and Finishing	Once solidified, excess material such as gates and runners is removed. Parts may undergo further processes like machining, polishing, or surface treatments.

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Benefits of Copper/Brass Die Castings

Copper and brass die castings offer numerous benefits, including superior electrical conductivity, excellent corrosion resistance, high durability, and design flexibility. These advantages make them ideal for use in various industries such as automotive, electrical, plumbing, and aerospace applications.

Benefits	Description
Excellent Electrical Conductivity	Copper and brass alloys have superior electrical conductivity, making them ideal for electrical components like connectors and terminals that require reliable performance in power distribution systems.
Corrosion Resistance	Copper and brass die castings offer exceptional corrosion resistance, making them suitable for applications in harsh environments, such as plumbing fixtures, marine components, and outdoor hardware.
High Durability and Strength	Copper and brass alloys provide excellent strength, toughness, and wear resistance. These materials are ideal for high-performance applications in automotive, aerospace, and industrial machinery.
Design Flexibility	Copper and brass die casting allows for intricate shapes, thin walls, and complex features, offering greater design freedom while minimizing material waste and the need for additional machining.

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Typical Casting Copper/Brass Alloys

Typical Casting Copper/Brass Alloys** are widely used in die casting due to their strength, durability, and corrosion resistance. Popular alloys like C87600 (Bronze), C93200 (Bearing Bronze), and C36000 (Free-Cutting Brass) offer versatility for various industrial, automotive, and marine applications.

Copper/Brass Alloys	Aliases	Tensile Strength (MPa)	Yield Strength (MPa)	Fatigue Strength (MPa)	Elongation (%)	Hardness (HB)	Density (g/cm³)	Applications
CuZn37	CW510L (EU), C23000 (US)	350-450	220-300	100-150	25-30%	60-90	8.40-8.60	General-purpose brass, plumbing fittings, hardware
CuZn40	CW507L (EU), C24000 (US)	370-460	230-310	110-160	20-30%	80-100	8.40-8.60	Automotive, electrical components, marine hardware
CuZn10	CW508L (EU), C26000 (US)	330-420	210-280	90-130	25-35%	60-90	8.50-8.70	Electrical parts, connectors, architectural hardware
Brass 360	C36000 (US)	520-690	340-420	150-220	30-40%	70-120	8.40-8.60	Precision machining, electrical connectors, fasteners
Brass 380	C38000 (US), CuZn38 (EU)	420-530	270-350	120-180	15-25%	60-90	8.50-8.70	Electrical components, valves, pumps, mechanical parts
Brass 464	C46400 (US)	450-550	300-380	130-200	20-30%	85-110	8.60-8.80	Marine hardware, fittings, pumps, valves
CuNi10Fe1	CW351H (EU)	300-450	210-290	100-160	15-20%	60-90	8.70-8.90	Marine components, valves, pump parts, heavy-duty fittings
CuNi30Fe1	CW352H (EU)	330-480	220-310	110-170	15-20%	70-100	8.70-8.90	Marine applications, chemical and water industry
C17500	Beryllium Copper (US)	690-1100	450-850	250-350	3-5%	160-200	8.35-8.45	High-strength electrical contacts, connectors, springs
C18200	Beryllium Copper (US)	600-1000	400-800	220-320	4-7%	150-200	8.35-8.45	Aerospace, electrical contacts, high-performance springs

Typical Surface Treatment for Copper Castings

Typical surface treatments for copper castings include electroplating, powder coating, painting, polishing, shot blasting, vibratory finishing, chemical etching, clear coating, and PVD. These processes enhance properties such as corrosion resistance, surface hardness, appearance, and strength, while also improving durability and performance in various industrial applications.

