Brass Sand Casting, Brass Casting Foundry, Brass Green Sand Casting Foundry
Premium Brass Sand Casting and Brass Cast and Machined Components
We are one of the leading manufacturers and exporters of high-quality Brass Castings and Brass Sand Casting components from India. We have been supplying precision-engineered Brass components, Brass valve bodies, Brass fittings, and custom non-ferrous castings to the world market for many decades. Our expertise encompasses the entire production lifecycle, from initial design consultation and pattern making to sophisticated Brass Sand Casting and post-casting CNC machining operations. We serve a diverse global clientele across industries such as marine hardware, plumbing and sanitaryware, automotive components, and electrical fittings. Our commitment to stringent quality control, adherence to international standards like ASTM, DIN, and BS, and a customer-centric approach makes us a preferred partner for all your Brass casting needs. We also offer Lead Free Brass castings and DZR Brass castings at our foundry.
An Overview of Brass Casting
Brass Casting is a foundational manufacturing process for creating complex, high-strength, and corrosion-resistant metal parts. It involves melting Brass alloys and pouring the molten metal into a pre-formed mold cavity that holds the shape of the desired part. Upon solidification, the part, now called a casting, is removed and finished. The versatility of Brass Casting allows for the production of parts in various sizes and intricate geometries that would be difficult or uneconomical to achieve through other methods like forging or machining from solid bar stock. The choice of casting method—be it Sand Casting, Investment Casting, or Die Casting—depends on factors like required volume, dimensional tolerance, surface finish, and the part’s ultimate application. Our foundry specializes in Sand Casting, the most flexible and widely used method for Brass components.
In-Depth: Brass Sand Casting
Brass Sand Casting is a specific expendable mold casting process where a sand mold forms the cavity into which molten Brass is poured. This process is highly regarded for its flexibility, cost-effectiveness for low to medium production volumes, and ability to produce very large Brass castings. The process begins with creating a pattern, a replica of the final part. This pattern is then used to imprint its shape into a compacted sand mixture, creating the mold. After the molten Brass is poured and has cooled, the sand mold is broken away, revealing the raw casting. Brass Sand Casting is ideal for producing robust parts like valve bodies, pump impellers, gears, and marine hardware, where the excellent machinability and corrosion resistance of Brass are paramount.
Brass Green Sand Casting Explained
A predominant type of Sand Casting we employ is Brass Green Sand Casting. The term “green” refers to the fact that the sand mold is not baked or cured in an oven; it is held together by a natural clay binder (like bentonite) and moisture in its “green” or uncured state. This makes it a very efficient and economical process. Green Sand Casting offers good dimensional stability and a acceptable surface finish for a wide range of industrial applications. While the surface finish might not be as smooth as some other processes, it is perfectly suited for components that will undergo subsequent CNC machining, which is a standard practice for achieving precise tolerances on critical features like threads and sealing surfaces.
Post-Casting Precision: Brass CNC Machined Castings
The true potential of a Brass Sand Casting is often realized through precision CNC machining. A Brass CNC Machined Casting refers to a sand-cast part that has been finished on Computer Numerical Control (CNC) lathes, mills, and drills to achieve tight dimensional tolerances, smooth surface finishes, and precise geometric features. This secondary operation is critical for parts like brass fittings and valve components that require exact threads, sealing grooves, and bore diameters. Our integrated facility handles both casting and machining, ensuring seamless quality control and faster turnaround times. We machine to international tolerance standards, typically achieving ISO 2768-mK for general dimensions and much finer tolerances on critical features as per customer drawings.
Our Facility: A Modern Brass Casting Foundry
Our Brass Casting foundry is equipped with state-of-the-art technology and staffed by experienced craftsmen. We are a complete solution provider, managing the entire process under one roof. Our capabilities include:
Pattern Shop: In-house creation of wooden, metal, and resin patterns.
Molding: Automated and manual molding lines for Green Sand and other sand casting processes.
Melting: Induction furnaces for precise and clean melting of Brass alloys.
Finishing: Shot blasting, grinding, and cutting equipment.
Machining: A dedicated section with CNC and conventional machines.
Quality Assurance: Spectrometers for material verification, CMM for dimensional inspection, and pressure testing equipment.
This vertical integration allows us to maintain strict quality control from raw material to finished product, ensuring every Brass Sand Casting meets the highest standards.
