MIT International Journal of Mechanical Engineering, Vol. 4, No. 1, January 2014, pp.

6369
ISSN 2230-7680 MIT Publications

63

Micrography of Different Compositions of Brass

Developed at 980oC and 1100oC
Pooja Verma
PG Student, Deptt.of
Mechanical Engg., MIT
Moradabad
U.P., INDIA

Vineet Tirth
Professor, Deptt. of
Mechanical Engg.&
Director, MIT Moradabad
U.P., INDIA

Nitin Agarwal
Associate Professor, Deptt.
of Mechanical Engg.
MIT Moradabad
U.P., INDIA

Abhishek Saxena
Assistant Professor, Deptt.
of Mechanical Engg.
MIT Moradabad
U.P., INDIA

ABSTRACT
Brass is one of the most important domestic, industrial and ornamental alloy of Cu and Zn. Different compositions of brass ranging from Cu
wt% 60 to 80 are used wide over. In present study, brass in four compositions has been prepared by sand casting and optical micrography has
been done to compare the effect of composition on microstructure. The superheat temperature has also been varied in two steps viz. 980 oC
and 1100oC and the effect on microstructure has been reported.
Keywords-Brass, Microscopy, Dross, Grains, Casting.

I. INTRODUCTION
Brass alloy is used over a wide spectrum of applications in
manufacturing of machine components varying from electrical/
mechanical to chemical process equipment. Such components
include nuts, bolts, valves, bath fittings, tubes, pipes, bushes,
connectors and many kinds of fittings, which are produced by
casting, automatic machining processes or hot stamping of
extruded and drawn brass rods [1-3]. Brass has a characteristic
appearance which resembles gold, a symbol of elegance,
prosperity, purity and beauty. None other metal oy alloy than
brass has similar appearance with much lower cost than gold
and hence the importance of brass as a domestic and industrial
material is unmatched. To some extent, titanium alloys have
similar finish as gold but their cost is nearly as much as or even
higher than gold. Brass products can be readily electroplated by
Chrome, Nickel, Silver, Gold, Platinum etc. It can be lacquered
for corrosion prevention and many other decorative treatments
may be applied over them such as oxide coloring, making them
most attractive alloy for decorative domestic applications.
Metallography is the study of metals by optical and electron
microscopes. Structures which are coarse enough to be
discernible by the naked eye or under low magnifications are
termed macrostructures. Useful information can often be gained
by examination with the naked eye of the surface of metal objects
or polished and etched sections. Those which require high
magnification to be visible are termed microstructures.
Microscopes are required for the examination of the

microstructure of the metals. Optical microscopes are used for

resolutions down to roughly the wavelength of light (about half
a micron) and electron microscope are used for detail below
this level, down to atomic resolution. Microscopy may give
information concerning a materials composition, previous
treatments and properties. Particular features of interest are; grain
size, phases present, chemical homogeneity, distribution of
phases, elongated structures formed by plastic deformation etc.
A. Commercial Utility of Brass
Brass is the generic term for a range of copper-zinc alloys with
differing combinations of properties, including strength,
machinability, ductility, wear-resistance, hardness, color,
antimicrobial properties, electrical and thermal conductivity and,
corrosion resistance. Brasses set the standard by which the
machinability of other materials is judged and are also available
in a very wide variety of product forms and sizes to allow
minimum machining to finished dimensions. Brass does not
become brittle at low temperatures like mild steel. Brass also
has excellent thermal conductivity, making it a first choice for
heat exchangers (radiators). Its electrical conductivity ranges
from 23 to 44% that of pure copper. Silver colored copper-nickelzinc alloys containing 10-20% nickel can be regarded as special
brasses. Mostly they show similar corrosion characteristics to
the brasses, but the higher nickel versions have superior resistance
to tarnish and stress corrosion cracking. They are available in
all forms and are used for tableware (silver-plated),

MIT International Journal of Mechanical Engineering, Vol. 4, No. 1, January 2014, pp. 6369
ISSN 2230-7680 MIT Publications

telecommunication components, food manufacturing equipment,

jewelry, model making, tool brush anchor wire and pins, musical
instruments, e.g. silver bands, flutes, test probes and contact
springs.
B. Colors of Brass
Brasses have a range of attractive colors viz. red, yellow, gold,
brown, bronze, silver etc. Brass with 1% manganese will weather
to a chocolate brown color. Nickel silvers will polish to a brilliant
silver color. Brasses are easy to shape and, with all these colors
available, it is not surprising that architects and designers have
used brasses to enhance the appearance of new and refurbished
buildings, both inside and out.
C. Brass and Hygiene
Copper and brass are playing a leading role in the fight against
hospital-acquired infections. It has been shown that these
pathogens, which may spread by touch, will die in few hours on
copper/brass surfaces. This does not happen on stainless steel or
plastic.
D. Recycling Brass
The brass industry throughout the world is well organized and
equipped to recycle products at the end of their long service life
and process scrap. Making brass from new (virgin) copper and
zinc would be uneconomical and wasteful of raw materials so
new brass products are made from recycled scrap, illustrating
the sustainable nature of this material. In UK, brass
manufacturers use almost 100% brass scrap.

