Development of Lead-Free Copper Alloy-Graphite Castings

In this project, graphite is used as a substitute for lead in order to maintain the machinability of plumbing components at the level of leaded brass. Graphite dispersed in Cu alloy was observed to impart good machinability and reduce the sizes of chips during machining of plumbing components in a manner similar to lead. Copper alloys containing dispersed graphite particles could be successfully cast in several plumbing fixtures which exhibited acceptable corrosion rate, solderability, platability, and pressure tightness. The power consumption for machining of composites was also lower than that of the matrix alloy. In addition, centrifugally cast copper alloy cylinders containing graphite particles were successfully made. These cylinders can therefore be used for bearing applications, as substitutes for lead-containing copper alloys. The results indicate that copper graphite alloys developed under this DOE project have a great potential to substitute for lead copper alloys in both plumbing and bearing applications.