Master Distributor, Brass Mill, Bronze Foundry!

Transcription

1 National Bronze and Metals Technical Training Seminars 1. Continuous Cast Foundry A. Horizontal Cast B. Vertical Cast 2. Centrifugal Castings A. Horizontal Cast B. Vertical Cast 3. Brass/Copper Extrusion Mill A. Indirect Press B. Direct Press C. Green Movement 4. Metal To Metal Wear Applications 5. Welding Seminar A. Six Basic Types of Welding B. RWMA Welding Classifications 6. Top 5 Field Sales Call Seminar Andrew Meese Vice President of Sales ameese@nbmmetals.com Master Distributor, Brass Mill, Bronze Foundry!

2 PMPA Red Metal Clinic Continuous Cast Bronze Centrifugally Cast Bronze Extruded Brass Rod, Green Alloys Andrew Meese Vice President of Sales April 7,

3 Foundry Terminology Continuous Cast-Vertical & Horizontal Centrifugally Cast-Vertical & Horizontal Extrusion-Direct vs. Indirect, Green Alloys Brass vs. Bronze? ASTM B-16/B-249, ASTM B-271, ASTM B-505 Charge/Spectrographic Analysis/MTR Pickling/Pointing/Cold Drawing Billet/Canister/Ram Schumag-Temper/Size/Color First Operation Rough Blanking

4 Industry Table of Acronyms

5 Quality is a condition, a culture that must be created and nurtured. It is difficult to define, but you can recognize it when you see it. ISO 9001:2008

6 Lorain, Ohio New Foundry Over 40 different alloys produced- Continuous Cast Process

7 Durban, South Africa Non-Ferrous Metal Works 450 Employees 400,000 square feet

8 houston, texas Houston Warehouse Addition 33,000 SF 2nd Warehouse Addition ,000 SF

9 Houston Warehouse-155,000 S.F. Over 12 Million Pounds! Both North and South Locations!

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12 Copper Buss Bar F.R.E. or Sq. E.?

13 Small diameter brass rod carefully packaged for shipping

14 An Overview of Copper Based Alloys

15 Brass vs. Bronze What is the difference?

16 Alloying elements enhance the characteristics and properties of copper. Strength Color Corrosion Resistance Machinability Wear Resistance

17 National Bronze & Metals has valuable information and resources available online! International Cross Reference Metals Chart Comex and LME access Copper.org Website access ISO Cert download Check out our NEW Website!

18 Wrought Bars, Tubes, Wire, Sheet, and Plate C10200 C11000 C14500 C15000 C16200 C17200 C17300 C17500 C17510 C18000 C18150 C18200 C21000 C22000 C23000 C26000 Cartridge Brass 70% C27000 Yellow Brass 65% C27200 Yellow Brass 63.5% C27400 Yellow Brass 63% Oxygen Free Copper Electrolytic Tough Pitch Copper Tellurium Copper (Deoxidized Grades) Zirconium Copper Cadmium Copper Beryllium Copper Leaded Beryllium Copper Beryllium Copper Beryllium Copper Copper Chromium Nickel Silicon Copper Chromium Zirconium Chromium Copper Gilding Brass Commercial Bronze Red Brass C28000 Muntz Metal 60% C31400 Leaded Commercial Bronze C31600 Nickel Leaded Commercial Bronze C35300 High Leaded Brass 62% C36000 Free-Cutting Brass C37700 Forging Brass C38000 Architectural Bronze Low Leaded C38500 Architectural Bronze C44300 Admiralty Brass C46400 Naval Brass Lead Free C48200 Naval Brass Medium Lead C48500 Naval Brass High Leaded C51000 Phosphor Bronze 5% A C52100 Phosphor Bronze 8% C C52400 Phosphor Bronze 10% D C53400 Phosphor Bronze B-1 C54400 Phosphor Bronze B-2 Free Cutting C61300 Aluminum Bronze C61400 Aluminum Bronze C62300 Aluminum Bronze C62400 Aluminum Bronze C63000 Nickel Aluminum Bronze C63020 Nickel Aluminum Bronze C63200 Nickel Aluminum Bronze C64200 Silicon Aluminum Bronze C64700 Nickel Silicon Bronze C65100 Low Silicon Bronze B C65500 High Silicon Bronze A C66100 Leaded Silicon Bronze C67300 Manganese Bronze C67400 Manganese Bronze C67410 Manganese Bronze C67500 Manganese Bronze C67600 Manganese Bronze C68700 Aluminum Brass Arsenical C69400 Silicon Red Brass C70600 Copper Nickel 90/10 C71500 Copper Nickel 70/30 C75200 Nickel Silver C79200 Leaded Nickel Silver C79300 Leaded Nickel Silver UZ19AL6 Aircraft Bronze SAE 841 Sintered Bronze