64

obtained theoretically and experimentally indicated decrease in

the applied load cause increase in the age and applying high
loads in the beginning and at the end giving smaller specimen
age and the quick growth of short cracks followed by quick
growth of long cracks. The values taken from the theoretical
equations have been found to be greater than experimental values.
He et al. [7] performed transmission electron microscopy and
tensile tests to study alpha-brass nano-ligament deformation,
phase transformation and fracture. Phase transformation and its
effect on alloy nano-crystal fracture were also studied. Neishi et
al., [8] studied superplastic deformation in brass 60%Cu-40%
Zn brass at relatively low temperature.
In the light of commercial and domestic utility of brass, in present
study, an attempt has been made to process most widely used
compositions of brass viz. 80wt% Cu-20wt% Zn, 70wt% Cu30wt% Zn, 75wt% Cu-25wt% Zn, 60wt% Cu-40wt% Zn.
III. EXPERIMENTAL SET-UP
Brass was prepared with nominal compositions 80wt% Cu20wt% Zn-designated as 8020, 70wt% Cu-30wt% Zn-designated
as 7030, 75wt% Cu-25wt% Zn-designated as 7525 and 60wt%
Cu-40wt% Zn-designated as 6040.Micro controlled based
electric resistance furnace with Kanthal A-1 element and K-type
Alumal-Chromal Thermocouples has been employed for casting,
represented in Fig.1.

II. LITERATURE REVIEW

Significant research has been carried out on microscopic study
of different compositions of brass. Oca et al. [4] studied the
surface degradation of nickel-plated brass fittings designed for
ornamental plumbing purposes using optical and scanning
electron microscopy together with energy dispersive and X-ray
diffraction analysis. Mapelli et al. [5] performed the failure
analysis on different brass electro-valves body affected by
unexpected phenomena of cracking. Through the application of
optical and scanning electron microscopy, micro hardness Vickers
test and X-ray diffraction, the causes of damage were identified.
The study showed the dependence between roughness and
residual stresses associated to the tool wear. A solution to avoid
the failure is to use the combination of a tool with controlled
wear and stress relieving heat treatment.
Ameen et al. [6] investigated the effect of short and long cracks
for brass alloys specimens exposed to bending cyclic load. This
test has been applied on a group of standard specimens until its
fracture; data taken could be drawn as a curve between stress
and number of cycles (S-N) which gives the fatigue limit. Results

Fig. 1. Micro controlled based electric resistance furnace with

Kanthal A-1 element and K-type Alumal-Chromal Thermocouples

Hardness testing has been done on computerized Brinell

Hardness Testing Machine, Model-B-1000PC 250, Make FIE,
Kolhapur, India, load capacity (500-3000 kgf). Hardness testing
has been done as per ASTM E10 standard by applying 31.625
kg load with steel ball for 15 s. The Brinell hardness testing
machine is shown in Fig. 2.

MIT International Journal of Mechanical Engineering, Vol. 4, No. 1, January 2014, pp. 6369
ISSN 2230-7680 MIT Publications

65

inverted metallurgical microscope model; DMI victory. Dewinter

Material plus software 4.2 has been used for metallurgical
analysis. Microscope is represented in Fig. 3.
IV. RESULT AND DISCUSSION
The micrographs are in unetched and etched conditions and are
compared in the light of known physical phenomenon and
research knowhow. Results are reported and discussion is made
simultaneously comparing the micrographs.

Fig. 4. Unetched micrograph of 60wt% Cu, 40wt% Zn Brass

processed at 980oC with 15m holding time at 100x.

Fig. 2. Brinell hardness testing machine

Optical microscopy has been used to examine microstructures

of polished specimens of different compositions of brass in etched
and un-etched conditions. Etching has been done with HnO3 (80
ml) and distilled water (20 ml) applied by immersion for 40 s.
Microstructures have been examined at 100x to see the effect of
superheat temperature and holding time. Polished specimens have
been prepared by standard metallographic procedure.