Surface Treatment	Description	Purpose/Benefit	Applications
Electroplating (Nickel, Gold, etc.)	Depositing a metal layer onto the copper surface via electrochemical means.	Improves corrosion resistance, wear resistance, and surface hardness.	Electronics, decorative items, hardware, aerospace, automotive.
Powder Coating	A dry finishing process where a powdered coating is applied and then cured under heat.	Enhances corrosion resistance, improves aesthetics, and provides durable finishes.	Automotive parts, household appliances, outdoor equipment, furniture.
Painting	Application of liquid paints for decorative and protective purposes.	Offers color, increased durability, and corrosion resistance.	Consumer products, automotive, machinery, furniture, and outdoor products.
Polishing	Mechanical or chemical polishing to create a smooth, shiny surface.	Improves surface finish and aesthetic appeal, often used for decorative purposes.	Jewelry, decorative hardware, automotive parts, consumer electronics.
Shot Blasting	High-pressure blasting of abrasive particles onto the surface to clean or texture it.	Improves surface texture, removes casting defects, and enhances paint adhesion.	Metalworking, automotive, aerospace, foundries, construction.
Vibratory Finishing	Using abrasive media in a vibrating machine to smooth surfaces.	Reduces surface roughness and deburrs parts.	Automotive, aerospace, medical device manufacturing, jewelry finishing.
Chemical Etching	Use of chemicals to etch away unwanted material from the surface.	Provides fine surface finishes, often used for engraving or creating textured finishes.	Electronics, signage, jewelry, precision machining, aerospace.
Clear Coating	Application of a transparent coating to preserve the natural finish of copper.	Provides UV and corrosion resistance while maintaining the metallic look.	Automotive, electronics, marine, architectural, jewelry.
PVD Process	Physical Vapor Deposition process that applies thin metallic coatings to the copper surface.	Provides superior wear resistance, hardness, and enhanced aesthetics with metallic finishes.	Electronics, automotive, decorative hardware, medical devices, aerospace.

Applications of Copper and Brass Die Castings

Copper and brass die casting provide high-strength, corrosion-resistant solutions across industries. Ideal for electrical connectors, plumbing fittings, and HVAC heat exchangers, these alloys ensure durability and efficiency. From automotive cooling systems to pump components, mechanical hardware, and valve bodies, copper and brass die castings deliver precision and reliability in demanding applications.

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Copper Die Castings Design

A well-designed copper die casting ensures excellent durability, high thermal and electrical conductivity, and superior strength. It minimizes defects like porosity and improves material flow, reducing waste. Proper design allows for precise tolerances, enhances part integrity, and reduces the need for post-processing. This results in more efficient manufacturing, lower production costs, and higher-quality, long-lasting copper components.

Design Elements	Specific Value/Range
Uniform Wall Thickness	Aim for wall thickness between 2mm to 6mm to ensure consistent flow and avoid defects like porosity.

Draft Angles	Use a 1° to 2° draft angle on vertical surfaces to ease part removal and prevent damage to the mold.

Radii and Fillets	Incorporate 3mm to 5mm radii at corners and edges to reduce stress concentrations and improve flow.

Avoid Sharp Corners	Sharp corners should be avoided to reduce the risk of stress and defects; use at least 3mm radius for corners.

Incorporate Ribs and Bosses	Design ribs with 1mm to 2mm thickness and ensure proper spacing (2 to 3 times rib thickness) for added strength and structural integrity.

Correct Gate Placement	Gates should be placed in the thickest section, with gate thickness ranging from 2mm to 3mm to promote smooth metal flow.

Optimized Thickness for Strength	Use a wall thickness between 2mm to 6mm, balancing strength and material efficiency. Avoid excessive thickness that could lead to longer cooling times.

Proper Tooling Design	Design vents every 25mm to 40mm to allow for air evacuation, and ensure the runners are 5mm to 8mm wide for optimal metal flow.

Consider Post-Processing Needs	Account for 0.1mm to 0.3mm tolerance for post-casting machining or surface finishing, like polishing or coating.

Avoid Deep Blind Holes	Avoid blind holes deeper than 2 times their diameter. For easier casting, consider through holes or design changes.

Minimize Undercuts	Minimize undercuts, and if necessary, use side-action tooling or simplify the geometry to reduce tooling complexity.