19 Continuous and Centrifugal Cast Bars C83600 Leaded Red Brass C84400 Leaded Semi-Red Brass C86300 Manganese Bronze SAE 430 B C86400 Manganese Bronze C86500 Manganese Bronze C90200 Tin Bronze C90300 Tin Bronze Navy G C90500 Tin Bronze C90700 Tin Bronze C91000 Tin Bronze C91100 Tin Bronze C91700 Nickel Tin Bronze C92200 Leaded Tin Bronze Navy M C92300 Leaded Tin Bronze C92500 Leaded Tin Bronze C92600 Commercial Leaded Tin Bronze C92700 Leaded Tin Bronze C92800 Leaded Tin Bronze C92900 Leaded Nickel Tin Bronze C93200 High Leaded Tin Bronze SAE 660 C93400 High Leaded Tin Bronze C93600 High Leaded Tin Bronze C93700 High Leaded Tin Bronze C93800 High Leaded Tin Bronze C94100 High Leaded Tin Bronze C94300 High Leaded Tin Bronze C94500 Medium Bronze C94700 Nickel Tin Bronze Spinodal C94800 Leaded Nickel Tin Bronze C95400 Aluminum Bronze 9C C95500 Nickel Aluminum Bronze 9D C95510 Nickel Aluminum Bronze-AMS 4880 C95520 Nickel Aluminum Bronze-AMS 4881 C95800 Alpha Nickel Aluminum Bronze C96900 Nickel Tin Bronze Spinodal C97600 Nickel Silver Bronze Dairy Metal C97800 Nickel Silver Bronze 25% Other C80000 & C90000 Alloys Not Listed Can Be Made To Order

20 Best Bronze Trophies! What Year is The Volkswagen?

21 National Bronze & Metals, Inc. (Ohio Foundry) Lorain, Ohio 102 Employees Over 45 different alloys to ASTM B-505

22 National Bronze & Metals, Inc. (Ohio Foundry) Lorain, Ohio New Warehouse 25,000 square feet

23 Continuous Cast Specification ASTM B-505, C932 Bearing Bronze, C954 Aluminum Bronze Alloy C-932 bars and tubes are produced oversized to finish machine to the nominal size ordered.

24 Continuous Casting Process Molten bronze is poured from a furnace into a casting crucible fitted with a water-cooled die. The molten metal cools and sets in the die and is withdrawn in small steps using a roller indexing system. The size of the die determines the diameter of the bar produced. A travelling saw mounted below the roller cuts the bar to the required length. Continuous cast bar has greatly improved physical properties compared with sand-cast material. The net result is greater tensile strength and better wear resistance. Continuous cast bronze can be supplied in solid and hollow sections from rounds to flats, including a range of shapes and outside profiles. NBM continuous casting products comply with ASTM B-505 specification.

25 First Step: Charge Weighing out of the Scrap Metal

26 Weighing Out Charges

27 Second Step: Melt New Spectrographic Analysis-Chemistry

28 Continuous Cast Process-ASTM B-505 TOP LEVEL Charging and Melting of Raw Material - 6 Melters Holding Unit - 7 Casters MIDDLE LEVEL Withdrawal Unit and Cut-Off Saws FLOOR LEVEL Cooling Racks and Bar Straightener

29 Helps Maintain Lead Dispersion

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31 Advantages of Continuous Cast Material- ASTM B-505 Specification 1. Improved Mechanical Properties-Chill Cast 2. Uniform Microstructure-Superior Machinability 3. Cast Long Lengths/Improved Yield/Low Price 4. Chill Cast Prevents Lead Segregation 5. Virtually Any Shape Can Be Cast 6. Reduced Shrinkage and Porosity