Fig. 5. Unetched micrograph of 60wt% Cu, 40wt% Zn Brass

processed at 1100 oC 15 m holding time at 100x.

Fig. 3. Dewintertrinocular inverted metallurgical microscope

Microstructures have been examined using Dewintertrinocular

Fig. 4 and 5 represents the optical micrographs of brass with

60 w% Cu and 40 wt% Zn, processed at 980oC and 1100oC
respectively with 15 m holding time. This composition has been
designated as 6040. Holding time is required because after
melting, some time for diffusion of atoms and homogenization
of the composition is to be given to the alloy. On comparing the
micrographs in Fig. 4 and 5, we may observe that the surface is
more smooth at 980oC but at 1100oC the surface becomes rough
and some scales are appearing on the surface. Such scales are a

MIT International Journal of Mechanical Engineering, Vol. 4, No. 1, January 2014, pp. 6369
ISSN 2230-7680 MIT Publications

common defect in high zinc yellow brass and are called alligator
skin. Dark spots on the surface of micrographs are due to porosity
in which the debris has been trapped at the time of polishing.
Figs. 6 and 7 show etched micrograph of 6040 brass at 980 oC
and 1100oC. It may be observed that at higher processing
temperature, the grain size has increased. Dendrites are observed
in both the micrographs forming cells in Fig. 7 whereas in
Fig. 6 we see fine dendrites with secondary arms. It is hence
seen that due to increase in superheat temperature, bigger grains
have formed and instead of development of secondary arms,
dendrites have grown thicker and forming closed cells.

Fig. 8. Unetched micrograph of 70wt% Cu, 30wt% Zn Brass

processed at 980oC 15m holding time at 100x.

Fig. 6. Etched micrograph of 60wt% Cu, 40wt% Zn Brass processed

at 980oC 15m holding time at 100x.

Fig. 9. Unetched micrograph of 70wt% Cu, 30wt% Zn Brass

processed at 1100 oC 15m holding time at 100x.

Fig. 7. Etched micrograph of 60wt% Cu, 40wt% Zn Brass processed

at 1100 oC 15m holding time at 100x.

Fig.8 and 9 represent 7030 brass superheated upto 980oC and

1100oC. Alligator skin defect is seen over the micrograph
processed at 1100oC and some inclusions or dross particles are
seen in micrograph processed at 1100oC.

Fig. 10. Etched micrograph of 70wt% Cu, 30wt% Zn Brass processed at 980oC 15m holding time at 100x.

66

MIT International Journal of Mechanical Engineering, Vol. 4, No. 1, January 2014, pp. 6369
ISSN 2230-7680 MIT Publications

Fig. 11. Etched micrograph of 70wt% Cu, 30wt% Zn Brass processed at 1100 oC 15m holding time at 100x.

Fig. 13. Unetched micrograph of 75wt% Cu, 25wt% Zn Brass

processed at 1100 oC 15m holding time at 100x.

Etched micrograph of 7030 brass processed at 980 oC and

1100oC in Fig. 10 and 11show up dendrite cells but it may be
observed that the cell sizes are bigger in micrograph processed
at higher temperature. This may be due to more nucleation sites
in brass processed at 980 oC as compared to the one at higher
temperature. Different phases are observed in both the
micrographs probably due to different phases or differential
etching as a result of variation in composition across the surface.

Fig. 14. Etched micrograph of 75wt% Cu, 25wt% Zn Brass processed at 980oC 15m holding time at 100x.

Fig. 12. Unetched micrograph of 75wt% Cu, 25wt% Zn Brass

processed at 980oC 15m holding time at 100x.

Figs. 12 and 13 represent 7525 brass at 100x processed at low

and high temperatures respectively. We may see that as the
composition of Zn has reduced, microstructure is appearing
cleaner. At high temperature also, the alligator skin defect is not
observed.
Fig. 15. Etched micrograph of 75wt% Cu, 25wt% Zn Brass processed at 1100 oC 15m holding time at 100x.

67

MIT International Journal of Mechanical Engineering, Vol. 4, No. 1, January 2014, pp. 6369
ISSN 2230-7680 MIT Publications

68

In etched micrographsof 7525 brass processed at low and high

temperatures, shown in Figs. 14 and 15, one may see very fine
dendrite structure in low temperature brass. Bigger grains and
broader cells are seen in high temperature brass but if this
micrograph is compared with 7030 and 6040, the dendrite cells
are not clear and closed and their walls are also not that thick.
The micrographs of 8020 brass shown in Figs.16 and 17 reveal
clear surface with minimal dross formation. Some micropores
are seen at low processing temperature in Fig.16 whereas number
of these micropores appear to be increasing at high processing
temperature as seen in Fig. 17.Here in etched micrographs of
8020 brass processed at low and high temperatures in Figs. 18
and 19, we see that dendtite cells are fine and small in size at low
processing temperature.
Fig. 18. Etched micrograph of 80wt% Cu, 20wt% Zn Brass processed at 980oC 15m holding time at 100x.