Achieving Excellence with Precision Brass Casting
Precision Brass Casting is our hallmark. It is not just a process but a philosophy that integrates meticulous pattern making, controlled sand molding, expert pouring techniques, and precision machining to produce castings that consistently meet or exceed customer specifications. We achieve this through:
Advanced Pattern Making: Precision patterns minimize drafting and machining allowances.
Process Control: Strict control over sand composition, moisture, and melting temperatures.
Skilled Craftsmanship: Decades of foundry experience in handling molten metal.
Stringent Inspection: Every batch is tested for material composition and critical dimensions are inspected.
Material Grades and International Standards
We cast a wide range of Brass alloys and Bronze alloys to meet various mechanical, corrosion-resistant, and decorative properties. Understanding the specific alloy is crucial for selecting the right material for your application, whether it’s for high-strength marine components, pressure-tight valve bodies, or decorative architectural hardware. Key grades include:
Common Brass Sand Casting Alloys
| Common Name | UNS Number | ASTM Standard | DIN / EN Standard | Equivalent Standards (BS, JIS) | Key Properties & Typical Applications |
|---|---|---|---|---|---|
| Yellow Brass (High-Zinc) | C85300 | ASTM B62 | CuZn37 | – | Excellent castability and good machinability. General purpose fittings, low-pressure valves. |
| Leaded Yellow Brass | C85800 | ASTM B62 | CuZn39Pb3 | BS 249 | Superior machinability. Complex, detailed parts requiring extensive machining. |
| Leaded Red Brass (85-5-5-5) | C83600 | ASTM B62 | Rg5 / CuZn5Pb5Sn5 | BS 1400 LG2 | Excellent corrosion resistance, good pressure tightness. The industry standard for premium plumbing valve bodies, pump parts, and sanitary fittings. |
| Leaded Semi-Red Brass | C84400 | ASTM B62 | CuZn15Pb4Sn4 | – | Good balance of cost, corrosion resistance, and castability. Used for lower-pressure valves, plumbing fittings, and decorative hardware. |
| Non-Leaded Red Brass | C84800 | – | – | – | A modern alternative with excellent corrosion resistance for potable water applications, complying with lead-free legislation (e.g., NSF/ANSI 61). |
| Manganese Bronze | C86500 | ASTM B584 | CuZn40Mn1Al | – | Very high strength and excellent wear resistance. Heavy-duty applications like gears, bushings, ship propellers, and stern tubes. |
| Silicon Brass | C87500 | ASTM B30 | – | – | Good corrosion resistance, especially in seawater. Architectural fittings, marine hardware. |
| Architectural Bronze | C85700 | ASTM B584 | – | – | Excellent finish quality for decorative castings, door handles, and artistic fixtures. |
| Leaded Naval Brass | C86300 | – | CuZn25Al5Mn4Fe3-C | – | Exceptional resistance to dezincification and high strength. Manganese bronze alternative for high-load marine applications. |
Common Bronze Alloys Also Cast
| Common Name | UNS Number | ASTM Standard | Key Properties & Applications |
|---|---|---|---|
| SAE 660 Bronze | C93200 | ASTM B584 | Excellent wear resistance and low friction. Ideal for bushings, bearings, and thrust washers. |
| Aluminum Bronze | C95400 | ASTM B584 | Very high strength, excellent corrosion and wear resistance. Used in gears, valve components, and high-strength marine applications. |
| Tin Bronze | C90500 | ASTM B584 | Good corrosion resistance and strength. General engineering gears and bushings. |
Material Property Table (Typical Values for Common Alloys):
| Alloy (UNS) | Ultimate Tensile Strength (MPa) | Yield Strength (MPa) | Elongation (%) | Hardness (Brinell) | Primary Application |
|---|---|---|---|---|---|
| C83600 (Leaded Red Brass) | 275 | 125 | 20 | 65 | Premium Plumbing Valves, Pump Parts |
| C84400 (Leaded Semi-Red Brass) | 255 | 110 | 25 | 60 | General Plumbing Fittings, Low-Pressure Valves |
| C85300 (Yellow Brass) | 290 | 110 | 30 | 60 | General Purpose Fittings, Decorative |
| C86500 (Manganese Bronze) | 620 | 275 | 25 | 150 | High-Strength Gears, Marine Propellers |
| C93200 (SAE 660 Bronze) | 240 | 125 | 20 | 65 | Bushings, Bearings, Low-Friction Parts |
