Gunmetals and Leaded Bronzes

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Introduction to Gunmetal: History and Evolution

The term "gunmetal" originated in the mid-19th century when manufacturers first added zinc to binary bronze ordnance parts to enhance their casting characteristics. British Admiralty gunmetal, with its nominal composition of 88% copper, 10% tin, and 2% zinc, emerged as a standard formulation. Similar specifications became standard internationally, with the French ordnance alloy comprising Cu-90%, Sn-6%, Zn-4%, and the U.S. Ordnance alloy containing Cu-88%, Sn-8%, Zn-4% (now designated as G2-C).

Properties and Applications of Modern Gunmetals

Although no longer used in ordnance, gunmetal alloys have found extensive applications across various engineering fields. These alloys exhibit excellent casting characteristics, particularly in sand casting applications. They are frequently employed in manufacturing pump casings and components requiring high strength, pressure tightness, and corrosion resistance.

G1-C alloy has become particularly valuable in valve guides, bearings, and bushes, especially in gas and oil engine applications where proper bearing/shaft alignment and lubrication can be maintained. Its low coefficient of friction and superior corrosion resistance make it ideal for marine engine applications.

Nickel-enhanced gunmetals (containing 1% nickel) are preferred for valves and gears where hardness and toughness are crucial. However, it's worth noting that gunmetal's wear resistance is generally inferior to phosphor bronze.

Advanced Gunmetal Variations

G3 alloy demonstrates improved mechanical properties compared to Admiralty Gunmetal G1, particularly in sand-cast conditions. These improvements include enhanced tensile strength, better elongation characteristics, superior compressive strength, increased hardness, and improved impact resistance. While heat treatment can further enhance these properties, it may slightly reduce impact resistance and ductility.

Principal Uses of Standard Gunmetals

Each gunmetal type serves specific industrial applications:

• G1-C: Most commonly used lead-free gunmetal for marine conditions, bearings, bushes, pumps, valve bodies, and gears (especially with 1% nickel content)
• G2-C: Economical alternative to G1-C with similar applications but less commonly used due to lower tin content
• G3-C: Specialized for corrosive conditions, railway insulator supports, actuating nuts, valve and pump components at normal temperatures

Leaded Gunmetals: Composition and Applications

Leaded gunmetals (LG1-C through LG4-C) feature lower tin content than standard gunmetals and incorporate lead for specific applications. Their compositions are shown in Table 1 below.

Table 1. Leaded Gunmetal Compositions

LG1-C	Sn=2.0-4.0%;	Pb=3.0-6.0%;	Zn=7.0-10.0%;	Ni=1.0%;	Cu=Rem.
LG2-C	Sn=4.0-6.0%;	Pb=4.0-6.0%;	Zn=4.0-6.0%;	Ni=2.0%;	Cu=Rem.
LG3-C	Sn=6.0-8.0%;	Pb=1.0-3.0%;	Zn=3.0-5.0%;	Ni=2.0%;	Cu=Rem.
LG4-C	Sn=6.5-7.5%;	Pb=2.5-3.0%;	Zn=1.5-3.0%;	Ni=2.0%;	Cu=Rem.

These alloys excel in general and constructional castings, particularly for components where pressure tightness is crucial but high strength isn't required.

Each leaded gunmetal type has distinct industrial uses:

• LG1-C: Least used of leaded gunmetals, with applications similar to LG2-C
• LG2-C: Primary choice for valve bodies, pump bodies, elbows, pipes, taps, hydraulic fittings, and low-stressed bearings where pressure-tight properties are crucial
• LG3-C: General-purpose alloy for pressure components, pump parts, valve components, elbows, and pipes
• LG4-C: Traditional alloy extensively used in railways, bearing and engine components, tractor parts, pressure components, and valve parts

Leaded Bronzes: Technical Specifications and Applications

Leaded bronzes combine tin, lead, and copper as primary constituents, sometimes incorporating zinc and nickel. Their structure consists of an alpha phase matrix (copper with tin in solution) interspersed with a harder tin-rich delta phase.

The composition ranges for standard leaded bronze alloys are shown in Table 2 below.

Table 2. Leaded Bronze Compositions

LB1-C:
Sn=8.0-10.0%;	Pb=13.0-17.0%;	Zn=max.1.0%;	Ni= max.2.0%;	Cu=Rem.
LB2-C:
Sn=9.0-11.0%;	Pb=8.5-11.0%;	Zn= max.0.75%;	Ni=max.2.0%;	Cu=Rem.
LB3-C:
Sn=9.0-11.0%;	Pb=4.0-6.0%;	Zn=max.1.0%;	Ni=max.2.0%;	Cu=Rem.
LB4-C:
Sn=4.0-6.0%;	Pb=8.0-11.0%;	Zn=max.2.0%;	Ni=max.2.0%;	Cu=Rem.
LB5-C:
Sn=4.0-6.0%;	Pb=18.0-23.00%;	Zn=max.1.0%;	Ni=max.2.0%;	Cu=Rem.

Each leaded bronze type is designed for specific uses:

• LB1: Specialized for bearings in mining machinery with corrosive water conditions and unlined bearings under poor lubrication
• LB2: Used for lower loads and medium speeds, general-purpose bushes, mill bearings, railway bearings, and oil industry applications
• LB3: General purpose alloy for reasonable mechanical properties, corrosive mine waters, and lower load/medium speed applications
• LB4: General purpose bearing bronze tolerant of faulty lubrication and minor misalignment, similar applications to LB2
• LB5: High-lead content alloy for steel-backed motor and aero engine bearings, specifically for higher temperature applications than traditional white metal linings

All leaded bronzes can be sand cast, chill cast, or continuously cast, with LB1 through LB4 also suitable for centrifugal casting. These alloys particularly excel in applications requiring corrosion resistance, tolerance of poor lubrication, and ability to handle misalignment.