Fig. 16. Unetched micrograph of 80wt% Cu, 20wt% Zn Brass

processed at 980oC 15m holding time at 100x.

Fig. 19. Etched micrograph of 80wt% Cu, 20wt% Zn Brass processed at 1100 oC 15m holding time at 100x.

V. CONCLUSIONS
Following broad conclusions may be drawn from this study:
1. As the wt% of Zn has increased in the alloy, dross
formation has increased due to more oxidation.
2. Alligator skin defect is observed in high Zn wt% brass
(6040 and 7030). This defect is not visible in low Zn and
high Cu brass (8020 and 7525).
3. Within same Zn wt% brass (6040 and 7030) the alligator
skin defect is observed in brass processed at high
superheat temperature (1100 oC).
Fig. 17. Unetched micrograph of 80wt% Cu, 20wt% Zn Brass
processed at 1100 oC 15m holding time at 100x.

Minimal dross is abserved along the edges of the cells. At high

processing temperatures, we can see that cells are not formed
but bigger grains are being observed. Dross is in the form of fine
particles scattered around the surface of alloy.

4. With the increase in superheat temperature;

a. The dross formation has increased due to increase in
oxidation.
b. The dendrite cells have become thicker due to more
time available for their growth.

MIT International Journal of Mechanical Engineering, Vol. 4, No. 1, January 2014, pp. 6369
ISSN 2230-7680 MIT Publications

69

c. The dendrite cell size has become bigger due to more

time available for solidification and hence slow
nucleation.

[2] G. Pantazopoulos, A. Vazdirvanidis Characterization of the

microstructural aspects of machinable brass. Microscopy
and Analysis, 22 (5), 2008, pp. 1316.

d. The grain sizes have become bigger due to more

cooling time available and hence more time available
for grain growth until the grain boundary of adjacent
grain intersects and both boundaries fuse together to
form grains.

[3] G.A. Pantazopoulos, A.I. Toulfatzis Fracture Modes and

Mechanical Characteristics of Machinable Brass Rods.
Metallography, Microstructure, and Analysis, 1 (2), 2012,
pp. 106114.

e. The defect of alligator skin is observed in brass at

high processing temperature.
5. For economic point of view, it may be concluded from
comparative study of micrographs that low superheating
temperature (980 oC) should be used to minimize dross
formation and getting high casting yield. The holding time
shall also be kept to minimum.
ACKNOWLEDGEMENTS
The authors gratefully acknowledge the financial support given
by AICTE under Research Promotion Scheme and the facilities
and resources provided by Moradabad Institute of Technology,
Moradabad-India for carrying out this work.
REFERENCES
[1] G. Pantazopoulos. A Review of Defects and Failures in Brass
Rods and Related Components Practical Failure Analysis, 3 (4),
2003, pp. 1422.

[4] N.F. Garza-Montes-de-Oca, N.A. Garca-Gmez, I. AlvarezElcoro, R. Colsa. Surface Degradation of Nickel-plated Brass
Fittings.Engineering Failure Analysis, Volume 36, 2014, pp.
314321.
[5] C. Mapelli, D. Mombelli, S. Barella, A. Gruttadauria. Influence
of the Residual Stresses induced by Tool Wear on the Failure of
Brass Electro-valves. Engineering Failure Analysis. Volume 27,
2013, pp. 141149.
[6] Ameen, H.A. and Ismail A.H., Study of the short and long
Fatigue Cracks for Brass Alloy. Journal of Mechanical
Engineering Research,Vol. 3. (6), 2011, pp. 181-185.
[7] Y.I. He, Y.J. Yan, L.J. Qiao, Alex A. Volinskya. In situ
Transmission Electron Microscopy Study of Alpha-brass
Nanoligament Formation, Microstructure Evolution and
Fracture Scripta Materialia Volume 65, Issue 5, 2011, pp. 444
447.
[8] K, Neishi, T, Uchida, A. Yamauchi, K, Nakamura, Z., Horita,
T.G. Langdon, Low-temperature superplasticity in a Cu-Zn-Sn
alloy processed by severe plastic deformation, Materials Science
and Engineering, A307, 2001, pp. 23-28.