We cast a wide range of Brass alloys to meet various mechanical and corrosion-resistant properties. Key grades include:
| Common Name | UNS Number | ASTM Standard | DIN Standard | Equivalent Standards (BS, JIS) | Key Properties |
|---|---|---|---|---|---|
| Yellow Brass | C85400 | ASTM B62 | CuZn39Pb3 | BS 249 | Excellent castability, good machinability |
| Leaded Red Brass | C83600 | ASTM B62 | CuZn39Pb1 | BS 1400 SCB3 | Good corrosion resistance, pressure tight |
| Manganese Bronze | C86500 | ASTM B584 | CuZn38Mn2Al | – | High strength, excellent wear resistance |
| Silicon Brass | C87500 | ASTM B30 | – | – | Good corrosion resistance, especially in seawater |
| Architectural Brass | C85700 | ASTM B584 | – | – | Excellent finish quality for decorative items |
Material Property Table (Typical Values for ASTM B62 Alloy):
| Property | Value | Unit |
|---|---|---|
| Ultimate Tensile Strength | 275 | MPa |
| Yield Strength (0.5% Ext) | 125 | MPa |
| Elongation (in 2″) | 20 | % |
| Hardness | 65 | Brinell |
| Density | 8.5 | g/cm³ |
Brass DZR and Lead-Free Alloys Table
DZR (De-Zincification Resistant) Brass Alloys
| Alloy Designation | UNS Number | Composition (%) | Key Properties | Applications |
|---|---|---|---|---|
| CuZn36Pb2As (DZR) | C85800 | Cu: 58-62, Zn: 35-39, Pb: 1.5-2.5, As: 0.02-0.15 | Excellent DZR properties, good machinability | Plumbing fittings, valves |
| CuZn39Pb1Al (DZR) | C85700 | Cu: 58-61, Zn: 37-40, Pb: 0.8-1.5, Al: 0.8-1.5, As: 0.02-0.15 | High strength, corrosion resistant | Marine hardware, pump components |
| CuZn40Pb2 (DZR) | C87850 | Cu: 57-60, Zn: 38-42, Pb: 1.5-2.5, As: 0.02-0.20 | Good hot workability, DZR resistant | Hot water systems, radiator components |
| CuZn36Pb1.5As | C85500 | Cu: 60-63, Zn: 35-38, Pb: 1.2-1.8, As: 0.02-0.15 | Balanced properties | General plumbing applications |
| CuZn42 (DZR) | C27400 | Cu: 57-61, Zn: remainder, As: 0.02-0.15 | Lead-free DZR option | Potable water systems |
Lead-Free Brass Alloys (≤0.25% Lead)
| Alloy Designation | UNS Number | Composition (%) | Lead Content | Key Properties | Applications |
|---|---|---|---|---|---|
| C89833 | C89833 | Cu: 66-68, Zn: 31-33, Bi: 0.8-1.2, P: 0.02-0.15 | ≤0.09% | NSF-61 certified, good machinability | Drinking water fittings |
| C89844 | C89844 | Cu: 75-79, Zn: 20-25, Si: 0.8-1.5 | ≤0.05% | High strength, corrosion resistant | Premium plumbing components |
| Eco Brass™ | C89520 | Cu: 76-79, Zn: 20-23, Bi: 0.8-1.2, P: 0.02-0.40 | ≤0.25% | Excellent machinability | Water meter components |
| C36000LF | C36000 | Cu: 60-63, Zn: 35.5-38.5, Bi: 0.8-1.5 | ≤0.25% | Free-cutting properties | Screw machine products |
| C27450 | C27450 | Cu: 58.5-61.5, Zn: remainder, As: 0.02-0.15 | ≤0.05% | DZR and lead-free | Potable water valves |
| C28000LF | – | Cu: 58-62, Zn: remainder, Bi: 0.5-1.2 | ≤0.25% | Corrosion resistant | Marine applications |
| Bismuth Brass | C89831 | Cu: 66-70, Zn: 28-32, Bi: 0.5-2.0 | ≤0.09% | Good castability | Cast valve bodies |
Silicon Brass Alloys (Lead-Free)
| Alloy Designation | UNS Number | Composition (%) | Key Properties | Applications |
|---|---|---|---|---|
| C87300 | C87300 | Cu: 78-82, Zn: 14-18, Si: 3.0-4.0 | High strength, wear resistant | Heavy-duty pump impellers |
| C87400 | C87400 | Cu: 75-79, Zn: 16-20, Si: 3.5-4.5 | Excellent casting properties | Marine propellers |
| C87500 | C87500 | Cu: 78-82, Zn: 13-17, Si: 3.5-4.5, Mn: 1.0-2.0 | Superior mechanical properties | Aerospace components |
Tin Brass Alloys (Lead-Free)
| Alloy Designation | UNS Number | Composition (%) | Key Properties | Applications |
|---|---|---|---|---|
| C83600 | C83600 | Cu: 83-87, Zn: 6-10, Sn: 4-6, Pb: 6-8 | High strength (traditional) | Bearings, gears |
| C83600LF | – | Cu: 86-90, Zn: 6-10, Sn: 4-6 | Lead-free version | Food processing equipment |
| C92300 | C92300 | Cu: 86-89, Zn: 1-4, Sn: 5.5-7.5, Ni: 0.8-1.5 | Corrosion resistant | Marine hardware |
Aluminum Brass Alloys (Lead-Free)
| Alloy Designation | UNS Number | Composition (%) | Key Properties | Applications |
|---|---|---|---|---|
| C68700 | C68700 | Cu: 76-79, Zn: 19-23, Al: 1.8-2.5 | Excellent corrosion resistance | Condenser tubes |
| C68800 | C68800 | Cu: 74-77, Zn: 20-24, Al: 2.2-2.8 | Seawater resistant | Marine heat exchangers |