32 Travelling Band Saw on Horizontal

33 New High Production Large Diameter Saw!!! 13 Multiple No Charge!

34 Mechanically Straightened- Large Diameters!

35 Bag House Collection System!

36 Cast Shape Round ID-Rect. OD

37 Large Diameters Available From Stock Up to 30 inch diameters

38 Large Solids Available from Stock

39 First Operation Rough Blanks

40 Tricks in Machining High Strength Bronze 1. Don t use blunt tools as work hardening will occur-freshly Sharpened tool is important. 2. Material closes in on you as you drill & has great memory Ni-Brnz will walk due to internal stresses. 3. Intermittent tooth taps or rough, semi & finish taps works well. Negative rake on lead tap edge. 4. Allow clearance for chips to come out. 5. Grind off every other tooth and ball peen hammer the lead edge of the tap for negative rake angle. 6. Tin coated drill bits for throw-aways

41 National Bronze & Metals, Inc. (Ohio Foundry) New Warehouse-25,000 square feet Northern Inventory Location!

42 Shipping North and South Stocking Locations Houston, Texas Lorain, Ohio Toulon, France

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44 Centrifugal Casting ASTM B-271

45 Horizontal Centrifugal Casting Process Rotating Die Molten Metal Rotating Die Oxides & Impurities Directional solidification of sound metal progresses from outside toward the bore. Oxides & impurities are forced inward to the bore; metal is forced centrifugally to the outside and solidifies. Impurities are removed by maching, resulting in a defect-free structure. Casting Soundness Arrows show direction of cooling solidification Centrifugal Casting No shrinkage Static Casting Area of mid-wall shrinkage

46 Horizontal Centrifugal Casting It s like the old wood floor End Cap Top Safety Hood Rotating Die melting unit Drive Roll Guide Roll Electric Motor

47 Horizontal Centrifugal Casting ASTM B-271

48 Durban, South Africa Non-Ferrous Metal Works 450 Employees 400,000 square feet

49 NFM Process Control Steps C-360 Extrusions BRASS TURNING Moisture Analysis Chip Dryer Virgin Metal & Scrap MELTING Spectrometer SPC Control BILLET CASTING Horizontal Vertical EXTRUSION Direct or Indirect Coil or Straight Length PICKLING AUTOMATED FRACTURING DIRECT PRESS ONLY POINTING REDUCES DIA. COLD DRAWING OPERATION Coil Straight Length Cut to Length STRAIGHTENING Coil & Straight length Eddie Current PACKAGING & SHIPPING

50 NFM In Business for 75 Years since 1944 Extrusion Mill Built in 1967

51 Green Movement Pb Free Laws NFS-61 to AB 1953 Al Bronze

52 Baled Copper

53 Casting Furnaces 7,000 lbs each

54 All Electric Furnaces

55 Horizontal Continuous Caster-10 Dia.

56 Flying Saw Cuts Billets to 8 ft. lengths

57 Vertically Cast-Homogenous Grain

58 Can You Find the Uncounted Bar???

59 South African Biker Dude!

60 Billet Stockpile

61 Pre-Heating of Billets

62 Pre-Heat of Billets 1300 Degrees

63 Billet Loader

64 Loading Pre-Heated Billet into Direct Press

65 Indirect Extrusion Process CANISTER PISTON E XTR US ION R AM DIE B ILLE T CANISTER Die is pushed into billet O.D. of the die is smaller than the O.D. of the billet This process leaves a 1 butt High yield/high Quality

66 Direct Extrusion Process CANISTER EXTRUSION DIE BILLET RAM Billet is pushed through the Die This process leaves a 5 butt CANISTER

67 Close Up of Direct Extrusion

68 Pickling Line Removes Mill Oxides (3% Sulfuric Acid H 2 SO 4 Bath)

69 Ten Draw Benches Running Coil Stock

70 Schumag Draw Bench - H02, Half Hard 1. Temper (1/2 Hd) Draw Die 2. Size (+/- Tol.) 3. Color (Shiny) Finished Size Raw Extrusion (oversize) Reduces Diameter

71 Stockpile of Large Cast Diameters- Over 4 Dia.

72 Thank you on behalf of National Bronze& Metals, Inc. Best Brass, Bronze and Copper!