Key Standards and Certifications
- NSF-61: Lead content ≤0.25% for potable water applications
- California AB1953: Lead content ≤0.25% (weighted average)
- Safe Drinking Water Act: Federal lead-free requirements
- ASTM B584: Standard specification for copper alloy sand castings
- EN 12164: European standard for copper and copper alloys
Notes
- DZR: De-zincification occurs when zinc is leached from brass in corrosive environments
- Arsenic (As): Added to improve DZR resistance (typically 0.02-0.15%)
- Bismuth (Bi): Improves machinability in lead-free alloys
- Silicon (Si): Provides strength and corrosion resistance
- Lead-free: Defined as ≤0.25% lead content by weight for plumbing applications
Industries Served and Typical Parts
Here’s a comprehensive list of brass casting parts organized by industry:
Automotive Industry
- Brass Radiator components and fittings
- Carburetor parts
- Fuel injection components
- Transmission parts
- Brake system components
- Brass Electrical connectors and Brass terminals
- Brass Water pump housings
- Thermostat housings
- Oil pump gears
- Synchronizer rings
Plumbing & Water Systems
- Brass Pipe fittings and Brass couplings
- Brass Ball valves and gate valves
- Brass Water meters and Brass Water meter body components
- Brass Faucet bodies and cartridges
- Brass Compression fittings
- Backflow preventers
- Pressure reducing valves
- Check valves
- Shut-off valves
- Pipe unions and adapters
Marine Industry
- Brass Propeller hubs and blades
- Seacocks and through-hull fittings
- Rudder bearings
- Porthole frames
- Cleats and hardware
- Pump impellers
- Strainers and sea strainers
- Keel bolts
- Deck hardware
- Navigation equipment housings
Electrical & Electronics
- Brass Electrical junction boxes
- Brass Switch plates and covers
- Terminal blocks and connectors
- Brass, Bronze and Copper Grounding components
- Brass Cable glands and fittings
- Transformer bushings of Brass, Bronze, Copper
- Circuit breaker components
- Electrical enclosures, Bronze and Red Brass Hotline clamps (from casting)
- Lightning rod fittings
- Ground rod clamps, Earth rod clamps of Brass and Bronze, Transformer Grounding Connectors, Transformer Tank Connectors of Bronze and Brass
HVAC (Heating, Ventilation, Air Conditioning)
- Valve bodies and stems
- Pressure gauges components
- Thermostat housings
- Heat exchanger components
- Refrigeration fittings
- Compressor parts
- Fan motor housings
- Control valve components
- Brass Manifolds and headers
- Temperature sensors housings
Oil & Gas Industry
- Wellhead components
- Valve trim and seats
- Brass Pump Parts and components
- Instrumentation fittings
- Pressure vessel components
- Pipeline fittings
- Metering equipment parts
- Safety valve components
- Flanges and gaskets
- Control system housings
Agriculture & Irrigation
- Sprinkler heads and nozzles
- Valve components
- Pump impellers and casings
- Irrigation fittings
- Flow control devices
- Pressure regulators
- Quick-connect couplings
- Filter housings
- Manifold systems
- Water distribution components
Hardware & Fasteners
- Door hinges and handles
- Brass Lock components and cylinders
- Brass Cabinet hardware
- Window hardware
- Decorative brackets
- Architectural fittings
- Brass Furniture hardware
- Gate latches
- Padlock bodies
- Key blanks
Industrial Machinery
- Bearing housings and bushings
- Gear components
- Pump casings and impellers
- Hydraulic fittings
- Pneumatic components
- Machine tool parts
- Conveyor components
- Motor housings
- Coupling components
- Industrial valves
Telecommunications
- Antenna fittings
- Coaxial connectors
- Waveguide components
- Equipment housings
- Grounding hardware
- Cable management fittings
- Mounting brackets
- RF shielding components
- Terminal blocks
- Junction boxes
Defense & Aerospace
- Ammunition components
- Weapon system parts
- Navigation equipment housings
- Communication device components
- Radar components
- Missile guidance parts
- Aircraft fittings
- Shipboard hardware
- Electronic warfare components
- Precision instruments
Our Brass Sand Casting components are critical in numerous industries:
Plumbing & Sanitary: Valve bodies, tap internals, pipe fittings, showerheads.
Marine & Shipbuilding: Propeller blades, stern tubes, deck hardware, couplings.
Automotive: Bushings, gears, sensor housings, hydraulic components.
Electrical: Connector parts, conduit fittings, terminal blocks.
General Engineering: Gears, bearings, pump impellers, machine parts.
Dimensional Tolerances and Turnaround Time
Dimensional Tolerances: We generally adhere to ISO 8062-3 CT 8-10 for cast dimensions. Machined dimensions are held to ISO 2768-mK or as specified on the customer’s engineering drawing.
Turnaround Time: Our standard lead time for Brass Sand Casting projects is 4-6 weeks from the approval of patterns and final drawing. This includes pattern making, sampling, and production. For repeat orders, the timeframe can be shorter.
Why Choose Our Brass Castings Over Others?
Choosing us as your Brass casting manufacturer offers distinct advantages:
Three Decades of Global Experience: Our 30+ years of expertise ensure we can solve complex casting challenges.
Unmatched Customization: We offer complete customization, from alloy selection to final packaging with your logo.
Integrated Manufacturing: Control over casting and machining under one roof guarantees quality and saves time.
Superior Communication: We pride ourselves on clear, proactive, and technical communication throughout the project lifecycle.
Competitive Pricing: As a manufacturer and exporter from India, we offer high-quality products at very competitive price points.
Flexibility: We accommodate both large production runs and small, customized orders.
Packaging and Shipping
We understand the importance of safe transit. Our standard packaging includes wooden pallets and plywood boxes to prevent damage. We offer customized packaging solutions, including vacuum sealing and VCI papers for superior corrosion protection during long sea voyages, and can print customer labels and logos on the packaging. We have extensive experience in shipping containers worldwide, handling all necessary documentation for smooth export from India.
Customer Testimonials
“We have been sourcing our complex brass valve bodies from this foundry for over five years. The quality is consistently exceptional, and their technical team’s ability to understand our precise requirements and suggest design for manufacturability changes has saved us significant cost. Their communication is excellent, and they have never missed a deadline. A truly reliable partner.” – John Smith, Procurement Manager, Flow Dynamics Inc.
Glossary of Terms
Pattern: A replica of the part to be cast, used to form the mold cavity.
Cope and Drag: The top (cope) and bottom (drag) halves of a sand mold.
Sprue: The vertical channel through which molten metal enters the mold.
Runner: The channel that carries molten metal from the sprue to the gate.
Gate: The entry point into the mold cavity.
Riser: A reservoir of molten metal that feeds the casting as it solidifies, preventing shrinkage.
Draft: A slight taper on a pattern to allow it to be withdrawn from the sand easily.
Machining Allowance: Extra material added to a casting surface that is to be machined.
Related Parts:
Brass die casting, Brass investment casting, lost wax casting Brass, Brass gravity die casting, continuous casting Brass, Brass forging, Brass extrusion, Brass fabrication, Bronze sand casting, Aluminum sand casting. Lead Free Brass castings and DZR Brass castings
In foreign languages–
German:
Messing-Sandguss, Messing-Gießerei, Messing-Grünsandgießerei
Russian:
Латунное литье в песчаные формы, Литейный завод латуни, Литейный завод латуни по зеленому песку
French:
Moulage au sable en laiton, Fonderie de moulage en laiton, Fonderie de moulage au sable vert en laiton
Spanish:
Fundición de latón en arena, Fundición de latón, Fundición de latón en arena verde
Call to Action (CTA)
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📧 Email us at sales@brass-copper-parts. comfor a detailed quotation and a full-color brochure.
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Let’s build your next project together with quality and precision.
